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Chapter 2 System Approach To CBM-PHM

The document discusses maintenance management through a system approach to condition-based maintenance and prognostics and health management. It outlines topics including trade studies, failure mode effects and criticality analysis, system CBM test plans and design, performance assessment, and case studies on the impacts of CBM/PHM on maintenance and operations. The introduction describes CBM as using machinery data to determine current fault conditions and schedule repairs, while PHM refers to predicting future behavior and remaining useful life.

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181 views22 pages

Chapter 2 System Approach To CBM-PHM

The document discusses maintenance management through a system approach to condition-based maintenance and prognostics and health management. It outlines topics including trade studies, failure mode effects and criticality analysis, system CBM test plans and design, performance assessment, and case studies on the impacts of CBM/PHM on maintenance and operations. The introduction describes CBM as using machinery data to determine current fault conditions and schedule repairs, while PHM refers to predicting future behavior and remaining useful life.

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Dio
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© © All Rights Reserved
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Maintenance Management

(System Approach to CBM/PHM – Part I)

DR. ENG. ACHMAD WIDODO


Vibration & Machine Diagnostics Laboratory
Department of Mechanical Engineering
Diponegoro University

Vibration & Machine Diagnostics Lab. -1- Diponegoro University


Outline

1. Introduction
2. Trade Studies
3. Failure Mode Effects and Critically Analysis
(FMECA)
4. System CBM: Test Plan and Design
5. Performance Assessment
6. CBM/PHM Impacts on Maintenance and
Operations:Case Studies
7. CB/PHM in Control Contingency and Management

Vibration & Machine Diagnostics Lab. -2- Diponegoro University


Introduction

Condition-based maintenance (CBM) is the use of


machinery run-time data to determine the
machinery condition and hence its current fault /
failure condition, which can be used to schedule
required repair and maintenance prior to
breakdown
Prognostics and health management (PHM) refers
specifically to the phase involved with predicting
future behavior, including remaining useful life
(RUL), in terms of current operating state and the
scheduling of required maintenance actions to
maintain system health

Vibration & Machine Diagnostics Lab. -3- Diponegoro University


Introduction

The CBM/PHM designer:must have a thorough


understanding of methods for optimal selection of
monitoring strategies, tools, and algorithms
needed to detect, isolate, and predict the time
evolution of the fault, as well as systems
approaches for design of experiments and testing
protocols, performance metrics, and means to
verify and validate the effectiveness and
performance of the selected models.
New systems approaches, as well as established
ones from other disciplines, may be brought to the
CBM/PHM domain with suitable modifications.

Vibration & Machine Diagnostics Lab. -4- Diponegoro University


Introduction

Figure 2.1 depicts the main modules of an integrated


approach to CBM/PHM system design with the
systems-based components of the architecture
described in this chapter highlighted.
The schematic indicates feedback loops that are
intended to optimize the approach and complete
the data collection and analysis steps that are
essential inputs to the development of the fault
diagnostic and prognostic algorithms.

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Introduction

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Introduction

In Fig. 2.2 one can identify a preliminary offline


phase and an online implementation phase of
CBM/PHM. The online phase includes obtaining
machinery data from sensors, signal
preprocessing, extracting the features that are the
most useful for determining the current status or
fault condition of the machinery, fault detection
and classification, prediction of fault evolution, and
scheduling of required maintenance.
These components are discussed in detail in Chaps. 5
and 6.

Vibration & Machine Diagnostics Lab. -7- Diponegoro University


Vibration & Machine Diagnostics Lab. -8- Diponegoro University
2.2 Trade Studies

The major scope of a trade study is to arrive at the ‘‘best’’ or


most balanced solution to the diagnosis and prognosis of
critical component /subsystem failure modes leading to
optimal CBM/PHM practices.
Specific objectives of a trade study include

• Support the decision needs of the system engineering


process.
• Evaluate alternatives (requirements, functions,
configurations).
• Integrate and balance all considerations.
• Recommend ‘‘best’’ solution.
• Develop and refine a system concept.
• Determine if additional analysis, synthesis, or tradeoff studies
are required to make a selection.

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2.2 Trade Studies

A formal framework for trade studies follows a


methodology called integrated product and process
design (IPPD) (Schrage et al., 2002). The IPPD
meth- odology attempts to:
• Establish the need.
• Define the problem.
• Establish value objectives.
• Generate feasible alternatives.
• Make decisions.

Vibration & Machine Diagnostics Lab. - 10 - Diponegoro University


2.2 Trade Studies

In the Fig 2.3 , the quality function deployment (QFD), or


house of quality (Sullivan, 1986) as it is sometimes known,
captures the customer’s requirements and defines design
tradeoffs. It prioritizes the requirements, lists the
characteristics of the components under study, and ranks
capabilities versus the states requirements.
It is used to translate the ‘‘voice of the customer’’ to identify
the key ‘‘product and process characteristics/attributes.’’
The morphologic matrix (MM) is a technology forecasting tool
that can be used for initial synthesis of viable concepts that
then can be evaluated, initially qualitatively, in a Pugh
concept evaluation

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2.2 Trade Studies

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2.3 FMECA

An FMECA study basically attempts to relate failure events to their root


causes. Toward this goal, it addresses issues of identifying failure
modes, their severity, frequency of occurrence, and testability; fault
symptoms that are suggestive of the system’s behavior under fault
conditions; and the sensors/monitoring apparatus required to
monitor and track the system’s fault-symptomatic behaviors.
Furthermore, advanced FMECA studies may recommend algorithms to
extract optimal fault features or condition indicators, detect and
isolate incipient failures, and predict the remaining useful life of
critical components. Such studies generate the template for
diagnostic algorithms.
The FMECA framework may be integrated into existing supervisory
control and data acquisition (SCADA) or other appropriate data
management and control centers to provide the operator with
convenient access to information regarding failure events and their
root causes.

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2.3 FMECA

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2.3 FMECA

The design of an FMECA must identify failure modes and rank


them according to their severity, frequency of occurrence,
and testability. Severity categorizes the failure mode
according to its ultimate consequence. For example, a
possible class breakdown may be

Category 1: Catastrophic, a failure that results in death,


significant injury,or total loss of equipment.
Category 2: Critical, a failure that may cause severe injury,
equipment damage, and termination.
Category 3: Marginal, a failure that may cause minor injury,
equipment damage, or degradation of system performance.
Category 4: Minor, a failure that does not cause injury or
equipment damage but may result in equipment failure if left
unattended, downtime, or unscheduled maintenance/ repair.

Vibration & Machine Diagnostics Lab. - 15 - Diponegoro University


2.3 FMECA

Case Study:
An FMECA study was conducted for a shipboard chiller under
sponsorship by the Office of Naval Research (Propes et al.,
2002).
The relevant study information regarding one particular fault
condition is summarized below:
 Fault Refrigerant charge high
 Occurrence Probable
 Severity Critical
 Testability Can be monitored
 Description Due to overcharge during maintenance

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2.3 FMECA

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2.3 FMECA

The refrigerant is stored in the evaporator and under full load


conditions should barely cover the tops of the cooler tubes.
When refrigerant levels are high, the tubes are covered with
refrigerant, and less refrigerant is boiled off to the
compressors.
The overall effect is decreased efficiency, which may result in
loss of cooling. In addition, a very high charge level may
result in the compressor sucking up liquid refrigerant
droplets (instead of pure vapor), which can quickly erode the
impeller.

Vibration & Machine Diagnostics Lab. - 18 - Diponegoro University


2.3 FMECA

Symptoms
Refrigerant level very high Increased full-load T
across chill water
 Low compressor discharge temperature
 High compressor suction pressure
 High compressor discharge pressure
 High compressor motor amps
 or
 Compressor suction superheat less than 0 F

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2.4 SYSTEM CBM TEST-PLAN

The objective of a CBM test plan is to design the required


instrumentation, data-collection apparatus, and testing
procedures and operate the system/sub- system under
controlled conditions on a test cell or under real operational
regimes in order to acquire baseline and fault data that will
be used, eventually, to train and validate diagnostic and
prognostic algorithms.

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2.4 SYSTEM CBM TEST-PLAN

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2.4 SYSTEM CBM TEST-PLAN

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