Outline

● Maintenance philosophies
Condition Monitoring and ● Architecture for condition based maintenance
Fault Diagnostics ● Methods for Fault Detection and Isolation (FDI)
● Examples
Methods and Architectures

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Maintenance Philosophies Corrective Maintenance

● Corrective maintenance ● Run to failure
● Preventive maintenance ● The maintenance is done after some part breaks.
● Condition based maintenance ● Maintenance costs are low.
● Operating costs are high because of the down-
time and damages.

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 Preventive Maintenance Condition Based Maintenance
● Scheduled maintenance action. ● Maintenance when required
● Schedule is created from lifetime statistics of ● Unnecessary maintenance is avoided.
similar machines. ● Availability of the equipment is guaranteed
● High maintenance costs due unnecessary ● Overall cost of maintenance is reduced
maintenance actions.
● Monitoring creates costs.
● Possibility to equipment failures.

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Architecture for condition based

Total Cost of Maintenance
maintenance
● Open System Architecture for Condition Based
Maintenance (OSA-CBM)
● ISO 13374-1&2 Condition monitoring and
diagnostics of machines – Data processing,
communication and presentation

Lebold et al. 2003]

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 MIMOSA & OSA-CBM OSA-CBM
● Machinery Information Management Open ● Industry led team developed and demonstrated
Systems Alliance (MIMOSA) Open System Architecture for Condition Based
– Database schema to define all information needed in Maintenance.
maintenance management (Common Relational
Information Schema, CRIS) ● Boeing, Caterpillar, Rockwell Automation,
● MIMOSA OpenO&M standards: Rockwell Scientific, Newport news, Oceana
Sensor technologies. Partly funded by U.S. Navy
– OSA-EAI for ERP and operations management
defines interfaces to CRIS repositories ● Active development from 1999 to 2003.
– OSA-CBM for software component interfaces,
behavior and structure of their data

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OSA-CBM Architecture ISO 13374

• Functional CBM ● ISO Standard
components ● Prepared by technical Committee ISO/TC 108,
• Component behavior mechanical vibration and shock, Subcommittee SC5,
• Standard interfaces (AIDL) Condition monitotoring and diagnostics of machines.
– Request Data ● ISO 13374 consist of four parts
– Get Data
– Part 1: General guidelines (ready)
– Get Explanation
– Part 2: Data-processing requirements (draft)
– Get Config
– Part 3: Communication requirements (?)
• Data structures
– Part 4: Presentation requirements (?)

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 ISO 13374 Architecture Fault Detection and Isolation (FDI)

[Chieng et al, Data-driven techniques for fault

detection and diagnosis in chemical processes]

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FDI methods Examples

● Data-driven ● Straddle Carrier, Research Project
– Based on data measured from the model
– Statistical Process Control (SPC), Principal Component Analysis ● X-ray Analyzer, Research Project
(PCA), Artificial Neural Networks (ANN)
● Analytical
– Based on detailed mathematical models
– Parameter estimation, Observers, Parity relations
● Knowledge-based
– Based on qualitative models
– Causal analysis, Signed directed graph, Expert systems, Case
based reasoning, ANN

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 Straddle Carrier Brakes
• Manufactured by OK Faulty
Kalmar Industries
• Height 16 meters
• Weight 68 tons
• 20 or 40 feet
containers, weight up
to 50 tons

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Difference of desired and

Averages of velocity differences
measured velocity

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 Signed directed graph of the
Courier 3SL X-ray Analyzer
breaking system
● On-line X-ray
fluorescence analyzer
for concentrator process
● Takes samples from up
to three sample lines
● Analyses the
concentrations of the
elements in the sample
slurry
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Monitoring of Calibration Validity Calibration Validity

● Quality of the analyses is limited by the assay ● Ore is not traceable
calculation model calibration ● Indicator has to be data-based
● X-ray measurement data is correlated with the ● PCA indicator
laboratory analyses
– PCA model from the calibration data
● MLR (Multiple linear regression) model extended
– T2 and Q statistics
with heuristic rules
● Model must be maintained over time

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 PCA Indicator PCA Indicator
● T2 statistics measure the variation within the PCA
model 50

0
Cu error%
Mean

-50
● Q statistics measures how well each sample 10/01/00
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Zn error%
conforms the PCA model. 0 Mean

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– Predicts the assay calculation error 10
Q statistics
5 95% limit

– Reacts when ore drifts outside the calibration time 0

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PCA model T2 statistics
95% limit

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