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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……
© 2012 All Rights Reserved
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
© 2012 All Rights Reserved
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
© 2012 All Rights Reserved
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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© 2012 All Rights Reserved
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
© 2012 All Rights Reserved
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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© 2012 All Rights Reserved
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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© 2012 All Rights Reserved
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”……………………
© 2012 All Rights Reserved
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
$ $$ $ $$$ $$$$$$$ 16
Primarily Electronic Hardware that bolt to the AssetEnterpriseSoftware
© 2012 All Rights Reserved
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.17