OPEN predictorTM

INTRODUCTION

TO THE

OPENpredictor TM

CONDITION AND PERFORMANCE MONITORING

SYSTEMS

Copyright2005. All rights, title and interest in and the Software, Hardware and Services detailed in this document and all copyrights, patents,
trademarks, service marks or other intellectual property or proprietary rights relating thereto belong exclusively to ROVSING Dynamics A/S

Marielundvej 41 · DK-2730 Herlev · Denmark CBS_OP-Intro_Jan05.04_03

Tel: +45 46 90 72 00 · Fax: +45 44 84 60 40 · VAT No. 20 05 24 73

e-mail: info@rovsing-dynamics.com · www.rovsing-dynamics.com
OPENpredictor™
CONDITION AND PERFORMANCE
MONITORING SYSTEMS

Automatic fault diagnosis FAULTS ON FAULTS ON Operation via mimics Operation via browser
and health prediction ROTATING STATIONARY Operation via the mimics is also straightforward. For the vibration expert or process engineers the
To assess the mechanical and functional health of COMPONENTS COMPONENTS Machine pictograms or photos are used to present browser is an effective way to retrieve any data from
plant assets, the widest range of potential machinery Rotor/shaft: Foundation: sensor locations. Operator data is presented below the the database. Dedicated filtering functions allow
problems shall automatically be identified. Unbalance Looseness defined sensors. This data is automatically updated selective display of data, which eases trouble-shooting.
Bent rotor when new values have been identified. The color of
Casing:
Eccentricity
During different transient and stationary operational Electrical excitation the data represents the alarm status. By clicking on The experts can pre-configure preferred data displays
Oil whirl
states of the machines, the development of specific Misalignment a sensor a graphical plot is started showing the trend in order to ease future data retrieval.
Steam whirl
faults shall be identified. As the development of faults is Thermal uneven expansion data.
Rubbing in bearings & seals
related to machine operation, the measured data has to Blocked bearing movement The window contains four areas below the title bar:
be classified to transient and operational states in order Blades & impellers: • Menus
Combustor:
to achieve meaningful data comparison, automatic fault Rubbing • Toolbars
Resonance
Cavitation
diagnosis (AutoDiagnosis™) and health prediction. Flame instability • Current item/measurement selected
surge
Flame distribution • Left field: Item/measurement selector
Stall
In the following overview, several machinery • Right field: Item/measurement data
components, potential problems and their early Rolling element bearings:
diagnosis are presented. The OPENpredictor™ system Outer race defects Reporting
can however be configured to identify a wide range of Inner race defects
Cage defects
other machine specific problems when more detailed Report generator
Lubrication deficiency
machinery information is provided. OPENpredictor™ incorporates a report generator to
Journal bearings: create dedicated reports. These reports can be stored
Machine components Shaft lift fault under user-defined names for easy retrieval. Apart
The overall health of a machine depends on the Wear from these reports any graphical plot can be exported
condition of all components critical for the machine Thrust bearings: in HTML format for easy transfer via an e-mail system.
operation and all dynamic forces acting on the Example of Machine Mimic with real time measurement values and
Wear
links to other mimics and graphical plots.
components. The components are subdivided into Shift reports
Couplings:
rotating and stationary items such as: Shift reports will be printed out automatically at the
Locking
Mechanical and functional health assessment It is possible to create different levels of mimics, specified time, after they have been defined (once).
Gear wheels: which are actively linked together via "link buttons". They will contain the requested operation information
ROTATING STATIONARY Wear This allows easy navigation between machines located for the shift group in the control room, stating where
COMPONENTS COMPONENTS Back lash
in different plant sections without having detailed special attention is needed.
Rotor/Shaft Foundation Tooth defects
knowledge about machine names, tag identifiers and
Gear wheels Casing Pitting
sensor locations. Management reports
Blades Seals
For specific machinery design, additional potential Management reports have to be requested manually.
Couplings Bearings
faults can be specified. These reports typically will contain maintenance
Combustor
information on identified machinery faults, fault
When no design and/or installation problems exist, Monitoring of e.g. gas turbine performance degradation predictions and recommendations. For the experts
and then the typical sources of machine health Gas turbine performance degrades over time due to detailed data can be included to justify the
deterioration are component fatigue, wear, erosion and recoverable and non-recoverable mechanical changes. maintenance activities.
external factors. Machine mechanical health monitoring The result is a reduction of the power output and
provides information to optimize machine availability, an increase of the heat rate (a decrease of thermal
while machine functional health assessment provides efficiency).
information with regards to machine performance (e.g.
component efficiency). Typical recoverable losses are fouling of blades (mostly
compressor blades) and air filters. These losses can
Monitoring problems that influence machine availability be recovered by operational cleaning procedures or by
The following list is an overview of the most common external maintenance.
faults to be monitored in order to assess the
The OPENpredictorTM browser provides hierarchical machine/
mechanical machine health: Typical non-recoverable losses are blade erosion or components/measurement overview and configuration details.
From the browser, graphical representations of measurements can
deviations in tip clearance and seals. These losses
conveniently be invoked.

2 11
Fault diagnostic messages shall be acknowledged by the
user and can simply be printed or routed to the e-mail
system.
Fault Diagnostic Message.
From the fault diagnostic message, the user can access
a prediction plot (see example below), forecasting how
the fault will develop over time.
Operation via warning system
This is a very efficient way to retrieve information
about identified changes in the machine behavior, for
which no AutoDiagnosis™ can be provided yet. This
10
function minimizes machine operation risk, as any
important identified change in machine behavior will
give a warning. When OPENpredictor™ has identified an
"alert" or "alarm", a "warning lamp" starts flashing, and
by clicking the flashing "warning lamp" an "alert list"
will show detailed information. One more mouse click
reveals the information either as a graphical plot or as
an AutoDiagnosis™ message.
Accessing data is extremely simple using well-known
icons and menu-bars.
The Prediction curve presents graphically the specific fault Prediction,
together with the confidence range.
can only be recovered by replacement of internal gas (residual lifetime of concerned components).
turbine components.
The following illustrates some of the signatures used
To monitor the deviation from a new gas turbine in OPENpredictor™ together with their main fault
performance, is valuable to schedule compressor identification capabilities.
cleaning. The cleaning and filter exchange date can
be forecasted and performed on the most economical
date. Additionally, the long-term retrofitting can be
economically optimized.
The performance monitoring system uses existing
process measurements such as temperatures,
pressures, fuel specification, ambient conditions, etc.
The system provides actual and corrected (corrected to
reference ambient) estimates on:
• Power output
• Heat rate, thermal efficiency
• Compressor efficiency
• Turbine efficiency
• Fouling indices for compressor and filter
Process problems that influence machine availability
Potential dangerous process circumstances can cause
machine damage such as:
The Constant Percentage Bandwidth Signature (CPB) gives a general
• Cavitation health overview of the majority of mechanical fault characteristics,
• Surge such as, unbalance, misalignment, foundation looseness. It is however,
specifically sensitive in identifying faults such as rolling element
• Stall bearing faults, cavitation, combustor resonance and gas leaks.
• Combustion pulsation
When these problems occur, the operation shall be
changed in order to avoid strong dynamic forces to
blades, impellers and seals. The result is reduced
operational risk and longer service life.
OPENpredictor™ machine health
assessment methodology
Early fault identification
OPENpredictor™ provides a unique library of signatures
dedicated to detect and identify most mechanical
problems, which may be encountered for common
rotating and reciprocating machinery. The dedicated
signatures check for different fault characteristics
and provide selective information regarding fault
symptoms, fault development as well as fault
locations. Information provided by the different The Autospectrum Signature (FFT) is used to identify faults which can
only be diagnosed with a high frequency resolution, such as electrical
signatures form the basis for automatic fault diagnosis excitation, distinction between electrical and mechanical imbalance,
(AutoDiagnosis™) and prediction of fault development blade passing excitation and system resonance.
3

The Cepstrum Signature (CEP) provides a good selectivity to identify
gear wheel faults in complex gearboxes and any other faults, which
result in a signal with modulation character.
The Transient Signature (TRT) is used to automatically identify changes
in the run-up or coast-down behavior of a machine. Changed critical
frequencies and decreased damping are automatically diagnosed.
4 9
The Selective Envelope Detection Signature (SED) is specifically
sensitive to identify faults where symptoms are of repetitive impulse
character, such as rolling element bearing faults and cavitation.
The AutoDiagnosisTM function uses the repetition rate of the fault to
conclude the origin of the fault.
Vector Analysis is used extensively in the AutoDiagnosis models.
OPENpredictor™ provides a unique implementation of Order Tracking
Analysis (OTA) that provides accurate vector values, both in steady
state and transient conditions. A vector consists of both an amplitude
and phase value, referencing to the position of the shaft at the tacho
probe. The unique algorithm provides the vector values for four harmonic
components and the sub-harmonic representing shaft instability.
provides a high sensitivity for early fault identification
and is used for AutoDiagnosis™ and prediction.
OPENpredictor™ server
The OPENpredictor™ server receives the data
measured and processed by the SPU's. The server
stores the data in the internal RAM memory, from
which it is transferred into the relational database.
In this way large bursts of data will not result in data
loss. If data variations are less than a user-defined
percentage from previously stored values, then data is
automatically removed. This assures that the database
is not filled with data, which does not provide any
valuable information. Alarm information and fault
diagnostic results are also stored in the database.
The OPENpredictor™ server also runs the
AutoDiagnosis™ and health prediction programs, data
display and reporting programs as well as the remote
access program.
Man Machine Interface
The user
The man machine interface has been developed to
meet different user requirements. Users are typically
operators in the control room, maintenance engineers,
process engineers and system managers. As these
users have different responsibilities and demands,
the system can be configured to meet individual
information requirements.
OPENpredictor™ incorporates three different warning
systems, one each for operation, maintenance and
process optimization. System operation is similar for
each user but the type of information presented can be
adapted to the plant and user requirements.
Alarm Bar
Information retrieval
The OPENpredictor™ system has been designed
for unmanned operation. As machines are typically
operating reliably over a long period of time, it is
essential that a PMIS system automatically provide
warnings, when actions need to be defined.
There exists four different ways to operate the system:
• Via AutoDiagnosis™ messages
• Via the warning systems
• Via the mimics
• Via the browser
Operation via AutoDiagnosis™ messages
OPENpredictor™ automatically interprets changes
in machine behavior and will issue AutoDiagnosis™
messages when machinery faults have been positively
identified.
A distinction is made between instantaneous and
gradually developing faults. An instantaneous fault
does not have a prediction e.g. a shaft rub or
cavitation, as it occurs during a certain period as a
coincidence of operation circumstances.
Wear phenomena in bearings and gears however
typically have a long development path, for which a
prediction will be presented.
The AutoDiagnosis™ message pops up automatically
and provides information about the identified fault,
the component involved, the fault strength and if
configured by the plant a recommendation of the
action to be performed. If a prediction is available then
the fault strength can be plotted as a trend together
with its expected future development to assist in
planning of the corrective task.
SIGNATURE
PROCESSING SYSTEM

RO2000 Signature Processing Unit (SPU) The Circular Analysis Plot (CA) is used to
The advanced library of signatures provided by the monitor changes in symmetry for exhaust gas
OPENpredictor™ system supported by the very latest temperatures, thrust bearing pressure and
temperature.
technology and performance in signal processing as
implemented on the OPENpredictor™ signal processing
module, paves the way for detection and diagnosis for
a wide variety of all mechanical machine faults. Only
a limited number of sensors are required, of which
most may already be available on the machines to be
monitored.

Signals from field sensors are routed to the

OPENpredictor™ signature processing unit (SPU),
which consists of up to ten signal-processing modules,
each handling eight sensor inputs. Processing in the
SPU is performed by the individual signal processing
modules. Parameters and signatures (including alarms)
are transferred to the OPENpredictor™ server for
AutoDiagnosis™ processing, prediction, reporting and
display. All results are stored in the OPENpredictor™
database for retrieval later, as required.
Signature Processing Unit (SPU)
The SPU will be configured from the OPENpredictor™ The Shaft Centre Line Plot (SCL) shows the
server. The SPU performs data acquisition, signal location of the shaft centre in the bearing
conditioning, classification and signature calculation clearance. The acceptance location domain is
indicated by the yellow/red alarm limits.
functions. It also performs continuous alarm checks
on scalar and vector data as well as on the calculated
signatures.

Sensors

Existing sensors
Existing sensors will be used as much as possible.
The signal output of existing vibration sensors can be
duplicated to the SPU inputs using galvanic isolators
or direct-buffered sensor outputs of already installed
vibration-monitoring panels. This reduces engineering
and installation activities to a minimum.

Load and Reactive load signals will be directly measured Modulation spectrogram
as basis for SMD-function.
by the SPU for the major operation Classification.

RO2020-1 Signal Processing Module (SPM)

Other process signals, e.g. for gas turbine efficiency
monitoring will be duplicated using isolators in the Scalar dynamic data
marshaling racks or a serial link On-line scalar data are overall vibration values, position
from the control system. values, axial positions and machine speeds.

Additional sensors Vector data

The machines will be equipped
with additional dynamic sensors
as needed, in order to calculate
all the signatures needed for
complete fault detection and
diagnosis.
RO1000 Accelerometer (OEM product).
The SPU processes the raw vibration signals to
calculate vector values. These vector values improve
the AutoDiagnosis™ functions and provide the basic SMD function showing synchronous modulation
strength as function of time.
input to the balancing program (option).
Signature calculation and analysis
The signal processing modules acquire data and
perform the signature calculations. Signature analysis

8 5

Classification of signature processing
Machine behavior (and consequently measurement
performed on the machine) depends on how a machine
operates. Therefore, calculated signatures will also vary
with machine operation. Machine health assessment
has to be performed under comparable operating
conditions and fault symptoms shall be assessed only
within a given machine state. That is accomplished
by OPENpredictor™ and this concept is referred to as
"Classification of Signature Processing, Fault Diagnosis
and Prediction".
Typical start-up behaviour of a gas turbine
Level
1 2 3 4
Steady States Typical Transient and Steady States:
Transient States
Gradient States
Calibration
Left: Fault diagnosis, severity and recommendation are provided in
It is important to note that a number of faults will only clear text. User recommendations can freely be added in order to
reveal themselves in some or even in one machine assist the operators in their daily task.
Clicking with the mouse on Explorer Graph reveals the forecast curve.
state and that some faults will only reveal themselves
This fault description with severity estimation and recommendation can
during transient states, such as run-up/coast-down. then be directed to a maintenance management or reporting system.
In conclusion, Classification is essential to improve
Predictions are available in the defined machine
identification sensitivity, to create realistic prediction
states with the benefit of giving critical dates for
and to avoid false warnings.
alternative operating conditions. For faults where a
combination of parameters is required for diagnosis,
the AutoDiagnosis™ function provides fault symptom
prediction.
Engineers' tools
Detailed manual analysis is possible using the
signatures plots as well as the "manual analysis tools"
The AutoDiagnosis™ fault libraries are expandable to such as Orbit, 3-D, Multiple Trend Analysis, Scatter and
new experience and new machine designs. Nyquist analysis, etc. Statistical analysis functions are
available for easy data classification and investigation
Prediction of fault development of relationships between parameters.
Prediction of fault development is performed on
selective areas in signatures, for which the level Extensive data filter and sorting facilities allow fast
relates to specific machinery problems. The system and easy access to historic data and a wide scope of
Time
5 6 7 8 9 automatically forecasts the date that a fault symptom graphic tools provide presentation in any appearance
1. Test phase will reach the defined alarm level. As all data is domain for easy assessment and troubleshooting.
2. Slow roll classified to comparable process circumstances, the
3. Ventilation prediction provides a reliable estimate.
4. Run-up, cold, warm, hot
5. Over speed testing
6. Syncronisation to mains
7. Low load
8. Medium load
9. .............

The time a machine is not producing is defined
as <transient>. Production states are defined as
<operational states>.
TRANSIENT STATES
State 1 Calibration
State 2 Slow roll
State 3 Ventilation,
temperature
setting
State 4 Run-up
(cold and/or hot)
State 5 Over speed testing
State 6 Synchronization
Etc.
Automatic fault diagnosis (AutoDiagnosis™)
OPENpredictor™ provides automatic fault diagnosis
for faults in critical machine components and potential
faults. The foundation of AutoDiagnosis™ is the
OPERATIONAL STATES synergy between classification, normalization and fault
State 7 Low load, selective signatures. The result is early fault detection
inductive operation and accurate diagnosis with diagnostic messages
State 8 Medium load, presented to users in clear text. Locally defined
inductive operation recommendations for action, together with prediction
State 9 High load, of fault development as well as date for required
inductive operation
inspection/maintenance ease the tasks for the users.
State 7b Low load,
Any measured signature can be plotted in a 3-D presentation as The 3-D representation may also be viewed from a birds perspective
capacitive operation
Fault prediction provides the user with clear function of time, RPM or any other process parameter to show in the so-called Campbell plot. Here, the Frequency-Time dependent
dependencies. Applying data filters removes data, which is temporarily amplitude is shown in colour code.
State 8b Medium load,
information required for maintenance planning or not relevant.
capacity operation operation improvements.
State 9b High load,
capacity operation
Etc.

6 7

Classification of signature processing
Machine behavior (and consequently measurement
performed on the machine) depends on how a machine
operates. Therefore, calculated signatures will also vary
with machine operation. Machine health assessment
has to be performed under comparable operating
conditions and fault symptoms shall be assessed only
within a given machine state. That is accomplished
by OPENpredictor™ and this concept is referred to as
"Classification of Signature Processing, Fault Diagnosis
and Prediction".
Typical start-up behaviour of a gas turbine
Level
1 2 3 4
Steady States Typical Transient and Steady States:
Transient States
Gradient States
Calibration
Left: Fault diagnosis, severity and recommendation are provided in
It is important to note that a number of faults will only clear text. User recommendations can freely be added in order to
reveal themselves in some or even in one machine assist the operators in their daily task.
Clicking with the mouse on Explorer Graph reveals the forecast curve.
state and that some faults will only reveal themselves
This fault description with severity estimation and recommendation can
during transient states, such as run-up/coast-down. then be directed to a maintenance management or reporting system.
In conclusion, Classification is essential to improve
Predictions are available in the defined machine
identification sensitivity, to create realistic prediction
states with the benefit of giving critical dates for
and to avoid false warnings.
alternative operating conditions. For faults where a
combination of parameters is required for diagnosis,
the AutoDiagnosis™ function provides fault symptom
prediction.
Engineers' tools
Detailed manual analysis is possible using the
signatures plots as well as the "manual analysis tools"
The AutoDiagnosis™ fault libraries are expandable to such as Orbit, 3-D, Multiple Trend Analysis, Scatter and
new experience and new machine designs. Nyquist analysis, etc. Statistical analysis functions are
available for easy data classification and investigation
Prediction of fault development of relationships between parameters.
Prediction of fault development is performed on
selective areas in signatures, for which the level Extensive data filter and sorting facilities allow fast
relates to specific machinery problems. The system and easy access to historic data and a wide scope of
Time
5 6 7 8 9 automatically forecasts the date that a fault symptom graphic tools provide presentation in any appearance
1. Test phase will reach the defined alarm level. As all data is domain for easy assessment and troubleshooting.
2. Slow roll classified to comparable process circumstances, the
3. Ventilation prediction provides a reliable estimate.
4. Run-up, cold, warm, hot
5. Over speed testing
6. Syncronisation to mains
7. Low load
8. Medium load
9. .............

The time a machine is not producing is defined
as <transient>. Production states are defined as
<operational states>.
TRANSIENT STATES
State 1 Calibration
State 2 Slow roll
State 3 Ventilation,
temperature
setting
State 4 Run-up
(cold and/or hot)
State 5 Over speed testing
State 6 Synchronization
Etc.
Automatic fault diagnosis (AutoDiagnosis™)
OPENpredictor™ provides automatic fault diagnosis
for faults in critical machine components and potential
faults. The foundation of AutoDiagnosis™ is the
OPERATIONAL STATES synergy between classification, normalization and fault
State 7 Low load, selective signatures. The result is early fault detection
inductive operation and accurate diagnosis with diagnostic messages
State 8 Medium load, presented to users in clear text. Locally defined
inductive operation recommendations for action, together with prediction
State 9 High load, of fault development as well as date for required
inductive operation
inspection/maintenance ease the tasks for the users.
State 7b Low load,
Any measured signature can be plotted in a 3-D presentation as The 3-D representation may also be viewed from a birds perspective
capacitive operation
Fault prediction provides the user with clear function of time, RPM or any other process parameter to show in the so-called Campbell plot. Here, the Frequency-Time dependent
dependencies. Applying data filters removes data, which is temporarily amplitude is shown in colour code.
State 8b Medium load,
information required for maintenance planning or not relevant.
capacity operation operation improvements.
State 9b High load,
capacity operation
Etc.

6 7
SIGNATURE
PROCESSING SYSTEM

RO2000 Signature Processing Unit (SPU) The Circular Analysis Plot (CA) is used to
The advanced library of signatures provided by the monitor changes in symmetry for exhaust gas
OPENpredictor™ system supported by the very latest temperatures, thrust bearing pressure and
temperature.
technology and performance in signal processing as
implemented on the OPENpredictor™ signal processing
module, paves the way for detection and diagnosis for
a wide variety of all mechanical machine faults. Only
a limited number of sensors are required, of which
most may already be available on the machines to be
monitored.

Signals from field sensors are routed to the

OPENpredictor™ signature processing unit (SPU),
which consists of up to ten signal-processing modules,
each handling eight sensor inputs. Processing in the
SPU is performed by the individual signal processing
modules. Parameters and signatures (including alarms)
are transferred to the OPENpredictor™ server for
AutoDiagnosis™ processing, prediction, reporting and
display. All results are stored in the OPENpredictor™
database for retrieval later, as required.
Signature Processing Unit (SPU)
The SPU will be configured from the OPENpredictor™ The Shaft Centre Line Plot (SCL) shows the
server. The SPU performs data acquisition, signal location of the shaft centre in the bearing
conditioning, classification and signature calculation clearance. The acceptance location domain is
indicated by the yellow/red alarm limits.
functions. It also performs continuous alarm checks
on scalar and vector data as well as on the calculated
signatures.

Sensors

Existing sensors
Existing sensors will be used as much as possible.
The signal output of existing vibration sensors can be
duplicated to the SPU inputs using galvanic isolators
or direct-buffered sensor outputs of already installed
vibration-monitoring panels. This reduces engineering
and installation activities to a minimum.

Load and Reactive load signals will be directly measured Modulation spectrogram
as basis for SMD-function.
by the SPU for the major operation Classification.

RO2020-1 Signal Processing Module (SPM)

Other process signals, e.g. for gas turbine efficiency
monitoring will be duplicated using isolators in the Scalar dynamic data
marshaling racks or a serial link On-line scalar data are overall vibration values, position
from the control system. values, axial positions and machine speeds.

Additional sensors Vector data

The machines will be equipped
with additional dynamic sensors
as needed, in order to calculate
all the signatures needed for
complete fault detection and
diagnosis.
RO1000 Accelerometer (OEM product).
The SPU processes the raw vibration signals to
calculate vector values. These vector values improve
the AutoDiagnosis™ functions and provide the basic SMD function showing synchronous modulation
strength as function of time.
input to the balancing program (option).
Signature calculation and analysis
The signal processing modules acquire data and
perform the signature calculations. Signature analysis

8 5

The Cepstrum Signature (CEP) provides a good selectivity to identify
gear wheel faults in complex gearboxes and any other faults, which
result in a signal with modulation character.
The Transient Signature (TRT) is used to automatically identify changes
in the run-up or coast-down behavior of a machine. Changed critical
frequencies and decreased damping are automatically diagnosed.
4 9
The Selective Envelope Detection Signature (SED) is specifically
sensitive to identify faults where symptoms are of repetitive impulse
character, such as rolling element bearing faults and cavitation.
The AutoDiagnosisTM function uses the repetition rate of the fault to
conclude the origin of the fault.
Vector Analysis is used extensively in the AutoDiagnosis models.
OPENpredictor™ provides a unique implementation of Order Tracking
Analysis (OTA) that provides accurate vector values, both in steady
state and transient conditions. A vector consists of both an amplitude
and phase value, referencing to the position of the shaft at the tacho
probe. The unique algorithm provides the vector values for four harmonic
components and the sub-harmonic representing shaft instability.
provides a high sensitivity for early fault identification
and is used for AutoDiagnosis™ and prediction.
OPENpredictor™ server
The OPENpredictor™ server receives the data
measured and processed by the SPU's. The server
stores the data in the internal RAM memory, from
which it is transferred into the relational database.
In this way large bursts of data will not result in data
loss. If data variations are less than a user-defined
percentage from previously stored values, then data is
automatically removed. This assures that the database
is not filled with data, which does not provide any
valuable information. Alarm information and fault
diagnostic results are also stored in the database.
The OPENpredictor™ server also runs the
AutoDiagnosis™ and health prediction programs, data
display and reporting programs as well as the remote
access program.
Man Machine Interface
The user
The man machine interface has been developed to
meet different user requirements. Users are typically
operators in the control room, maintenance engineers,
process engineers and system managers. As these
users have different responsibilities and demands,
the system can be configured to meet individual
information requirements.
OPENpredictor™ incorporates three different warning
systems, one each for operation, maintenance and
process optimization. System operation is similar for
each user but the type of information presented can be
adapted to the plant and user requirements.
Alarm Bar
Information retrieval
The OPENpredictor™ system has been designed
for unmanned operation. As machines are typically
operating reliably over a long period of time, it is
essential that a PMIS system automatically provide
warnings, when actions need to be defined.
There exists four different ways to operate the system:
• Via AutoDiagnosis™ messages
• Via the warning systems
• Via the mimics
• Via the browser
Operation via AutoDiagnosis™ messages
OPENpredictor™ automatically interprets changes
in machine behavior and will issue AutoDiagnosis™
messages when machinery faults have been positively
identified.
A distinction is made between instantaneous and
gradually developing faults. An instantaneous fault
does not have a prediction e.g. a shaft rub or
cavitation, as it occurs during a certain period as a
coincidence of operation circumstances.
Wear phenomena in bearings and gears however
typically have a long development path, for which a
prediction will be presented.
The AutoDiagnosis™ message pops up automatically
and provides information about the identified fault,
the component involved, the fault strength and if
configured by the plant a recommendation of the
action to be performed. If a prediction is available then
the fault strength can be plotted as a trend together
with its expected future development to assist in
planning of the corrective task.
Fault diagnostic messages shall be acknowledged by the
user and can simply be printed or routed to the e-mail
system.
Fault Diagnostic Message.
From the fault diagnostic message, the user can access
a prediction plot (see example below), forecasting how
the fault will develop over time.
Operation via warning system
This is a very efficient way to retrieve information
about identified changes in the machine behavior, for
which no AutoDiagnosis™ can be provided yet. This
10
function minimizes machine operation risk, as any
important identified change in machine behavior will
give a warning. When OPENpredictor™ has identified an
"alert" or "alarm", a "warning lamp" starts flashing, and
by clicking the flashing "warning lamp" an "alert list"
will show detailed information. One more mouse click
reveals the information either as a graphical plot or as
an AutoDiagnosis™ message.
Accessing data is extremely simple using well-known
icons and menu-bars.
The Prediction curve presents graphically the specific fault Prediction,
together with the confidence range.
can only be recovered by replacement of internal gas (residual lifetime of concerned components).
turbine components.
The following illustrates some of the signatures used
To monitor the deviation from a new gas turbine in OPENpredictor™ together with their main fault
performance, is valuable to schedule compressor identification capabilities.
cleaning. The cleaning and filter exchange date can
be forecasted and performed on the most economical
date. Additionally, the long-term retrofitting can be
economically optimized.
The performance monitoring system uses existing
process measurements such as temperatures,
pressures, fuel specification, ambient conditions, etc.
The system provides actual and corrected (corrected to
reference ambient) estimates on:
• Power output
• Heat rate, thermal efficiency
• Compressor efficiency
• Turbine efficiency
• Fouling indices for compressor and filter
Process problems that influence machine availability
Potential dangerous process circumstances can cause
machine damage such as:
The Constant Percentage Bandwidth Signature (CPB) gives a general
• Cavitation health overview of the majority of mechanical fault characteristics,
• Surge such as, unbalance, misalignment, foundation looseness. It is however,
specifically sensitive in identifying faults such as rolling element
• Stall bearing faults, cavitation, combustor resonance and gas leaks.
• Combustion pulsation
When these problems occur, the operation shall be
changed in order to avoid strong dynamic forces to
blades, impellers and seals. The result is reduced
operational risk and longer service life.
OPENpredictor™ machine health
assessment methodology
Early fault identification
OPENpredictor™ provides a unique library of signatures
dedicated to detect and identify most mechanical
problems, which may be encountered for common
rotating and reciprocating machinery. The dedicated
signatures check for different fault characteristics
and provide selective information regarding fault
symptoms, fault development as well as fault
locations. Information provided by the different The Autospectrum Signature (FFT) is used to identify faults which can
only be diagnosed with a high frequency resolution, such as electrical
signatures form the basis for automatic fault diagnosis excitation, distinction between electrical and mechanical imbalance,
(AutoDiagnosis™) and prediction of fault development blade passing excitation and system resonance.
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OPENpredictor™
CONDITION AND PERFORMANCE
MONITORING SYSTEMS

Automatic fault diagnosis FAULTS ON FAULTS ON Operation via mimics Operation via browser
and health prediction ROTATING STATIONARY Operation via the mimics is also straightforward. For the vibration expert or process engineers the
To assess the mechanical and functional health of COMPONENTS COMPONENTS Machine pictograms or photos are used to present browser is an effective way to retrieve any data from
plant assets, the widest range of potential machinery Rotor/shaft: Foundation: sensor locations. Operator data is presented below the the database. Dedicated filtering functions allow
problems shall automatically be identified. Unbalance Looseness defined sensors. This data is automatically updated selective display of data, which eases trouble-shooting.
Bent rotor when new values have been identified. The color of
Casing:
Eccentricity
During different transient and stationary operational Electrical excitation the data represents the alarm status. By clicking on The experts can pre-configure preferred data displays
Oil whirl
states of the machines, the development of specific Misalignment a sensor a graphical plot is started showing the trend in order to ease future data retrieval.
Steam whirl
faults shall be identified. As the development of faults is Thermal uneven expansion data.
Rubbing in bearings & seals
related to machine operation, the measured data has to Blocked bearing movement The window contains four areas below the title bar:
be classified to transient and operational states in order Blades & impellers: • Menus
Combustor:
to achieve meaningful data comparison, automatic fault Rubbing • Toolbars
Resonance
Cavitation
diagnosis (AutoDiagnosis™) and health prediction. Flame instability • Current item/measurement selected
surge
Flame distribution • Left field: Item/measurement selector
Stall
In the following overview, several machinery • Right field: Item/measurement data
components, potential problems and their early Rolling element bearings:
diagnosis are presented. The OPENpredictor™ system Outer race defects Reporting
can however be configured to identify a wide range of Inner race defects
Cage defects
other machine specific problems when more detailed Report generator
Lubrication deficiency
machinery information is provided. OPENpredictor™ incorporates a report generator to
Journal bearings: create dedicated reports. These reports can be stored
Machine components Shaft lift fault under user-defined names for easy retrieval. Apart
The overall health of a machine depends on the Wear from these reports any graphical plot can be exported
condition of all components critical for the machine Thrust bearings: in HTML format for easy transfer via an e-mail system.
operation and all dynamic forces acting on the Example of Machine Mimic with real time measurement values and
Wear
links to other mimics and graphical plots.
components. The components are subdivided into Shift reports
Couplings:
rotating and stationary items such as: Shift reports will be printed out automatically at the
Locking
Mechanical and functional health assessment It is possible to create different levels of mimics, specified time, after they have been defined (once).
Gear wheels: which are actively linked together via "link buttons". They will contain the requested operation information
ROTATING STATIONARY Wear This allows easy navigation between machines located for the shift group in the control room, stating where
COMPONENTS COMPONENTS Back lash
in different plant sections without having detailed special attention is needed.
Rotor/Shaft Foundation Tooth defects
knowledge about machine names, tag identifiers and
Gear wheels Casing Pitting
sensor locations. Management reports
Blades Seals
For specific machinery design, additional potential Management reports have to be requested manually.
Couplings Bearings
faults can be specified. These reports typically will contain maintenance
Combustor
information on identified machinery faults, fault
When no design and/or installation problems exist, Monitoring of e.g. gas turbine performance degradation predictions and recommendations. For the experts
and then the typical sources of machine health Gas turbine performance degrades over time due to detailed data can be included to justify the
deterioration are component fatigue, wear, erosion and recoverable and non-recoverable mechanical changes. maintenance activities.
external factors. Machine mechanical health monitoring The result is a reduction of the power output and
provides information to optimize machine availability, an increase of the heat rate (a decrease of thermal
while machine functional health assessment provides efficiency).
information with regards to machine performance (e.g.
component efficiency). Typical recoverable losses are fouling of blades (mostly
compressor blades) and air filters. These losses can
Monitoring problems that influence machine availability be recovered by operational cleaning procedures or by
The following list is an overview of the most common external maintenance.
faults to be monitored in order to assess the
The OPENpredictorTM browser provides hierarchical machine/
mechanical machine health: Typical non-recoverable losses are blade erosion or components/measurement overview and configuration details.
From the browser, graphical representations of measurements can
deviations in tip clearance and seals. These losses
conveniently be invoked.

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 OPEN predictorTM

INTRODUCTION

TO THE

OPENpredictor TM

CONDITION AND PERFORMANCE MONITORING

SYSTEMS

Copyright2005. All rights, title and interest in and the Software, Hardware and Services detailed in this document and all copyrights, patents,
trademarks, service marks or other intellectual property or proprietary rights relating thereto belong exclusively to ROVSING Dynamics A/S

Marielundvej 41 · DK-2730 Herlev · Denmark CBS_OP-Intro_Jan05.04_03

Tel: +45 46 90 72 00 · Fax: +45 44 84 60 40 · VAT No. 20 05 24 73

e-mail: info@rovsing-dynamics.com · www.rovsing-dynamics.com