Gestão integrada de ativos num contexto real

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia de Manutenção

Lyhyen kantaman radiolähettimien soveltuvuus sähkökäyttöjen kunnon-valvonnan ja etädiagnostiikan tiedonsiirtotarpeisiin

Lyhyen kantaman radiolähettimien käyttö on kasvanut muutaman viime vuoden aikana huomattavasti. Osaltaan tähän on vaikuttanut uusien taajuusalueiden allokointi lupavapaiden radiolähettimien käyttöön, standardoitujen tekniikoiden yleistyminen ja laitteiden parempi saatavuus. Tässä työssä tarkastellaan lyhyen kantaman radiolähettimien soveltuvuutta sähkökäyttöjen kunnonvalvonnan ja etädiagnostiikan tiedonsiirtotarpeisiin. Työssä luodaan katsaus teollisuusympäristön vaikutuksiin langattomassa tiedonsiirrossa ja tarkastellaan sähkökäyttöjen kunnonvalvonnan ja etädiagnostiikan vaatimuksia tiedonsiirrolle ja tiedonsiirtojärjestelmälle. Työssä käydään läpi lyhyen kantaman radiolähettimiin liittyvät säädökset ja luodaan katsaus standardoituihin sekä valmistajakohtaisiin lyhyen kantaman radiotekniikoihin. Tiedonsiirtojärjestelmän suunnittelun kannalta tarkastellaan tiedonsiirtojärjestelmän topologiaa, protokollaa ja saatavilla olevia tekniikoita ja niiden implementoimista järjestelmään. Valmistajakohtaisia lyhyen kantaman radiomoduulien toimintaa ja Bluetoothin sisältävää älypuhelinta tutkitaan laboratoriomittauksin. Lopuksi kootaan yhteen langattoman tiedonsiirron ja eri tekniikoiden soveltuvuus sähkökäyttöjen kunnonvalvonnan ja etädiagnostiikan sovelluksiin.

PGW-linjan käyttövarmuuden ja kunnossapidon tehokuuden parantaminen kiinteällä kunnonvalvonnalla

Tämän diplomityön lähtökohtana on tutkia kiinteän kunnonvalvonnan ja ehkäisevän kunnossapidon edellytyksiä ja mahdollisuuksia Anjalan Paperitehtaan painehiomossa. Työn tavoitteena on kunnossapidon kustannustehokkuuden parantaminen ja häiriöaikojen vähentäminen ja sitä kautta koko tuotantoprosessin tuottavuuden nostaminen. Työn alussa tarkastellaan tämänhetkisiä prosessilaitteiston häiriötekijöitä ja kunnossapidon vaikutusmahdollisuuksia häiriöiden korjaukseen ja kustannuksiin. Tarkastelun perusteella päädyttiin painehiomossa ehkäisevän kunnossapidon määrän nostamiseen ja kiinteän kunnonvalvontajärjestelmän käyttöönottoon H4-linjalla. Jatkuvatoimisen kunnonvalvonnan edut tutkimuksen ja teorian perusteella ovat laitteiden käyttövarmuuden olennainen paraneminen ja kunnossapitokustannusten aleneminen. Työn kokeellisen osan perusteella kunnossapitokustannukset alenivat noin 24 % ja käytettävyyden tehostumisen johdosta laitehäiriöt alenivat 50 %:lla. Tulokset saatiin aikaan toteuttamalla suunnitellut ehkäisevät huollot kriittisille laitteille. Kiinteä kunnonvalvonta antoi kunnossapidolle tiedon laitteiden oikea-aikaisesta huoltovälistä. Investoinnin hyödyt saatiin täysmääräisesti käyttöön jo laitteiston ensimmäisen käyttövuoden aikana. Henkilöstön osaamiskapasiteetin nosto tulee vielä lisäämään edellä mainittuja hyötyjä.

Elinjaksoajattelun soveltaminen kunnossapidon toiminnanohjaukseen

Kunnossapidon tavoitteena on ylläpitää riittävää käyttövarmuutta mahdollisimman kustannustehokkaasti. Kunnossapito-organisaation menestys riippuu kyvystä toteuttaa oikeita kunnossapitotöitä sekä kyvystä suoriutua töistä mahdollisimman pienillä resursseilla. Elinjaksoajattelulla tarkoitetaan käyttöomaisuuden omistamisen luoman arvon ja vaatimien resurssien mallintamista. Tällöin jo hankintojen suunnitteluvaiheessa pohditaan omistamisen luomia vaatimuksia tuotantohyödykkeen tuoman hyödyn ohella. Elinjaksoajattelu tuo toiminnanohjaukseen yksittäisten kohteiden optimaalisten käyttökustannusten suunnittelun näkökulman, mikä on yksi tärkeä tekijä kunnossapidon päätöksentekotilanteissa. Se ohjaa organisaatiota hahmottamaan kunnossapidon tämän hetken ja tulevaisuuden työkuormaa. Elinjaksosuunnittelun määrittelemän työkuorman ja olemassa olevien resurssien vertaaminen keskenään kertoo käyttöomaisuuteen kohdistuvan korjausvelan määrän. Korjausvelan määrän kehitys vaikuttaa kohteen toimintavarmuuteen. Korjausvelka kertoo elinjaksosuunnitelman realistisuudesta, ja käyttöomaisuuden hallinnan luotettavuudesta. Elinjaksoajattelu mahdollistaa kunnossapitotoiminnan suunnittelun kustannustavoitelähtöisesti. Tällöin budjetointi toteutetaan suunnittelemalla käyttövarmuustaso vastaamaan tahdottua kustannustasoa.

Possibilities and challenges in utilization of information provided by Industrial Internet applications

Global digitalization has affected also industrial sector. A trend called Industrial Internet has been present for some years and established relatively steady position in businesses. Industrial Internet is also referred with the terminology Industry 4.0 and in consumer businesses IoT (Internet of Things). Eventually, trend consists of many traditionally proven technologies and concepts, such as condition monitoring, remote services, predictive maintenance and Internet customer portals. All these technologies and information related to them are estimated to change the rules of business in industrial sector. This may result even a new industrial revolution. This research has its focus on Industrial Internet products, services and applications. The study analyses four case companies and their digital service offerings. According to this analysis the comparison of these services is done to find out if there is still space for companies to gain competitive advantage through differentiation with these state of the art solutions. One of the case companies, Case Company Ltd., is working as a primary case company and a subscriber of this particular research. The research and results are analyzed primarily from this company’s perspective and need. In empirical part, the research clarifies how Case Company Ltd. has allocated its development resources through last five years. These allocations in certain categories are then compared to other case companies’ current customer offering and conclusions are made how the approach of different companies differ from each other. Existing theoretical knowledge of Industrial Internet is about to find its shape. In this research we take a look how the case company analysis and findings correlate with the existing knowledge and literature of the topic.

Integrated plant monitoring to improve plant operation strategy and results

The more and more demanding conditions in the power generation sector requires to apply all the available technologies to optimize processes and reduce costs. An integrated asset management strategy, combining technical analysis and operation and maintenance management can help to improve plant performance, flexibility and reliability. In order to deploy such a model it is necessary to combine plant data and specific equipment condition information, with different systems devoted to analyze performance and equipment condition, and take advantage of the results to support operation and maintenance decisions. This model that has been dealt in certain detail for electricity transmission and distribution networks, is not yet broadly extended in the power generation sector, as proposed in this study for the case of a combined power plant. Its application would turn in direct benefit for the operation and maintenance and for the interaction to the energy market

Metrological characterization of sensors and instrumentation for distribution grid monitoring and electrical asset diagnostics

The Smart Grid needs a large amount of information to be operated and day by day new information is required to improve the operation performance. It is also fundamental that the available information is reliable and accurate. Therefore, the role of metrology is crucial, especially if applied to the distribution grid monitoring and the electrical assets diagnostics. This dissertation aims at better understanding the sensors and the instrumentation employed by the power system operators in the above-mentioned applications and studying new solutions. Concerning the research on the measurement applied to the electrical asset diagnostics: an innovative drone-based measurement system is proposed for monitoring medium voltage surge arresters. This system is described, and its metrological characterization is presented. On the other hand, the research regarding the measurements applied to the grid monitoring consists of three parts. The first part concerns the metrological characterization of the electronic energy meters’ operation under off-nominal power conditions. Original test procedures have been designed for both frequency and harmonic distortion as influence quantities, aiming at defining realistic scenarios. The second part deals with medium voltage inductive current transformers. An in-depth investigation on their accuracy behavior in presence of harmonic distortion is carried out by applying realistic current waveforms. The accuracy has been evaluated by means of the composite error index and its approximated version. Based on the same test setup, a closed-form expression for the measured current total harmonic distortion uncertainty estimation has been experimentally validated. The metrological characterization of a virtual phasor measurement unit is the subject of the third and last part: first, a calibrator has been designed and the uncertainty associated with its steady-state reference phasor has been evaluated; then this calibrator acted as a reference, and it has been used to characterize the phasor measurement unit implemented within a real-time simulator.

Análise por ultra-sons no controlo de condição

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia Mecânica

The importance of control monitoring systems in wind parks maintenance

The objective of every wind energy producer is to reduce operational costs associated to the production as a way to increase profits. One other issue that must be looked carefully is the equipment maintenance. Increase the availability of wind turbines by reducing the downtime associated to failures is a good strategy to achieve the main goal of increase profits. As a way to help in the definition of the best maintenance strategies, condition monitoring systems (CMS) have an important role to play. Informatics tools to make the condition monitoring of the wind turbines were developed and are now being installed as a way to help producers reducing the operational costs. There are a lot of developed systems to do the monitoring of a wind turbine or the whole wind park, in this paper will be made an overview of the most important systems.

Web-based Implementation of Winter Maintenance Decision Support System Using GIS and Remote Sensing, May 2005

Winter maintenance, particularly snow removal and the stress of snow removal materials on public structures, is an enormous budgetary burden on municipalities and nongovernmental maintenance organizations in cold climates. Lately, geospatial technologies such as remote sensing, geographic information systems (GIS), and decision support tools are roviding a valuable tool for planning snow removal operations. A few researchers recently used geospatial technologies to develop winter maintenance tools. However, most of these winter maintenance tools, while having the potential to address some of these information needs, are not typically placed in the hands of planners and other interested stakeholders. Most tools are not constructed with a nontechnical user in mind and lack an easyto-use, easily understood interface. A major goal of this project was to implement a web-based Winter Maintenance Decision Support System (WMDSS) that enhances the capacity of stakeholders (city/county planners, resource managers, transportation personnel, citizens, and policy makers) to evaluate different procedures for managing snow removal assets optimally. This was accomplished by integrating geospatial analytical techniques (GIS and remote sensing), the existing snow removal asset management system, and webbased spatial decision support systems. The web-based system was implemented using the ESRI ArcIMS ActiveX Connector and related web technologies, such as Active Server Pages, JavaScript, HTML, and XML. The expert knowledge on snow removal procedures is gathered and integrated into the system in the form of encoded business rules using Visual Rule Studio. The system developed not only manages the resources but also provides expert advice to assist complex decision making, such as routing, optimal resource allocation, and monitoring live weather information. This system was developed in collaboration with Black Hawk County, IA, the city of Columbia, MO, and the Iowa Department of transportation. This product was also demonstrated for these agencies to improve the usability and applicability of the system.

Development of the Acoustic Emission Based Diagnostics Concept for the Rotary Lime Kiln

Reaaliaikainen, ennakoiva kunnonvalvonta on erittäin tärkeä osa modernin tehtaan tai tuotantolinjan toimintaa. Diplomityön teettäjä haluaa edelleen kehittää akustiseen emissioon perustuvaa kunnonvalvonta järjestelmäänsä, jotta siitä olisi enemmän hyötyä asiakkaalle. Diplomityö sisältää johdannonakustiseen emissioon ja akustisiin emissio sensoreihin. Työn tavoitteena oli kehittää päätöksentekojärjestelmä, jota käytettäisiin työn teettäjän valmistamien sensoreiden antaman tiedon automatisoituun analysointiin. Työssä on vertailtu kolmea eri ohjelmistotoimittajaa ja heidän ohjelmiaan, ja tehty ehdotus hankittavasta ohjelmistosta. Lisäksi työssä on kehitetty ohjeita, joiden avulla ohjelmisto ohjelmoidaan tuottamaan reaaliaikaista tietoa ja huolto-ohjeita sen käyttäjille. Lisäksi työssä annetaan ehdotuksia kunnonvalvonta- ja päätöksentekojärjestelmän edelleen kehittämiseen.

Monitoring of centrifugal pump operation by a frequency converter

Centrifugal pumps are widely used in industrial and municipal applications, and they are an important end-use application of electric energy. However, in many cases centrifugal pumps operate with a significantly lower energy efficiency than they actually could, which typically has an increasing effect on the pump energy consumption and the resulting energy costs. Typical reasons for this are the incorrect dimensioning of the pumping system components and inefficiency of the applied pump control method. Besides the increase in energy costs, an inefficient operation may increase the risk of a pump failure and thereby the maintenance costs. In the worst case, a pump failure may lead to a process shutdown accruing additional costs. Nowadays, centrifugal pumps are often controlled by adjusting their rotational speed, which affects the resulting flow rate and output pressure of the pumped fluid. Typically, the speed control is realised with a frequency converter that allows the control of the rotational speed of an induction motor. Since a frequency converter can estimate the motor rotational speed and shaft torque without external measurement sensors on the motor shaft, it also allows the development and use of sensorless methods for the estimation of the pump operation. Still today, the monitoring of pump operation is based on additional measurements and visual check-ups, which may not be applicable to determine the energy efficiency of the pump operation. This doctoral thesis concentrates on the methods that allow the use of a frequency converter as a monitoring and analysis device for a centrifugal pump. Firstly, the determination of energy-efficiency- and reliability-based limits for the recommendable operating region of a variable-speed-driven centrifugal pump is discussed with a case study for the laboratory pumping system. Then, three model-based estimation methods for the pump operating location are studied, and their accuracy is determined by laboratory tests. In addition, a novel method to detect the occurrence of cavitation or flow recirculation in a centrifugal pump by a frequency converter is introduced. Its sensitivity compared with known cavitation detection methods is evaluated, and its applicability is verified by laboratory measurements for three different pumps and by using two different frequency converters. The main focus of this thesis is on the radial flow end-suction centrifugal pumps, but the studied methods can also be feasible with mixed and axial flow centrifugal pumps, if allowed by their characteristics.

A simulation model of the optimal maintenance strategy: conceptual agent-based approach

In this Master’s thesis agent-based modeling has been used to analyze maintenance strategy related phenomena. The main research question that has been answered was: what does the agent-based model made for this study tell us about how different maintenance strategy decisions affect profitability of equipment owners and maintenance service providers? Thus, the main outcome of this study is an analysis of how profitability can be increased in industrial maintenance context. To answer that question, first, a literature review of maintenance strategy, agent-based modeling and maintenance modeling and optimization was conducted. This review provided the basis for making the agent-based model. Making the model followed a standard simulation modeling procedure. With the simulation results from the agent-based model the research question was answered. Specifically, the results of the modeling and this study are: (1) optimizing the point in which a machine is maintained increases profitability for the owner of the machine and also the maintainer with certain conditions; (2) time-based pricing of maintenance services leads to a zero-sum game between the parties; (3) value-based pricing of maintenance services leads to a win-win game between the parties, if the owners of the machines share a substantial amount of their value to the maintainers; and (4) error in machine condition measurement is a critical parameter to optimizing maintenance strategy, and there is real systemic value in having more accurate machine condition measurement systems.

Evaluation of Condition Scoring of Feeder Calves as a Tool for Management and Nutrition

Two experiments were conducted to evaluate the effects of body condition scores of beef calves on performance efficiency and carcass characteristics. In Experiment 1, 111 steer calves were stratified by breed and condition score (CS) and randomly allotted to 14 pens. The study was analyzed as a 2 x 3 factorial design, with two breeds (Angus and Simmental) and three initial CS (4.4, 5.1, and 5.6). In Experiment 2, 76 steer calves were allotted to six pens by CS. The resultant pens averaged 3.9, 4.5, 4.7, 5.0, 5.1, and 5.6 in CS. Calves in both studies were fed a corn-based finishing diet formulated to 13.5% crude protein. All calves were implanted with Synovex- SÒ initially and reimplanted with Revalor-SÒ. In Experiment 1, 29-day dry matter intake (lb/day) increased with CS (17.9, 18.1, and 19.1 for 4.4, 5.1, and 5.6, respectively; p < .04). Daily gain (29 days) tended to decrease with increasing CS (4.19, 3.71, and 3.26; p < .13). Days on feed decreased with increasing CS (185, 180, and 178d; p < .07). In Experiment 2, daily gains also increased with decreasing initial CS for the first 114 days (p < .05) and tended to increase overall (p < .20). In Experiment 1, calves with lower initial CS had less external fat at slaughter (.48, .53, and .61 in. for CS 4.4, 5.1, and 5.6, respectively; p < .05). This effect was also noted at slaughter (p < .10), as well as at 57 days (p < .06) and at 148 days (p < .06) as measured by real-time ultrasound. Measurements of intramuscular fat and marbling were not different in either study. These data suggest that CS of feeder calves may be a useful tool for adjusting energy requirements of calves based on body condition. Also, feeder cattle may be sorted into outcome or management groups earlier than currently practiced using body condition and/or real-time ultrasound.

Vibration based health monitoring of civil infrastructure using energy harvesting techniques

The use of structural health monitoring of civil structures is ever expanding and by assessing the dynamical condition of structures, informed maintenance management can be conducted at both individual and network levels. With the continued growth of information age technology, the potential arises for smart monitoring systems to be integrated with civil infrastructure to provide efficient information on the condition of a structure. The focus of this thesis is the integration of smart technology with civil infrastructure for the purposes of structural health monitoring. The technology considered in this regard are devices based on energy harvesting materials. While there has been considerable focus on the development and optimisation of such devices using steady state loading conditions, their applications for civil infrastructure are less known. Although research is still in initial stages, studies into the uses associated with such applications are very promising. Through the use of the dynamical response of structures to a variety of loading conditions, the energy harvesting outputs from such devices is established and the potential power output determined. Through a power variance output approach, damage detection of deteriorating structures using the energy harvesting devices is investigated. Further applications of the integration of energy harvesting devices with civil infrastructure investigated by this research includes the use of the power output as a indicator for control. Four approaches are undertaken to determine the potential applications arising from integrating smart technology with civil infrastructure, namely • Theoretical analysis to determine the applications of energy harvesting devices for vibration based health monitoring of civil infrastructure. • Laboratory experimentation to verify the performance of different energy harvesting configurations for civil infrastructure applications. • Scaled model testing as a method to experimentally validate the integration of the energy harvesting devices with civil infrastructure. • Full scale deployment of energy harvesting device with a bridge structure. These four approaches validate the application of energy harvesting technology with civil infrastructure from a theoretical, experimental and practical perspective.