Veros Systems on IBM

Confidential

Empower IntelligenceThe Veros System

Allan Wilson

Chief Executive Officer

Confidential

the Veros vision

Bring to market a breakthrough software technology solution the will become the industry standard for the management of the health of all electrically powered rotating assets to maximize asset reliability, improve efficiency and ensure energy sustainability

Confidential

electrically powered assets – industrial

Smart Grid

Oil & Gas

Manufacturing – Discrete

MiningPower Generation

Manufacturing – Continuous

¹Harbor Research, http://www.harborresearch.com

Outnumber People by 10:11

Less than 1% are Continuously Monitored

Confidential

No visibility of what is happening inside the overwhelming majority of mission critical electrically driven assets. Catastrophe is just around the corner

Major negative impact on productivity and financial performance

1. Globally over 50 million industrial electric motors and power trains.2. Less than 1% are continuously monitored or measured.3. They consume over 60% of the world’s electricity.4. Failures cost US Industry $3 Trillion annually in lost production and repair costs. 5. A failure in one asset in the Oil & Gas Industry can cost over $3M a day.6. A 1% power efficiency degradation in ONE large motor - $10,000/year

Why is this so?No cost effective and easily deployable technology has existed until now!

the problem

Confidential

keys to good asset health & reliability

• Early detection of emerging problems in the motor and driven load (both electrical and mechanical

• Measurement of motor efficiency and energy consumption• Fast and accurate diagnoses• Timely action to prevent failure• Route cause analysis to detect failure patterns

© 2012 All Rights Reserved

how does the Veros System solve these problems?

• A non invasive monitor was available that you could buy for a few Dollars.•This monitor could pick up your body’s electrical energy.•This information is communicated 24x7 to a hosted diagnostic system.•From this raw electrical energy the system determines developing health problems and determines risk and pace of deterioration by using predictive analytics.•This health intelligence is sent by way of alerts and watch lists to your mobile device of choice.•Remedial action is suggested.•Action is taken to put plans in place to avoid catastrophe and improve condition going forward.

As an example let’s imagine……

Now let’s look at the Veros System……


the Veros system

Key Features• A non invasive monitor is installed in the motor control center in a couple of hours.•This monitor picks up the raw electrical waveforms from the incoming power (current and voltage)•This information is sent 24x7 wirelessly to a hosted (or on premis) diagnostic system which can detect from the raw electrical waveforms, any emerging health problems in the motor and driven load (both electrical and mechanical) a year in advance or more.•Asset health and motor efficiency elements of intelligence are produced using predictive analytics.•Pace of deterioration is determined to allow calculation on the severity of the problems found.

Available Today For All Electrically Powered Industrial Assets


the Veros system

Integration with Enterprise Applications•Alerts are sent to your mobile device of choice.•Remedial action is suggested and can be managed by Enterprise Asset Management Systems (EAM)•Motor efficiency is reported to enable energy sustainability.•Action is taken to put plans in place to avoid catastrophe and improve asset condition going forward (EAM and Mobile applications).•Historical trends are stored for future asset reliability intelligence diagnostics.

A completely integrated, cost effective OT and IT solution

Available Today For All Electrically powered Industrial Assets

The creation of the Intelligent Asset


architecture – indirect integration

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Can be On Premis or Hosted “Cloud” service


Veros – key features• Autonomous – Automated diagnostics & assessment• Simple – Continuous, plug-and-play solution• Non-intrusive – Existing electrical signals only; no

sensors on or access to machines• Preemptive – Early diagnosis of developing faults• Comprehensive – Electrical and mechanical faults

on entire power train• Environmental – Real-time energy consumption and

energy efficiency information• Reliable – Reduced false alarms or missed faults• Cost-scalable – Fleet-wide continuous monitoring

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motor intelligence

Electrical• Operational Faults

– Voltage Unbalance– Other Harmonics– Overloading/Underloading– Overvoltage/Undervoltage

• Stator– Turn-to-turn short– Phase-to-phase short– Neutral-to-ground short– Stator eccentricity

• Winding contamination• Rotor

90+% of Motors are Induction

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Mechanical• Bearings

– Contamination– Vibration– Misalignment– Lubrication– Electrical discharge

• Rotor– Rotor Bar/End-ring cracks– Unbalance– Eccentricity– Rotor bow– Cooling

• External Misalignment


pump intelligence

Centrifugal Pumps:• Operational Faults

– Cavitation– Partial Flow or Low Flow Operation– Dry Running

• Mechanical Faults– Impeller Damage– Bearing Degradation– Seal Degradation

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energy intelligence

• Electric motor energy sub-metering– Estimates in real-time • Energy Consumption, • Real Power, • Reactive Power,• Apparent Power, and,• Power Factor.

– Communicates information for trending, aggregation, etc.

– Aggregates information over time periods for comparisons

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what does industry to today?

• For very expensive, critical assets, very expensive complex vibration systems are the norm (the 1%).

• For everything else they either take the risk and run to failure or have maintenance crews do physical monthly checks (routes)

• Some electronic hardware solutions are available that bolt to the asset but are not enterprise scalable and are not enterprise software solutions that can be part of an “Industrial Internet”……………………


competitive matrix

Veros PIP GE AnomAlert SKF Baker GE Smart SignalGE Bently +

System 1

InputsRaw Electrical

WaveformsRaw Electrical

WaveformsRaw Electrical

WaveformsFrom PI Server

OnlyRaw Vibration

Waveforms

Enterprise Integration EAM/ERPGE System 1

(MES)None None

GE System 1 (MES)

Always ON

Early Autonomous Detection of Faults ×

Depends on PI Server Data

Energy Efficiency & Management × ×

Depends on PI Server Data ×

Machines CoveredMotors (VFDs), &

Driven LoadsMotors (VFDs) &

Driven Loads Motors (no

VFDs)Depends on PI

Server Data

Motors (no VFDs), & Driven

Loads

Installation & Commissioning

Non-intrusive & Simple

Intrusive & Complex

Non-intrusive & Complex

Non-intrusive & Complex

Intrusive & Complex

Scalability

× × ×Per Power Train Cost

$ $$ $ $$$ $$$$$$$ 15

Primarily Electronic Hardware that bolt to the AssetEnterpriseSoftware


technology matrixVeros System Vibration Analysis MCSA/ESA

Inputs Continuous Electrical Waveforms.

Periodic or Continuous Vibration Waveforms.

Periodic or Continuous Electrical Waveforms.

Sensors Transformers, CTs & PTs. Accelerometers, velocity or proximity probes.

Transformers, CTs & PTs.

Detects Changes in Mechanical Motion/ Forces

Lateral/axial motion, and torsional motion; radial, axial

and tangential forces.

Lateral/axial motion from radial & axial forces. No torsional

motion detected.

Lateral/axial motion; radial and axial forces. No torsional motion

detected

Source of InformationAir-gap geometry (radial &

axial) and torsional (tangential) impact on magnetic field.

Structure/rotor lateral and axial motion.

Air-gap geometry (radial & axial) impact on magnetic field.

Mechanical Faults – Lateral/Axial Motion

Detection through air gap geometry change. Comparable to vibration, e.g eccentricity.

Detection through structure, rotor lateral motion.

Comparable to electrical.

Detection through air gap geometry change. Comparable to

vibration, e.g. eccentricity.

Mechanical Faults – Torsional Motion

Detection through torsional excitation, e.g. bearings. Most

sensitive signature. Also detects torsional resonance excitation.

No detection until damage excites lateral/axial motion.

Less sensitive than electrical. No detection of torsional resonance

excitation.

No detection unless air-gap geometry is impacted; damage must be severe. No detection of torsional resonance excitation.

Driven Load FaultsDetection via torsional

excitation through coupling, gear box, etc., e.g. seals.

No detection until damage excites lateral/axial motion with

vibration sensors on the load.No driven load fault detection.

Electrical FaultsDetection of stator electrical

signature changes. More variety of faults detected at early stage.

Only if stator changes cause lateral/axial motion; magnetic

forces. Faults detected late.

Detection of stator electrical signature changes. More variety of faults detected at early stage.

Automated Detection & Diagnosis

Enabled through detectors; only motor nameplate needed.

Challenging; too many asset component details needed.

Challenging; too many asset component details needed.

Energy Management Consumption and energy efficiency.

Not feasible. Consumption only.16

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Veros Systems on IBM