P08452: Fault Detectioin in Rotating Equipment for Energy Industry
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FD Establish Target Specifications

Table of Contents

Step 1. Prepare the List of Metrics

The table below presents the metrics, or engineering specifications, that will be used by the team to design against.

List of Metrics
Metric No. Metric Importance Units
1 Measure Ranges of Parameters High List
2 System Compatibility Moderate List
3 Faults Induced Moderate Binary (Pure Number)
4 Remote Access/Control High Binary
5 Guidelines Presented (Relative to Faults Induced) High Percentage (of Faults Induced)
6 Generate Data Plots Moderate List (Binary)
7 Power Supplied to System High Volts
8 Database Creation/Implementation High List

The metrics, or engineering specifications, that you created in the preceding list should be directly related to the customer needs. In other words, if you have created an engineering specification, it should have some relationship to a need imposed by the customer or the marketplace. Use the table below to map your customer needs against the metrics (or engineering specifications). In many design and product development circles, the rows along the left is often referred to as the voice of the customer, while the columns across the top are often referred to as the voice of the engineer.

Customer Needs as Related to Engineering Metrics Matrix
Needs and Metrics Measure Ranges of Parameters System Compatibility Faults Induced Remote Access/Control Guidelines Presented Data Plots Power Supplied Database Use
Data Acquisition x x x
Generic Solution x x
Control Systems x x x
User Interface x x x x x
Failure Data x x x x
Machine Responses x x x x

Step 2. Collect Competitive Benchmarking Information

Relatively few Sr. design projects start from a clean sheet of paper. In most cases, there are some baseline solutions or products that could meet the vast majority of the customer's needs.

Write one or two paragraphs about each benchmark solution from the market place. Include a picture of the product, preferably illustrating the product in use or operation.

Benchmark 1: Bently-Nevada System 1 - Optimization and Diagnostics Software
 System 1

System 1

System 1

Bently-Nevada

Provides software and hardware for product optimization, condition monitoring, and event diagnositcs. This is done through integration of all systems into one display with a strong centralized database. System 1 is applicable to a wide range of products and equipment including compressors, turbines, and electrical devices. The type of faults detected are related to thermo/fluids and vibrations with the ability to give warnings and trend data.
Benchmark 2: Prognost Condition Monitoring
 Prognost

Prognost

Prognost Condition Monitoring

PROGNOST Systems GmbH

On-line condition monitoring of reciprocating compressors and pumps. Allows for improved safety, machine availability, and efficiency. Improves decision making in terms of repair and replacements by providing knowledge on the operation characteristics of the machine. Has the ability to monitor, analyze, and interpret high frequency data to help determine machine reliability. Helps maintain critical economic efficiency of reciprocating compressors.

Benchmark 3: Windrock Incorporated
 Windrock

Windrock

Windrock Inc.

Provides on-line performance monitoring for reciprocating engines, compressors, and centrifugal products. Measure mechanical condition and unit performance as well as parameters of horsepower, flow balance, temperature, ultrasonic, and vibration. Incorporates the use of software, hardware (sensors), and systems. Allows the user to monitor, trend, alarm, and diagnose compressor condition and performance.

Competitive Benchmarking Comparison

Use this table below to compare how pre-existing solutions should compare against the design team's efforts. See the example Table 5-6 on Page 80 of the text by Ulrich and Eppinger.
Competitive Benchmarking Matrix
Metric No. Need Nos. Metric Importance Units Bently-Nevada System 1 Prognost Condition Monitoring Windrock Inc.
1 Need 1,2,6 Measure Ranges of Parameters High Vary
2 Need 2,3 System Compatibility Moderate List (Binary)
3 Need 5,6 Faults Induced Moderate Binary
4 Need 3,4 Remote Access/Control High Binary (List)
5 Need 4,5 Guidelines Presented High Percentage
6 Need 1,4,5,6 Data Plots Moderate List (Binary)
7 Need 3,4 Power Supplied High Volts
8 Need 1,4,5,6 Database Use High List (Binary)

Step 3. Set Ideal and Marginally Acceptable Target Values

Given the customer needs, awareness of the marketplace, and resource limitations of the current project, assign preliminary engineering specifications on each of the metrics. In addition to setting the nominal or target value or each specification, provide guidance to the team on the ideal value or direction that the team should strive for, once the nominal target values have been realized.

List of Metrics
Metric No. Need Nos. Metric Importance Units Marginal value Ideal Value
1 Need 1,2,6 Measure Ranges of Parameters High Vary Specific to Donation Compressor (Outlet Only) Wide Ranges(Outside Donation Compressor Use) at Inlet/Outlet
2 Need 2,3 System Compatibility Moderate List (Binary) Yes (Works with compressor and some DR Products) Yes (Operating Systems, DI-Tronics IV (PLC) Control System, Collection, etc.)
3 Need 5,6 Faults Induced Moderate Binary Yes (some) Yes (critical faults)
4 Need 3,4 Remote Access/Control High Binary (List) Could be Yes (no presence required)
5 Need 4,5 Guidelines Presented High Percentage 75% 100%
6 Need 1,4,5,6 Data Plots Moderate List (Binary) Show data collected (Independently) Provide Comparison (Failure vs. Normal)
7 Need 3,4 Power Supplied High Volts Whatever it takes 110 Volts (Or Standard Voltage)
8 Need 1,4,5,6 Database Use High List (Binary) Limited Archives with Clear Display Offers documentation archives of past normal/failure operation with clear accessibility
List of Possible Parameters to Measure
Metric No. Metric Importance Units Marginal Value Ideal Value
1 Temperature (Inlet) High degrees F Ambient (Donation Compressor Specific) -40 to 180
2 Temperature (Outlet) High degrees F 200 (Donation Compressor Specific) 200 to 350
3 Pressure (Inlet) High psi Ambient (Donation Compressor Specific) Ambient to 100
4 Pressure (Outlet) High psi 150 (Donation Compressor Specific) 20 to 4500 (Main Product line at 1500
5 Flow Rate (Inlet/Outlet) High CFM 25 (Donation Compressor Specific) 10 to 8000
4 Vibration Moderate Hz Low (Donation Compressor Specific ~300 RPM) Low (<400 RPM) & High (>400 RPM)
5 Acoustics Low dB Donation Compressor Specific Wide Range of Products
6 Power Low HP ~25 (Donation Compressor Specific) 10,000 HP (max 45,000 HP)

Step 4. Reflect on the Results and the Process

Had a difficult time coming up with specifications due to vagueness of the results/impact of each metric or need on the end project result. Also, implementation in Dresser-Rand products could be difficult due to the large ranges of values for each parameter due to a large product line.

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