Abstract: In order to better understand the long term
implications of the grout wear failure mode in large-diameter plainsided
grouted connections, a numerical model has been developed
and calibrated that can take advantage of existing operational plant
data to predict the wear accumulation for the actual load conditions
experienced over a given period, thus limiting the requirement for
expensive monitoring systems. This model has been derived and
calibrated based on site structural condition monitoring (SCM) data
and supervisory control and data acquisition systems (SCADA) data
for two operational wind turbine generator substructures afflicted
with this challenge, along with experimentally derived wear rates.
Abstract: This paper presents a 4-DOF nonlinear model of a
cracked de Laval rotor-stator system derived based on Energy
Principles. The model has been used to simulate coupled torsionallateral
response of the faulty system with multiple parametric
excitations; rotor-stator-rub, a breathing transverse crack, eccentric
mass and an axial force. Nonlinearity of a “breathing” crack is
incorporated in the model using a simple hinge mechanism suitable
for a shallow crack. Response of the system while passing via its
critical speed with intermittent rotor-stator rub is analyzed. Effects of
eccentricity with phase and acceleration are investigated. Features of
crack, rub and eccentricity in vibration response are explored for
condition monitoring. The presence of a crack and rub are observable
in the power spectrum despite excitations by an axial force and rotor
unbalance. Obtained results are consistent with existing literature and
could be adopted into rotor condition monitoring strategies.
Abstract: In this paper, we present a new maintenance model
for a partially observable system subject to two failure modes,
namely a catastrophic failure and a failure due to the system
degradation. The system is subject to condition monitoring and the
degradation process is described by a hidden Markov model. A
cost-optimal Bayesian control policy is developed for maintaining
the system. The control problem is formulated in the semi-Markov
decision process framework. An effective computational algorithm is
developed, illustrated by a numerical example.
Abstract: In this paper, we investigate the residual life prediction
problem for a partially observable system subject to two failure
modes, namely a catastrophic failure and a failure due to the system
degradation. The system is subject to condition monitoring and the
degradation process is described by a hidden Markov model with
unknown parameters. The parameter estimation procedure based on
an EM algorithm is developed and the formulas for the conditional
reliability function and the mean residual life are derived, illustrated
by a numerical example.
Abstract: Vibration analysis of most critical equipment is considered as one of the most challenging activities in preventive maintenance. Utilities are heart of the process in big industrial plants like petrochemical zones. Vibration analysis methods and condition monitoring systems of these kinds of equipments are developed too much in recent years. On the other hand, there are too much operation factors like inlet and outlet pressures and temperatures that should be monitored. In this paper, some of the most effective concepts and techniques related to gas turbine vibration analysis are discussed. In addition, a gas turbine SIEMENS 162MW - V94.2 vibration case history related to Iran power industry in Fars province is explained. Vibration monitoring system and machinery technical specification are introduced. Besides, absolute and relative vibration trends, turbine and compressor orbits, Fast Fourier transform (FFT) in absolute vibrations, vibration modal analysis, turbine and compressor start up and shut down conditions, bode diagrams for relative vibrations, Nyquist diagrams and waterfall or three-dimensional FFT diagrams in startup and trip conditions are discussed with relative graphs. Furthermore, Split Resonance in gas turbines is discussed in details. Moreover, some updated vibration monitoring system, blade manufacturing technique and modern damping mechanism are discussed in this paper.
Abstract: Vibration monitoring methods of most critical equipment like main turbine and compressors always plays important role in preventive maintenance and management consideration in big industrial plants. There are a number of traditional methods like monitoring the overall vibration data from Bently Nevada panel and the time wave form (TWF) or fast Fourier transform (FFT) monitoring. Besides, Shaft centerline monitoring method developed too much in recent years. There are a number of arguments both in favor of and against this method between people who work in preventive maintenance and condition monitoring systems (vibration analysts). In this paper basic principal of Turbine compressor vibration analysis and rotor movement evaluation by shaft centerline method discussed in details through a case history. This case history is related to main turbine compressor of an olefin plant in Iran oil industry. In addition, some common mistakes that may occur by vibration analyst during the process discussed in details. It is worthy to know that, these mistakes may one of the reasons that sometimes this method seems to be not effective. Furthermore, recent patent and innovation in shaft position and movement evaluation are discussed in this paper.
Abstract: Vibration analysis of screw compressors is one of the most challenging cases in preventive maintenance. This kind of equipment considered as vibration bad actor facilities in industrial plants. On line condition monitoring systems developed too much in recent years. The high frequency vibration of ball bearings, gears, male and female caused complex fast Fourier transform (FFT) and time wave form (TWF) in screw compressors. The male and female randomly are sent to balance shop for balancing operation. This kind of operation usually caused some bending in rotors during the process that could cause further machining in such equipment. This kind of machining operation increased the vibration analysis complexity beside some process characteristic abnormality like inlet and out let pressure and temperature. In this paper mechanical principal and different type of screw compressors explained. Besides, some new condition monitoring systems and techniques for screw compressors discussed. Finally, one of the common behavior of oil injected twin rotary screw compressors called hydraulic unbalance that usually occurred after machining operation of male or female and have some specific characteristics in FFT and TWF discussed in details through a case history related to Iran oil industries.
Abstract: One of the most challenging times in operation of big industrial plant or utilities is the time that alert lamp of Bently Nevada connection in main board substation turn on and show the alert condition of machine. All of the maintenance groups usually make a lot of discussion with operation and together rather this alert signal is real or fake. This will be more challenging when condition monitoring vibrationdata shows 1X(X=current rotor frequency) in fast Fourier transform(FFT) and vibration phase trends show 90 degree shift between two non-contact probedirections with overall high radial amplitude amounts. In such situations, CM (condition monitoring) groups usually suspicious about unbalance in rotor. In this paper, four critical case histories related to SIEMENS V94.2 Gas Turbines in Iran power industry discussed in details. Furthermore, probe looseness and fake (unreal) trip in gas turbine power plants discussed. In addition, critical operation decision in alert condition in power plants discussed in details.
Abstract: Vibration analysis is the most important factor in preventive maintenance. Gas turbine vibration analysis is also one of the most challenging categories in most critical equipment monitoring systems. Utilities are heart of the process in big industrial plants like petrochemical zones. Vibration analysis methods and condition monitoring systems of this kind of equipment developed too much in recent years. On the other hand, too much operation condition consideration in this kind of equipment should be adjusted properly like inlet and outlet pressure and temperature for both turbine and compressor. In this paper the most important tools and hypothesis used for analyzing of gas turbine power plants discussed in details through a real case history related to an Alstom Typhoon gas turbine power plant in Iran oil industries. In addition, the basic principal of vibration behavior caused by mechanical unbalance in gas turbine rotor discussed in details.
Abstract: Researches show that probability-statistical methods application, especially at the early stage of the aviation Gas Turbine Engine (GTE) technical condition diagnosing, when the flight information has property of the fuzzy, limitation and uncertainty is unfounded. Hence the efficiency of application of new technology Soft Computing at these diagnosing stages with the using of the Fuzzy Logic and Neural Networks methods is considered. According to the purpose of this problem training with high accuracy of fuzzy multiple linear and non-linear models (fuzzy regression equations) which received on the statistical fuzzy data basis is made. For GTE technical condition more adequate model making dynamics of skewness and kurtosis coefficients- changes are analysed. Researches of skewness and kurtosis coefficients values- changes show that, distributions of GTE work parameters have fuzzy character. Hence consideration of fuzzy skewness and kurtosis coefficients is expedient. Investigation of the basic characteristics changes- dynamics of GTE work parameters allows drawing conclusion on necessity of the Fuzzy Statistical Analysis at preliminary identification of the engines' technical condition. Researches of correlation coefficients values- changes shows also on their fuzzy character. Therefore for models choice the application of the Fuzzy Correlation Analysis results is offered. At the information sufficiency is offered to use recurrent algorithm of aviation GTE technical condition identification (Hard Computing technology is used) on measurements of input and output parameters of the multiple linear and non-linear generalised models at presence of noise measured (the new recursive Least Squares Method (LSM)). The developed GTE condition monitoring system provides stageby- stage estimation of engine technical conditions. As application of the given technique the estimation of the new operating aviation engine technical condition was made.
Abstract: Oil debris signal generated from the inductive oil
debris monitor (ODM) is useful information for machine condition
monitoring but is often spoiled by background noise. To improve the
reliability in machine condition monitoring, the high-fidelity signal
has to be recovered from the noisy raw data. Considering that the noise
components with large amplitude often have higher frequency than
that of the oil debris signal, the integral transform is proposed to
enhance the detectability of the oil debris signal. To cancel out the
baseline wander resulting from the integral transform, the empirical
mode decomposition (EMD) method is employed to identify the trend
components. An optimal reconstruction strategy including both
de-trending and de-noising is presented to detect the oil debris signal
with less distortion. The proposed approach is applied to detect the oil
debris signal in the raw data collected from an experimental setup. The
result demonstrates that this approach is able to detect the weak oil
debris signal with acceptable distortion from noisy raw data.
Abstract: This paper deals with condition monitoring of electric switch machine for railway points. Point machine, as a complex electro-mechanical device, switch the track between two alternative routes. There has been an increasing interest in railway safety and the optimal management of railway equipments maintenance, e.g. point machine, in order to enhance railway service quality and reduce system failure. This paper explores the development of Kolmogorov- Smirnov (K-S) test to detect some point failures (external to the machine, slide chairs, fixing, stretchers, etc), while the point machine (inside the machine) is in its proper condition. Time-domain stator Current signatures of normal (healthy) and faulty points are taken by 3 Hall Effect sensors and are analyzed by K-S test. The test is simulated by creating three types of such failures, namely putting a hard stone and a soft stone between stock rail and switch blades as obstacles and also slide chairs- friction. The test has been applied for those three faults which the results show that K-S test can effectively be developed for the aim of other point failures detection, which their current signatures deviate parametrically from the healthy current signature. K-S test as an analysis technique, assuming that any defect has a specific probability distribution. Empirical cumulative distribution functions (ECDF) are used to differentiate these probability distributions. This test works based on the null hypothesis that ECDF of target distribution is statistically similar to ECDF of reference distribution. Therefore by comparing a given current signature (as target signal) from unknown switch state to a number of template signatures (as reference signal) from known switch states, it is possible to identify which is the most likely state of the point machine under analysis.
Abstract: In this paper, we present a maintenance model of a
two-unit series system with economic dependence. Unit#1 which is
considered to be more expensive and more important, is subject to
condition monitoring (CM) at equidistant, discrete time epochs and
unit#2, which is not subject to CM has a general lifetime distribution.
The multivariate observation vectors obtained through condition
monitoring carry partial information about the hidden state of unit#1,
which can be in a healthy or a warning state while operating. Only the
failure state is assumed to be observable for both units. The objective
is to find an optimal opportunistic maintenance policy minimizing
the long-run expected average cost per unit time. The problem
is formulated and solved in the partially observable semi-Markov
decision process framework. An effective computational algorithm
for finding the optimal policy and the minimum average cost is
developed, illustrated by a numerical example.
Abstract: As an effort to promote wind power industry in Korea,
Korea South-East Power Corporation has been developing 22MW
YeungHeung wind farm consisting of nine 2 to 3MW wind turbines
supplied by three manufacturers. To maximize its availability and
reliability and to solve the difficulty of operating three kinds of
SCADA systems, Korea Electric Power Corporation has been
developing a condition monitoring system integrated with control
functions. This paper presents the developed condition monitoring
system and its application to YeungHeung wind test bed, and the
design of its control functions.
Abstract: This paper presents an experimental investigation using Acoustic Emission (AE) technology to monitor sand transportation in multiphase flow. The investigations were undertaken on three-phase (air-water-sand) flow in a horizontal pipe where the superficial gas velocity (VSG) had a range of between 0.2msˉ¹ to 2.0msˉ¹ and superficial liquid velocity (VSL) had a range of between 0.2msˉ¹ to 1.0msˉ¹. The experimental findings clearly show a correlation exists between AE energy levels, sand concentration, superficial gas velocity (VSG), and superficial liquid velocity (VSL).
Abstract: In metal cutting industries, mathematical/statistical
models are typically used to predict tool replacement time. These
off-line methods usually result in less than optimum replacement
time thereby either wasting resources or causing quality problems.
The few online real-time methods proposed use indirect measurement
techniques and are prone to similar errors. Our idea is based on
identifying the optimal replacement time using an electronic nose to
detect the airborne compounds released when the tool wear reaches
to a chemical substrate doped into tool material during the
fabrication. The study investigates the feasibility of the idea, possible
doping materials and methods along with data stream mining
techniques for detection and monitoring different phases of tool
wear.
Abstract: The vibrations produced by a single point defect on
various parts of the bearing under constant radial load are predicted
by using a theoretical model. The model includes variation in the
response due to the effect of bearing dimensions, rotating frequency
distribution of load. The excitation forces are generated when the
defects on the races strike to rolling elements. In case of the outer
ring defect, the pulses generated are with periodicity of outer ring
defect frequency where as for inner ring defect, the pulses are with
periodicity of inner ring defect frequency. The effort has been carried
out in preparing the physical model of the system. Different defect
frequencies are obtained and are used to find out the amplitudes of
the vibration due to excitation of the bearing parts. Increase in the
radial load or severity of the defect produces a significant change in
bearing signature characteristics.
Abstract: In this paper, some common gearboxes vibration analysis methods and condition monitoring systems are explained. In addition, an experimental gearbox vibration analysis is discussed through a critical case history for a mixer gearbox related to Iran oil industry. The case history also consists of gear manufacturing (machining) recommendations, lubrication condition of gearbox and machinery maintenance activities that caused reduction in noise and vibration of the gearbox. Besides some of the recent patents and innovations in gearboxes, lubrication and vibration monitoring systems explained. Finally micro pitting and surface fatigue in pinion and bevel of mentioned horizontal to vertical gearbox discussed in details.
Abstract: The manufacture of large-scale precision aerospace
components using CNC requires a highly effective maintenance
strategy to ensure that the required accuracy can be achieved over
many hours of production. This paper reviews a strategy for a
maintenance management system based on Failure Mode Avoidance,
which uses advanced techniques and technologies to underpin a
predictive maintenance strategy. It is shown how condition
monitoring (CM) is important to predict potential failures in high
precision machining facilities and achieve intelligent and integrated
maintenance management. There are two distinct ways in which CM
can be applied. One is to monitor key process parameters and
observe trends which may indicate a gradual deterioration of
accuracy in the product. The other is the use of CM techniques to
monitor high status machine parameters enables trends to be
observed which can be corrected before machine failure and
downtime occurs.
It is concluded that the key to developing a flexible and intelligent
maintenance framework in any precision manufacturing operation is
the ability to evaluate reliably and routinely machine tool condition
using condition monitoring techniques within a framework of Failure
Mode Avoidance.
Abstract: In this paper an analytical crack propagation scenario
is proposed which assumes that a crack propagates in the tooth root in
both the crack depth direction and the tooth width direction, and
which is more reasonable and realistic for non-uniform load
distribution cases than the other presented scenarios. An analytical
approach is used for quantifying the loss of time-varying gear mesh
stiffness with the presence of crack propagation in the gear tooth root.
The proposed crack propagation scenario can be applied for crack
propagation modelling and monitoring simulation, but further
research is required for comparison and evaluation of all the
presented crack propagation scenarios from the condition monitoring
point of view.