Electrical Signature Analysis

By measuring voltage and current signals we are able to analyze any electrically driven asset onto four levels. First, the complete power quality condition of the grid or the Variable Frequency Drive (VFD) can be analyzed. Second, the electric condition of the machine can be thoroughly analyzed (stator/rotor). Third, the electromechanical condition of the machine can easily be assessed (rotor bar condition, stator slots, magnetization). Last, the mechanical condition of the machine and near drivetrain components can be diagnosed (torsional and lateral rotor vibrations).

PRACTICAL APPROACH

  • Visual inspection of the drivetrain and topology
  • Technical information (part lists, technical drawings…)
  • Operator and maintenance history briefing
  • Sensor installation (may be upfront the site visit)
  • Electrical signal acquisition with data validation
  • Time waveform analysis (shape, impacts, distortions)
  • Power quality analysis (CF, FF, RMS, P, THD, PF…)
  • Spectral analysis (ES, SS, MS, CS with kinematic model)
  • Trending characteristics over time (or reference machine)
  • Analysis, diagnostics and prognostics
  • Reporting (linking data with FMECA, RCFA)
  • Communication with client and asset owner
  • Confirmation, evaluation and feedback
 

DIAGNOSTICS & REPORTING

The diagnostic analysis and the diagnostic process of the electrical signals is very extensive. The report contains the objectively acquired information of the drivetrain regarding the machine topology, maintenance history, operational behavior, environmental influences… This includes the assessment of the most dominant failure modes in this application. Additionally, the kinematic model of the drivetrain is obtained in order to match spectral patterns with the machine components.

The diagnostic process is the search for a match between the potential failure modes and the machine aberrant failure patterns in the electrical signals. If applicable, this already includes the necessity of several load/speed conditions and process conditions. If a match is found, the backward and forward failure mode timeline is estimated in order to focus on the root cause as well on the prognosis of the failure behavior.

The last part of the report is very specific proactive maintenance advice in order to solve the probable failure process and avoid in the future. The potential solutions are usually listed with the risk of introducing new failure modes and the proactive effect of the solution.

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