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Operator`s Guide

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1. Tu Operation My Cylinde View Definition Mg Cylinde View AutoDiagnosis Configuration Mg Cylinde View AutoDiagnosis Messages Ng Cylinde View Instantaneous AutoDiagnosis Messages g Cylinde XN View Note Reports g Cylinde F So Cylinde Reset Zero Gap jurces o Cylinde Recalculate BDC Baseline Description Enabled MOS Flag SPU Server t o Cylind iho Ge tee Process Input M L Undefined XN k Hte Cylinde x aoe kea a Set bearing wear when sensors or bearing parts have been replaced e Cylinde i Reset MOS Flag e Cylinde A lt My Cylinde Clear Baseline Sesi ap Set Baseline Hitachi Collapse All et OPC Expand All KY Plots Bal 2 A table is displayed in which values of all Wear measurements under the selected component can be entered fea Initial Wear value Unit Mark Main DPLF Wear pm Mark Main DP2F Wear um Mark Main DP3F Wear um Mark Main DP4F Wear um Mark Main DPSF Wear um Mark Main DP6F Wear um Mark Main DP7F Wear um Mark Main DP8F Wear 1 um Mark Main DPSF Wear um Mark Main DPLOF Wear um Mark Main DP11F Wear um Mark Main DP12F Wear um Mark Main DP13F Wear um Mark Main DP14F Wear um OK Cancel 3 Enter manually the values for those measurements for which the value Shall be changed and click OK 2008 11 20 OPEN
2. RDM reports RDM Reliability Data Management is a system special module reporting how often a machine is running and why it s stopped Single graph plot A report for a single plot in HTML format The file report contains the requested plot and all relevant data for evaluating the plot Procedures see section 2 7 1 Multiple graph plots A report for all the plots within a Plot Manager report window The HTML file contains all plots and all relevant data for evaluating the plots Procedures see section 2 7 2 Mimic Report A report from a Mimic in HTML format The file contains a screen dump of the Mimic Procedures see section 2 5 3 Special modules are not relevant for all applications and may not be included in your installation All reports are in HTML format The benefits of this are e They can then be read and printed out by means of the generally well known Microsoft Internet Explorer which comes with Windows In the Microsoft Internet Explorer you can use the Favourites Ctrl I or History Ctrl H facilities to display them The image below shows a typical layout of a Management or Shift report 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 26 ac OPEMpred epee perl hird Horoera Inbertect Expderer Fie Edt Wew Faworbes Took ep move DD A Gren prot Goma Yo Ey oe a Adan EI enda epcets Maragemertiepert Herd re e 2000 09 29 24 87 83 Khor Reports Mar
3. Crank Bearing Main Bearing For a more reliable measurement the OPENpredictor BDC measurement uses two sensors in each cylinder to measure tilting of the crosshead too The measurement values are influenced by and compensated for shaft speed RPM 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 53 The data can be displayed in two ways e Ona graph where it s easy to see if the wear is coming close to or has crossed the acceptable limits e Ona mimic with a schematic drawing of the engine as background and e g a level bar with data and limit lines to display the actual situation The level bar colour indicates the warning condition o Green OK Yellow Alert Red Alarm Blue System error A white line inside the coloured column means that the measure ment is under calibration a temporary correction curve is used If the measurement is out of the range displayed this is indicated by a blue arrow up or down O O O Fieni vemen eera EE Mie Vim Go Drown Options Repot Hele Sees tE m T DPE hpredibor EDOPDALSEDOPRDST a Van Drone hapot Toot mnb Drin mog aer oo meo neo we eo PIO eo i ia mo i M MN En i 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 54 2 9 2 BDC baseline calibration Whenever a bearing or a sensor has been replaced repaired moved or reassembled it is necessary to calibrate the baseline again This automat
4. flags are unchecked or if any MOS flags are set Note It is also possible to see change MOS and Enabled flags in the browser when e The right part of the browser window is displayed and e The related Machine Machine Section or Machine Part is displayed 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 25 2 4 Reports There are five types of main reports in the system Shift Report A report on the current problems i e for hand over to the next shift The report covers faults to be dealt with within the next few hours or days It is generated automatically at the end of each shift The format is normally fixed but can be changed Each user can store their preferred report format under a unique name Comments on the current status can be included Procedures see section 2 4 1 Management Report A report for the maintenance manager focusing on predictions of future machine faults and the general health of the plant The report is generated e g monthly The format is normally fixed but can be changed Each user can store their preferred report format under a unique name Comments on the current status can be included Procedures see section 0 An Excel file containing data for AutoDiagnosises and alarms A text file containing data for the number of mea Statistics report surements recorded in the specified period of time Oil Analysis Excel file containing oil data special module
5. The menu selected is highlighted blue background The possible menus are Menu Used with Explanation View Definition All Display the definition window for the item measurement clicked View AutoDiagnosis Configuration View RDM Report RDM Reliability Data Management View Reliability Report View Downtime Report View AutoDiagnosis Messages View Instantaneous AutoDiagnosis Messages View Machine States View Note All except Reports FA Measurement Company Plant Plant section Machine Machine section Machine component Company Plant Plant section Machine 4 Machine Machine Machine component Machine Machine component x Machine Display Note Reports see section 2 4 4 Opens the View AutoDiagnosis Configuration window for the item selected From here you have an overview of the related possible Auto Diagnosis and the AutoDiagnosis recommendation can be edited if you have the proper rights Display the RDM Reports window if RDM is installed for this item or any item below see section 2 4 6 Display the Reliability Report window if RDM is installed for this machine see section 2 4 6 Display the Downtime Report window if RDM is installed for this machine see section 2 4 6 Displays the latest a list of all Predictive AutoDiagnosis messages for this machine Displays the latest a list of all Instantaneous AutoDiagnosis messa
6. It is used for giving an overview over the condition of a plant The list con tains specific fault data for each machine one worksheet per machine 2 4 3 Measurements Statistics report In the OPENpredictor menu bar select the menu Reports gt Measurements Statistics This opens a box to open the file database analysis txt placed in the OPENpredictor reports directory The file is generated by a script which is run as a Windows Service at a specified time typically daily It shows how many data of each type which have been added to the database The data are mainly used for trimming the system but a significant change in the number of measurements is a good indicator that something is wrong The data are shown in this window Machine all machines Eu Measurement Statistics RDOPOSIM RDOPO10g Aa x A oe Total Size 58 2 KB Machine Size KB No of Wales E E Machine Measurement ki Size KB Mo of Values Relay Machine 2 Acc Harm 20 12 a Relay Machine 2 Acc Overall 20 Relay Machine 3 Acc Overall 25 Relay Machine VirtualDanger Ova et Relay Machine Work Alarm Rela Relay Machine Work Criteria Ala Relay Machine Work Criteria Ala Relay Machine Work Alarm Rela Relay Machine Virtual Alert Over Relay Machine Work Criteria Ala Relay Machine Work Alarm Rela Relay Machine Work Alarm Rela Relay Machine Work Alarm Rela Relay Machine Work Alarm Rela Relay Machine Work Crite
7. TRE Mg Cylinder 12 Mg Cylinder 13 Senin Mg Cylinder 14 a AD Sag Hitachi ory oe 1 GT1 amp Operation 2 is rurbine SU ap If the Warning Severity button is activated the worst warning condition of each item is displayed in front of the name of the item e Alarm Alert System e AutoDiagnosis or Instantaneous AutoDiagnosis D gt amp depending on severity see 2 3 1 3 and 2 3 1 4 You can track an alarm down from Plant level to Machine Component level which item the problems relates to by expanding the items Click 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 21 To display the complete message for an AutoDiagnosis or Instantaneous AutoDiagnosis right click the item select the floating menu Browser and then in the browser right click the item To display the item in the normal Browser with access to graphics etc right click the item and select the floating menu Browser For further information about the other functions please see the OPENpre dictor User Manual section 6 2 2 3 4 Measurement warning indicators in Mimics 40 gt Mimic Yiewer Steam turbine File View Go Browse Options Report Help 8g SI BY amp A Mimic is an image of a plant machine or machine sections which can be used as an informative background to display selected measurements and provide links via active buttons to
8. Velocity C Status verified Comment None tad Calibrated 2003 06 09 2 Check if the MOS flag is check marked EF IMPORTANT when you have changed a flag In order to activate the changed setting of a MOS flag or Enabled flag the SPU must be rebooted see section 2 9 4 the Data Server must be stopped and restarted see section 2 9 5 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 24 2 3 5 4 How to see which transducers are switched off To see which transducers are switched off for maintenance by means of the Enabled or Maintenance MOS flags L 2 In the Browser select the menu View gt SPU Definition This opens the SPUs window File View SPUs 1O x SA ipt Transducers 72IROVSIN Name Code Channel No Enabled MOS Flag 5368710 10 20 4 64 ROVSIN JacyTii Turbine ACYT11 1 M O FA ACYT12 Turbine ACYT12 2 M C ACYT15 Turbine ACYT15 3 M O ACYT16 Turbine ACYT16 4 M O ACYT23 Turbine ACYT23 5 M O ACYT24 Turbine ACYT24 6 M O ACYT41 Turbine ACYT41 7 M O ACYT42 Turbine ACYT42 8 M O ACYT45 Turbine ACYT45 9 M O ACYT46 Turbine ACYT46 10 M O ACYTS3 Turbine ACYTS3 alal M O x virtual Transducers Name Code Operational Turbine Operational Operational PULV 14 Operational Operational PULV 1B Operational Operational PULV 24 Operational For each SPU in the above case SPU1 and SPU2 check if any Enabled
9. 0 Total 0 Utilization 100 0 This window contains a number of tabs on each of which you can read further details for example about each stop 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 35 To enter edit data about each stop in the RDM report click the Downtime list button 2 4 6 5 RDM machine I nfo In the Machine Reliability Report or the Downtime List see below click RDM Machine Info to open a window with basic RDM data and alarm alert settings for this machine 28 RDM Machine Info a aj Code Rod sema KAA Ke E T For an explanation to the fields see eis eae cesta po the OPENpredictor User Manual Typa wi section 5 12 5 7 No of Stages Driver Type Power Rangi 9 kw Installed Capacty ROM Warning Levels Reliability Alarm Low goo Reliability Alert tow 400 Awailabdity Alarm kom yog 0 Awailabality Alert Low 500 Utilization Alarm Low ggg Utilization Alertlow agg Equivalent Running Hours Factors Scheduled gp oo perasa SC Unscheduled Stop P ao Keda P Schedule Into AOMSK 7OO14PIsc 2 lt 4 Last Machine Changeout Perang izsoio7 Skid Start Time 2007 01 01 12 s0 19 Min Tone bor Sucoecail tart 10 Min Clase 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 36 2 5 Mimics Mimics are interactive graphical user interface windows displaying Images of the system e Imag
10. 2 18 Watchdog 2 61 Zoom 1 2 2 49 Zooming 2 48 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 1 Page 4 3 Document information 1 Unclassified f 1 Config controlled for approval _ 4 Confidential 4 For information CONTRACT OPENpredictor Rovsing Dynamics A S www rovsing dynamics dk Contract number Contractual date Work package number Title Operator s Guide Issue 2 1 OPENpredictor Version 2 8 0 Internal O Peter Ring Manuals amp Bundles 2 8 0 English 2008 reference 03 28 OP 2 8 0 OPERATOR guide En doc Language English UK No of annexes 0 Summary Keywords operator s guide OPENpredictor CCB date 1 Automatically inserted from File gt Properties field Refresh with F9 Automatically generated Refresh with F9 Document change loc Modified Reason for change sections 0 93 2001 Sep 18 Derived from User Manual v 0 93 draft for version 2 6 2 2 10 New section on database backup changes for OP 2 8 0 found 2 2 2008 Nov 20 9 4 Reboot of SPU 10 Legend updated for new design of RO2010 Communication Processor Module 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 1 Page 4 4
11. 2 65 RDM reports 2 34 Rebooting Servers 2 61 SPU 2 62 Reliability Data Management See RDM Remove Warnings from list 2 19 Report Management 2 5 2 29 Mimic 2 40 Shift 2 5 2 27 Reports survey 2 26 RO2000 SPU unit 2 65 RO2010 CPU module 2 65 RO2020 SPM module 2 65 RPM 3 1 Scalar 3 1 Scroll one grid width 2 49 Server Rebooting 2 61 Starting 2 61 Server PC 2 66 Shift report 2 26 Shift Report 2 5 2 27 Short term risks warnings 2 15 Signal Processing Module SPM 2 67 Signature 1 7 3 1 Single plot report 2 26 SPM 3 1 SPU 1 7 3 1 Rebooting 2 62 SPU operation verify 2 63 Starting 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 1 Page 4 2 Servers 2 61 Starting OPENpredictor 2 2 System warnings 2 15 System warnings 2 5 Trademarks 1 3 Transducers 1 7 Transducers existing 1 7 Transducers list of Enabled 2 25 MOS flag 2 25 User ID 2 2 User Interface main panel 2 4 User Interface opening 2 2 Vector 3 1 Verify SPU operation 2 63 Warning history lists 2 17 Warning lists 2 4 2 17 Actual 2 17 MOS 2 17 Warnings 2 6 2 15 Acknowledge 2 19 Alarm 2 5 2 15 Alert 2 5 2 15 All 2 5 Displayed on mimics 2 22 Maintenance 2 15 MOS 2 6 2 16 2 23 Operation 2 15 Overload 2 5 2 15 Performance 2 15 Remove from list 2 19 System 2 5 2 15 Warning History lists 2 19 Warning indicators 2 15 Warning levels 2 15 Warning List window
12. 62 4 If new data lines are added regularly the SPU operates and transmits data to the system Please note that if the machines are stopped the measurement intervals are long minutes If the connection between the SPU and the Server doesn t work properly the System blue System Warning Lamp will flash 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 63 2 10 OPENpredictor System Hardware There are two versions of the electronics hardware e A 19 inch rack containing the electronics described below e National Instruments cRIO data acquisition unit Basic Bearing Wear Monitoring Systems only See the manuals for this unit The electronics convert the analogue signals from the transducers into digital data which is transferred to a database on the Server PC 2 10 1 The RO2000 Signature Processing Unit SPU The RO2000 SPU is the heart of the system as it executes all measurements and data transfer to other parts of the system Up to three SPUs can be located in a standard instrumentation rack Each RO2000 contains e 1 pcs RO2Z010 Communication Processor Module CPM see section 2 10 2 e 1to 10 pcs RO2020 Signal Processing Module SPM see section 2 10 3 e 1 pcs Integrated Power Supply placed on the rear panel behind the motherboard It is fused with one 230V 10 Amp T slow fuse placed on the rear panel of RO2000 in a small drawer below the power inlet connector The normal maximum power c
13. Bar select the menu Report gt Shift Report ioi x Report shit l for 365 days Report Comments prr Report Options M Comments W AutoDiagnosis Alarms MM Recommendations I Report only warnings not acknowledged Html Path c opENpredictor Reports ShiftReport html Report Fields W Date M Offline Warnings MM Measurement Value MM Operation Warnings M System Warnings M Warning Settings IM Maintenance Warnings MM Machine Code MM Forecast Time M Performance Warnings M Measurement IM Warning Status M RDM Warnings M Machine State IY Acknowledges 2 Inthe Report drop down list select the script for Shift Reports in the above example Shift Report 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 27 3 If needed make amendments to the window settings see below 4 Click Save to save the contents to the script selected in point 2 5 Click Close to close the window To open the report use sa gt Documents or if that fails open the file defined in Html path for example c OQPENpredictor Reports ShiftReport html with the Internet browser for example Microsoft Internet Explorer They are always saved on the OPENpredictor Server 2 4 1 1 Shift Report fields Displays the script name of the current settings for the report To enter a new setting name e g ShiftReport2 type it here ee possible settings report setting you want The r
14. Operator s Guide Issue 2 2 Page 2 1 2 1 Opening the OPENpredictor User Interface Application IMPORTANT Before opening the OPENpredictor User I nterface Application all the OPENpredictor Servers top be used must be running if the User I nterface is to be used online But the OPEN predictor User Interface Application can run offline without the Servers About starting the Servers etc see section 2 9 The SPU see section 2 10 may be restarted without restarting the Servers and the User I nterface Application nn Fa Eat a 1 Double click the SEKS icon to start the OPENpredictor User Interface Application This opens a Work Console window from where the OPENpredictor User Interface Application is started It may take a minute or more to start depending of the number of warnings present When completed the OPENpredictor login window is displayed 4 OPENpredictor Login lo xj User Id Phan Ke Password II OK Cancel 2 Type your User ID for example John and your Password for example waeY38 9u1 Note The Password is case sensitive To change your Password In the login window After entering a valid User ID Password combination but before clicking OK Click the Saman Standard User ie icon to open the User Con pp Pon figuration window Password o Confirm Password Extra Rights Enter the NEW password in Enable Disable Flags IM Pass
15. Pending Faults list Field Explanation The problem Level The severity level of the problem Levels Detected Predicted e Action Required For definitions see section 2 3 1 3 The date and time of the diagnosis Name of the machine with the pending fault Mach Section Name of the machine section with the pending fault Name of the machine component with the pending fault 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 14 2 3 2 Measurement warnings Measurement warnings are shown by traffic light indicators in the Menu Bar The warnings may be investigated by means of Warning Lists giving directly access to the related measurement data Some of these bars may be hidden see section 2 2 2 System Operation 1 ali Co allal zz 1 Oal ai o Co al a I IL E f Maintenance T Performance MOS The flashing Warning Indicators shows that there are unacknowledged measurement warnings of the related type System Operation Maintenance Performance Offline RDM Alarm Alert System see section 2 3 2 1 The MOS indicator doesn t flash as it only warns for deactivated transducers The number to the right of a measurement Warning Indicator shows the actual number of different warnings in the Warning List from this particular group The number at the MOS Maintenance Override Switch indicator shows the number of transducers in MOS or not Enabled mode Cl
16. Reading Warning list details To display an Actual Warning List either Click the All warnings icon PE This displays the Actual Warning List window with all warnings except MOS warnings Click the text of the Warning Indicator Block for example Operation This displays the Actual Warning List window with all warnings in the related Warning Indicator block Click the appropriate warning indictor lamp for example This displays the Actual Warning List window with all warnings of the related type for example Operation Alarm warnings For a better view maximize the window FZ All Warnings RDOPOSi RDOPO10g Baa PAN File Edit Filter Columns Acknowledge All Acknowledge Selected SYSTEM W SYSTEM W SYSTEM W 3196 Offline OVERLOAD 2006 12 11 10 31 06 OVERLOAD Lal 2006 12 11 10 55 32 OVERLOAD P M Displ2 2006 12 11 10 55 32 OVERLOAD HAM TG22 252 5 2006 05 15 00 00 00 HAM TG22 HAM TG22 55 2006 05 15 00 00 00 HAM TG22 HAM TG22 16 2006 05 15 00 00 00 HAMTG22 HAM TG21 200 2006 05 15 00 00 00 HAM TG212 P M Tacho 1011 39 2006 12 19 06 45 13 PM 3197 Offline AlarmHigh 3198 Offline AlertLow 3256 Offline OVERLOAD 21468 Maintenance HighII aaa kaka i ka To display the Warning History List In the Menu Bar select the menu Browse gt Warning History List From here select the relevant list The title bar shows wh
17. To export all records to an Excel file select the menu Report gt Generate or click the BE button All data fields except Parameter and Unit are freely editable 3 After editing save the changes Click E or select the menu File gt Save Ctrl S 2 4 5 1 Importing Oil report data To import oil report data the data must have the same format as the export Excel file In the OPENpredictor Menu Bar select the menu Tools gt Import Oil data and then select the Excel file to import If the import fails you will get an error message which could be Unknown label puissances XXX 16 Illegal value XXX 6 2 Unknown parameter masse volumique XXX 26 Blole ne Illegal date xxx 15 06 2006 Date not found Close If the Data Server is not running you will get an error message about that In that case start the server see section 2 9 5 The imported data will appear as a new line in the Oil Analysis window if the date is inside the Surveillance Period S Oil Analyses RDOPOSiI RDOPO10g lol x File amp amp Data Sheet Surveillance Period Update fa Year From 2006 10 06 15 54 19 To 2007 10 09 15 54 19 HAM TG21 ee 2007 04 19 HAM TG21 Sample Date 2007 04 17 2006 11 13 If the Sample Date is the same as an existing Sample Date the old data will be replaced 2008 11 20 OPE
18. Uptime in where downtime is unsche duled downtime caused by the machine e Availability red bar Uptime in no matter the cause of the stop e Utilization yellow bar Uptime in where downtime includes scheduled unscheduled stops only If the Surveillance Period data have been changed click Update to recalculate the bars Click HEI to save the window as an HTML report You will be prompted for file name and directory 2 4 6 4 The Machine Reliability Report To get more details for the machine highlighted e In the RDM Report window click Reliability Report e directly from the browser Right click the Machine icon and select the floating menu Reliability report 4 Machine Reliability Report RDOPOSi RDOPO10g Ioj x File view Report EJ Downtime List Oh Machine Rom SK 7001 1 v Resolution p Month v RDM Machine Info Surveillance Period Update f Month From 2007 09 12 14 13 02 To 2007 10 12 14 13 02 Unscheduled Downtime Root Causes Parfarmanra Ralia ility Availability Utilization GE Maintenance Monitor Surveillance Downtime Causes Starts Running Hours Operation No Total Surveillance Failed 0 Actual 5886 Total Uptime Successful 0 Equivalent 5896 Total 0 Skid StandBy rReliability Info Downtime Stops Hours No Unscheduled 0 Scheduled 0 Reliability 100 0 Scheduled 0 Unscheduled 0 Availability 100 0 Total
19. Zero Help FJA Company E Eg SysTest ie P E z RDM SysTest a g Ham Qe TG21 RDM RDM RDM E SD Oil Server Source pei sal oA Couleur NA Massa v l Plots Plots Used for test of RDM with Calc bY Viscosity 40 State test State test Hi YN HPA Viscocity 100 NI NI PA Viscosity index Overload Overload PR Acid No PConf PConf oA X Temperature F p P2 PAK Test MoviP MoviP NI2 NI2 KA Particles FAx Property i Ei Ta22 Each parameter has as uSual a definition right click the parameter and select the floating menu View Definition e g xi Name Code Ham TG21 Oil Viscosity 40 Description Unit cSt ue Warning Type offline Enabled VV Label viscosit cin matique 40 C Data may be measured automatically or entered manually To enter the data manually and or read the data 1 Open the Oil Analyses window In the OPENpredictor menu bar select the menu Reports gt Oil Reports PADIl Analyses RDOPOSI RDOPO10g i loj x File amp amp Data Sheet Update a Year From 2006 10 06 15 54 19 To 2007 10 09 15 54 19 machine LL bw LL SGS L YJ LL Sample Date HAMTG21 TG21 2007 04 19 HAM TG21 2007 04 17 HAM TG21 2006 12 01 HAM TG21 2006 11 13 eae Period 2 In this window select the surveillance period click Update if changed alike double click a record one machine one date to Sucka i
20. alert limit has been passed Blue System warnings warning for system functionality see 2 3 2 2 Warnings are divided into five Warning Systems groups System General System warnings only 6 that the connection to the SPU is lost Operation Warnings for problems that require action within a one or two shift period Maintenance Warning for long term maintenance planning Performance Warning about reduced machine efficiency or process problem RDM Warnings about Reliability Data Management which is a special module for certain applications See section 2 4 6 For example if measurement m has an outstanding alert yellow and a more severe alarm red is encountered for the same measurement the number of alerts in the Alert group will be decreased and the number of alarms in the Alarm group will be increased 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 15 Offline Warnings originating from offline Oil Analysis measurements which IS a Special module for certain applications See section 2 4 5 MOS Maintenance Override Switch warnings only The Maintenance Override Switch flag is set for one or more the number transducers MOS warnings and how to handle them are described in more details in section 2 3 5 In the OPENpredictor Menu Bar the number of warnings in each group is displayed next to each warning lamp 2 3 2 2 Measurement warnings overview table
21. data No calculation OPENpredictor will try every hour to see if there are any data in the machine state range and calculate the correction curve if there are 2 measurements Advice contact Rovsing Dynamics 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 59 Server starting and rebooting procedures IMPORTANT The Server PC and the User Interface PCs must have the Same time zone Otherwise the time displayed may be wrong Starting and rebooting is normally a job for the system administrator However it may be useful for the regular OPENpredictor user in an emergency situation The OPENpredictor Server Computer is responsible for All communication between the Server the SPUs and the User Interface s All direct interfaces to the Distributed Control System DCS if used Data storage Warning generation AutoDiagnosis The OPENpredictor Server Computer must be operating continuously The operating language of the Server software is always English This is required to allow Rovsing Dynamics to support the users and to service the system via a remote link The OPENpredictor User Interface Application runs only on OPEN predictor Client Computers where local language versions can be used The OPENpredictor User Interface Application should NOT be run on the OPEN predictor Server Computer 2 9 3 Starting closing the OPENpredictor system In case of a p
22. for lt value gt or lt acceptable Required predicted time to fault gt has developed to a level where ACTION REQUIRED warning is issued At this level an D action is required for example an inspection and or a preventive maintenance task Recommendation identifies for the user the particular fault and the actions that are required Local users with AutoDiagnosis Recommendation rights may edit the content of recommendation field Confidence identifies the certainty of the prediction None Low Significant or High 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 10 Status Accept By is used to identify that an AutoDiagnosis has been accepted acknowledged acknowledge it and by whom See section 2 3 1 2 To view the symptom history and forecast click on Plot Manager This launches the Default plot for the prediction To display close a list of all the current predictive AutoDiagnosis Messages click More Less Pj AutoDiagnosis Message loan Location TR GCK10 4PO01 TestRig MUOZ Shaft HS Component REBOSO Diagnosis Outer Race Defect Outer Race Defect symptoms have developed to a state where some action is recommended Prediction Date of Diagnosis 7002 11 26 12 00 00 Prediction of Required Action Level Nominal Prediction 19 Days Early Prediction 15 Days Late Prediction 4 Days Recommendation Confi
23. icon kasi 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 17 e To display all actual measurement warnings in one of the five Warning p Opel Systems click the All word button Ve Example to display all Operation warnings click All in the Operation group e To display all actual measurement warnings of a specific warning type in a warning system click its lamp Example To display all Operation Alarm warnings click the red lamp in the Operation warning group Operation Al Qt This displays the related Warning list For a full description see section 2 2 2 1 FA Warnings RDOPO8I RDOPO10g g o o x File Edit Filter Columns Acknowledge All Acknowledge Selected ___Code Warning Severity Acknowle Measure Description __Value Meas time Machine Rpm state Type Info 4 System SYSTEM wy v P M Acc 2006 12 11 10 31 06 PM SPU OVERLOAD isl 6 System SYSTEM W vi p M Displ 2006 12 11 10 33 32 PM SPU OVERLOAD 7 System SYSTEM W v P M Displ2 2006 12 11 10 55 32 PM SPU OVERLOAD 3196 Offline OVERLOAD v HAM TG22 252 5 2006 05 15 00 00 00 Ham TG22 O Default Scalar 3197 Offline AlarmHigh IV HAM TG22 55 2006 05 15 00 00 00 HAM TG22 O Default Scalar 3198 Offline AlertLow C HAM TG22 16 2006 05 15 00 00 00 HAM TG22 O Default Scal 3256 Offline OVERLOAD M HAM TG21 200 2006 05 15 00 00 00 HAM TG212 0 Scalar 21468 Maintenance HighII P
24. investigate why a vibration was high was not integrated into the systems so trans portable vibration analysers were used to analyse vibration signals The next generation of CM systems integrated diagnostic measurements such as vectors orbits and frequency spectra When warnings occurred on basic condition parameters such as overall vibration levels bearing temperatures and casing expansion the system would execute the diagnostic measurements The vibration specialist used these diagnostic measurements for trouble shooting in order to explain why vibration was high Later it became possible to periodically collect and store the diagnostic data so trends of some fault phenomena could manually be retrieved from a database The drawback of this traditional approach was that not many machine faults cause of problems were being monitored rather a range of derivative parameters effect of problems which resulted in late warnings and a limited number of machine faults actually being monitored The term post mortem analysis was created as typically the analyses were carried out after a machine had failed in order to investigate why it had happened The reliability of automatic warnings was therefore inadequate for early fault detection and fault forecasting both prerequisites for Predictive Maintenance This therefore called for a new pro active approach 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 1 5 1 2 2 Pre
25. system log and error messages It is however OK to minimise the window Gh OPENpredictor 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 3 2 2 The OPENpredictor Menu Bar PS OPENpredictor vky rdopolOg f Oj x File View Browse Report Tools Help Maintenance 5 Mosq Operation Ofline System T iia QA e D O KA 7 al 11 11 Di z 4l 1 3 e6 al o Oo o The OPENpredictor Menu Bar is the basic control centre for the OPEN predictor system Measurement warnings see section 2 3 2 are indicated here by a flashing warning lamp AutoDiagnosis warnings see section 2 3 1 will pop up as a separate window and are not indicated via these traffic lights The buttons and warning lamp sections displayed are selected from the View gt Toolbars menu To make sure the Menu Bar is always visible on the pc monitor screen use the menu Tools gt Options gt Always on top 2 2 1 Menus and their related toolbar icons PS OPENpredictor vky rdopolOg loan File View Browse Report Tools Help Maintenance J pose T peration Ofline System lee ea eS 7 All ii ii 1 z all i D 6 Al o ITI special installation configurations could be mentioned here but now shown View Toolbars Select deselect the File Browse Tools Warnings gt Operation Maintenance displayed See section 2 3 2 1 Histor
26. will take place between the SPU and Server The aim of the event principle is to reduce the quantity of redundant data to be transferred and stored Hence only values events with a significant difference are stored Each event has its own timestamp HTML HyperText Markup Language The standard code language for Internet webpages Measurement Signal processing algorithm for example OTA Overall Tacho CPB FFT Etc A measurement is defined in a measurement configuration specifying the parameters of the measurement The SPU will perform the measure ments repeatedly A measurement is only stored in the database if the Event criteria for the measurement are met see Event Interactive image of e g a plant or machine e g show ing the position of the transducers and their main data MOS Maintenance Override Switch Shows transducers where warning is temporarily disengaged Measurement data still can be viewed OPENpredictor The application programme described in this manual User Interface used to operate the OPENpredictor system Item in a measurement configuration for example Lower Frequency Number of Lines or Gain Graphical presentation of measurement result s Predictive Maintenance Information System Revolutions Per Minute Scalar One dimensional measuring value e g a temperature or over all vibration value A named user accessible sub programme Signature A set of data taken at a specifi
27. 095 CPB TestRig GCK1LO CY095 SED Cavitation E Plot Manager Browser Warning Settings Cancel The buttons are e Plot Manager Open the DEFAULT plot for this measurement e Browser Open the Browser with the measurement selected e Warning Settings Open the warning settings window for this measurement 2 5 3 How to make a Mimic Report 1 Inthe Mimic window click the Generate Report icon and select a name and path for it The name must end with htm or html 2 To open the report use Start gt Documents or if that fails open the file Html path for example C OPENpredictor Reports xxxx html with the Internet browser for example Microsoft Internet Explorer 3 C OPENpredictor Reports mimicreport html Microsoft Internet Explorer File Edit View Favorites Tools Help Back gt gt Q 2 Search Favorites C4 History Ey 7 Address C OPENpredictor Reports mimicreport html l Uma 2 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 40 2 5 4 Mimic menus and related toolbar icons Explanation a i File Open Open the Mimic Viewer Open window to select which Mimic to open x Mimics BFP A BFP B BFP C OVERVIEW PULYV 14 PULV 1B PULYV 24 PULYV 2B TURBINE ee zi OK Cancel amp Print Print the Mimic screen dump no additional text landscape view Exit the Mimic Viewer View Toolbars EI Fil
28. 10 19 500 1000 10 10 O 2 Validate Settings ox Cancel Warning In this window it is possible to change the figures inserted except the State definitions Do NOT change these figures UNLESS you really know what you are doing and why Explanation to the fields Column State Defines a number of RPM ranges where a defined number of measurements must be made In the above case there are five states e 20 48 not shown In this state the machine is running at a constant RPM between 20 and 48 RPM e gt 20 48 The RPM is changing in the 20 48 RPM range 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 58 e 48 105 In this state the machine is running at a constant RPM between 48 and 105 RPM e gt 48 105 The RPM is changing in the 48 105 RPM range e 10 20 In this state the machine is running at a constant RPM between 10 and 20 RPM Columns Range from and Range to Ranges are sub states defined in of max RPM for the machine in the above case 105 RPM defined in the Machine configuration window Column Min Values The minimum number of measurements in this speed range required for calculating the baseline in this state Column Max Values The maximum number of measurements in this speed range utilized for calculating the baseline in this state If there is more than the maximum number required the latest values are used Column M
29. 12 RPM P M Virtual State 12 45 The images above are showing examples of detailed Mimics A measurement is shown as a leading text normally the parameter name the actual value for the parameter Values without warning are green If ina warning condition the measurement is shown in the colour of the warning condition Alert yellow Alarm red System fault blue Buttons are links to other mimics If the colour of a button is different from green it relates to a measurement with one or more warnings The colour of the button indicates the worst warning level indicated on the related Mimic For more information on a specific measurement displayed Double click the tag name value or meter to display the Default Plot of the measurement or Select the measurement click its label or value and click 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 39 S to display the Default Plot of the measurement 4 to display the measurement in the Browser From there you can select any plot script related to the measurement or e Right click the measurement to open the Mimic Viewer Select Measurement window with all measurements for the transducer i Mimic iewer Select Measurement Measurements TestRig GCK1O CY095 OTA TestRig GCK10 CyYO95 OTA TRT TestRig GCK1LO CYO95 AS TestRig GCK10 CyY095S 451 TestRig GCK1LO CyYO95 AS diag TestRig GCK1LO CYO095 AS Cal TestRig GCK10 CY
30. Function PE System System The connection to the SPU has been lost Operation Operator action Pre warning for required improving operator P operation and minimising ris Maintenance Inspection or Inspection or long maintenance to be term maintenance scheduled action to be defined The range limit for required P the transducer or the measurement has been passed related to this AD function k AD Performance Performance pro Performance blem has passed the problem to be acceptable level investigated action required RDM See Machine stops section 2 4 6 RDM Reliability Data Management Offline See Offline Oil Analysis Offline Oil Analysis section 2 4 5 data has reached an data has reached alarm level an alert level MOS The MOS flag is set for lt the number gt Maintenance transducers Override Switch Transducer Enabled flag NOT checked NO open indication NO measurements NO warnings AD Predictive and Instantaneous AutoDiagnosis messages may appear for this type of fault Only used and consequently shown with certain user applications 2 3 2 3 How to react on a new Measurement warning Indication the related Warning Lamp on the Menu Bar starts flashing Operation Il example one or more and the number next to the flashing lamp is increased by 1 Check physically if the transducer with warning is under main tenance
31. M Tacho 1011 39 2006 12 19 06 45 13 PM 96 s2 Scal x In an Actual Warning List a warning will at most appear once per machine state This means that when a measurement has generated warnings of different warning types in the same machine state only the most severe warning type will be shown The title bar shows which Warning List has been selected here All Warnings The lamps indicate the selected warning levels one or three lamps The Warning List is by default sorted by Meas Time with the latest warnings first To sort it by any other parameter click the heading for this parameter e g click Severity or Machine To reverse the sorting order click the selected sorting heading once To investigate a specific warning 1 Select the warning Click it It is then marked with blue 2 Right click the warning to display the floating menu The floating menu right Secondary mouse button has the following options Opens the Browser showing the measurement causing the warning For CM specialists only Acknowledge the warning s selected For CM specialists only Plot Manager add in filters list lt list of plots plot scripts gt Display the plot related Use DEFAULT with the last 7 days of data as your first choice to display the Default plot for the measurement Double clicking the warning will display the DEFAULT plot Consider in each case if any of th
32. Mengemant report generator all in aline alerts for It daye Lan P 30 days maenagamani repork Conte Sarl feel end dera meanman n report Machine hHessuremant Warning Forecast Forecast Warning attinga Hin Phase Status Pa i rarer Alann ee Hache Code i State Terthig GDID Teri GOR10 TEA Medan APON Tarif EED Cawan Ina TeRi GEKID Tegihig ASKID SADI Medham eS ADO Tegak OTA load 7 ence HRG GEKO fTeatRig SSK10 SY 011 Medien APOGI Tedifieg OTA load sei GOR10 Cr 011 Medium fT fom Tete HIELD T itkig GOR CY Madi APYE Tedi TTA IETT Tarte GEL Teri GORLU CY M APG Tageiies OTA bhienane ona t amp cr t t a a L Li tdia 4 Medba Ei nad Terthig Glki Tariq GCekii YURA Meds GE I APDO Tarihi OER Iag Tar mck i Rig Ge oh A OL CA Rig Taat Changed i APOE Sha HE Robar Crack DS Tabir Tha ipi IAI Chadh hiit 2009 07 07 LAr F009 ER 2 4 1 How to generate a Shift Report A Shift Report is automatically generated at the end of each shift for handing over the status to the next shift The intended receiver is the user of OPENpredictor on the next shift The content selected should reflect the needs of the next shift The Shift Reports are generated at the times defined in scripts which can be edited by the OPENpredictor system administrator To change the contents of the Shift Report for example the Report comments 1 Inthe OPENpredictor Menu
33. Npredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 33 2 4 6 Reliability monitoring special module RDM Reliability Data Management is a system used in some installations reporting how often a machine is running and why it s stopped 2 4 6 1 Menu Bar indicator Whenever a machine Is stopped it causes a Reliability warning The number of machine stops can be shown in the Menu Bar Select the menu View gt Toolbars gt Warnings gt RDM FOM Al o 4655 o amp yellow is the number machine stops scheduled and unscheduled blue is the number of RDM System warnings no contact to the system 2 4 6 2 The Downtime List The Downtime list is available e directly from the Browser Right click the Machine icon and select the floating menu Downtime list e by clicking the Downtime List icon in the Machine Reliability Report see below 4 Downtime List RDOPO8i RDOPO10g 1O x File Report Reliability Report SB oa Machine Rom SK 7001 1 RDM Machine Info Recalculate Period Update i Year y From 2006 10 12 14 16 23 2007 07 06 07 47 37 2007 07 06 07 53 19 1 Repaired 2007 07 06 07 45 49 2007 07 06 07 47 37 O UnScheduled 2007 07 05 14 06 09 2007 07 06 07 45 19 7 7 UnScheduled 2007 07 05 13 39 05 2007 07 05 13 40 11 O UnScheduled 2007 07 05 13 15 58 2007 07 05 13 37 40 4 UnScheduled 2007 07 05 13 15 55 O UnScheduled 2007 07 05 13 14 50 O U
34. The report is an HTML report for a single plot The HTML file contains a plot and all relevant data for evaluating the plot Ac OPENpredictor Reports Spectrum_ _TR_GCK10_C 105_A51_ All states htm Fie Edit View Favorites Tools Help Fie Edt view Favortes Took Hele Bak gt Q A Asearch Favorites media lt 4 D G Address C OPENpredictor Reports Spectrum_ _TR_GCK10_CY105_A51 _All_states html Spectum TR GCK10 CY105 AS1 All states Tile Value Unit Y 0 0 m s x 5 9 Hz Speed 2421 RPM Overall 1 555 State Full load im ype E 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 45 1 Inthe individual plot window e Select the menu View gt Toolbars gt Report and then click the Icon IM Scalar Trend TRGCK10 CY064 Overall All_ States File Options View Report Help EJ Short term ds lu PIE Set m G Af d Cursor point Zoom 1 2 DE of t or e use the menu Report gt Generate This opens a normal Save As box 2 In the Generate report Save box select a name with the extension HTML normally accept the proposed name and click Save 3 To open the report use Star gt Documents or if that fails open the file Html path for example C OPENpredictor Reports xxxx html with the Internet browser for example Microsoft Internet Explorer 2 7 2 How to make a Multiple Plot Report The report is an HTML report for all the plot
35. The route data contains information about where to get which measurements and in which Suggested order 2 8 1 Uploading the route to the data collector 1 Connect the data collector to the PC port specified for example COM1 Make sure the battery is full and in good condition 2 Inthe main window select the menu Tools gt Routes This opens the Route MMI window a Route MMI RDOPOSI RDOPO10g 0 x File Edit DataCollector PredefinedNotes Help La OA es i id Enab Load Message Data Colle Last Upload Last Download Iv gl To Upload Movi 04 00 mnis 5 days 00 2007 08 15 1 T 8 15 1 M To Download DI 04 00 mn s 5 days 00 2007 08 15 1 To display the route definition double click the Message field of the route 3 Select the route to be uploaded even there is only one route 4 Inthe Route MMI window select the menu DataCollector gt Upload to Data Collector 5 Wait until the data collector reports the route is loaded for example the progress bar disappears 6 Disconnect the data collector from the PC 2 8 2 Downloading the tour data from the data collector When the data has been collected do as follow 1 Connect the data collector to the PC port specified for example COM1 2 Inthe main window select the menu Tools gt Routes This opens the Route MMI window 3 Select the route with the data to be download
36. Wo z4 25 26 27 b Click OK to insert the new date and time The Recalculate Zero Gap Baseline window is now updated 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 56 c If a start time before the previous baseline date is selected you will get a warning message Click Cancel to enter a new date and time Click OK on the Recalculate Zero Gap Baseline window 4 Answer this question J Do you want to set the initial wear e If Yes Continue at section 2 9 2 3 Set Initial Wear step 2 e If No Initial wear will be set to 0 Continue with step 5 below 5 One of these messages is displayed Jil zero gap has been reset Jil BOC baseline recalculation has been initiated 2 9 2 3 Set Initial Wear Purpose To insert the value of initial wear if known 1 Inthe Browser right click on a Machine Machine Section Machine Component or Transducer and select Set Initial Wear KE File View Search Browse Report Options Set Zero Help IAK Company Maersk Main Engine Cylinder 1 a Transducers Pa Rom a K4 Ham Name Code Descript Type Enabled MOS Fiag sPu ser mark DP1A Mark Mai PR6424 0 Displacement Probe M C BDC SPU 1 QS Main Engine DP1F Mark Mai PR6424 0 Displacement Probe Vv ppc SPU 2
37. ask your OPENpredictor system administrator to set up the plots you need The plots can then be found on your list of default plots see 2 7 4 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 46 2 7 4 How to open a user defined plot To display a user defined plot 4 OPENpredictor i Ioj x File View Browse Report Tools Help E e e e A en Operation Maintenance Performance Mos he E a a e B osole 4 Open the Plot Manager window In the OPENpredictor Menu Bar click If you want to work with icons in the Plot Manager window select check mark the menu View gt Toolbars gt V Advanced toolbar This setting will be saved with your user profile Open the Open Data Selection window In the Plot Manager window lolx File Insert Report Option View Window Help SE e Wu OB be ae Fe 22 Bt a oe to a p t e Click the 4 icon or e Select the menu View gt Data selection gt Open 01x Data Selection Details Turbine HP Scalars 12 b Turbine HP Scalars 12 Turbine HP Sigs 12 S User john Cancel Select the desired stored plot settings which may contain one or several plots by clicking its name in the left field The selected setting is shown in blue Examples of the results of different stored plot scripts Click OK Opening the plots may take quite some time depending on the amount of data to calculated and displ
38. ax days The maximum number of days where measurements are taken into consideration for calculation of the baseline in this state Column Alpha Averages The minimum number of measurements needed in this state for the calculation of the preliminary correction curve in Reset zero gap The baseline is calculated separately in each state The RPM ranges for each state depends on the design of the engine 2 9 2 5 Reset zero gap Recalculate BDC Baseline what happens A preliminary correction curve is 1 Some of the old correction curve calculated from the first Alpha parameters are used for the average number of measure preliminary correction curve ments in each speed range Data are collected until there are enough data in all data ranges see below or the Max Days since the Start Time for Baseline Calculation has expired The final correction curve is calculated Data used in each speed range Too many data in a speed range The most recent Max Values data Enough data in a speed range between Min Values and Max Values All data are used Not enough data in some speed ranges within a machine state e Enough data in 3 ranges Data from all ranges are used e Enough data in 0 2 ranges only Wait until enough in 3 ranges but not more than the highest value of Max Days days for each machine state Afterwards The correction curve is calculated best possible Advice contact Rovsing Dynamics No
39. ayed A progress bar is displayed If more than one plot is displayed in the same Plot Manager window they may be cascaded click IB tiled click HH or tiled vertically click amp To close all plots click TA 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 47 The plots may also be maximized normalized minimized and closed in the normal way using the buttons 2 7 5 Navigation facilities of a plot This section aims to give you the skills to work with pre defined plots 2 7 5 1 Zooming by selecting Click and hold down the primary left mouse button while moving the pointer to select the part of the plot to zoom in When the mouse button is released the zooming takes place IM Spectrum TR GCK10 CY074 SED1 REB All_states oO x File Options View Report Help 1 1 RE 24 Independent mode 5 AT Ln dB Joriginal FI Please note e If the selection doesn t contain any curve points no zoom Is made This can be used for cancelling the zooming e As shown above going outside the borders includes an equivalent area outside the current selection e The co ordinates of the starting point corner and the pointer are displayed at the selection 2 7 5 2 Zooming moving and scrolling using shortcuts Shortcut Shortcut keys Function hee gt Move Move the point selected in the direction of the key point selected in the direction of the key the key selected select
40. but somebody has forgotten to mark the transducer as 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 16 Under maintenance set the MOS flag or disable the transducer uncheck Enabled If the transducer is under maintenance and If you have Flag rights depending on the situation set the MOS flag or uncheck Enabled for the transducer See section 2 3 5 e If you do NOT have Flag rights Notify the person in charge of the system about the problem See section 2 3 5 2 If according to point 1 the warning is reliable If the warning is an w Alarm for OPERATI ON Action required Immediately notify the person on watch in charge of the plant If the warning is a i System warning Immediately notify the person on watch in charge of the OPENpredictor system Else consider what to do Normally no immediate action should be necessary The warning will be reported automatically in the next Shift and or Management Reports see section 2 4 See below about using Warning Lists and for more warning information incl when and how to acknowledge a warning and when a warning disappears from the Actual Warning Lists 2 3 2 4 Opening a Warning List There are three types of measurement warning lists Actual Warning Lists called Warning lists only include details for the current measurement warnings to give a quick and accurate overview of the plant status Any measurement may gen
41. cvooz PA Overall PA Harmonic PA Harmonic TRT FFT PA FFT diag A FFT TRT PA FFT cal PA CPB HDA FSA gt The window contains five areas below the title bar e Menus e Toolbars e tem measurement selected e Left field Item Measurement selector See section 2 6 1 e Right field if displayed Item Measurement data To select an item click it with the left primary mouse button You can use the arrow keys to navigate in the Browser window Item Measurement Selector Icons used in the left side field showing the hierarchical structure of the CM Transducer Virtual transducer or AutoDiagnosis Server Closed default Items measurements in the next level s are hidden Click to expand Ca Open Items measurements in the next level s are displayed Click to hide lower level contents 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 42 The item measurement displayed with blue background is the currently selected one Its data is displayed in the right hand data field if displayed and its name full path is displayed above the window 2 6 2 Floating menu Put the pointer over an item measurement and right click to activate the floating menu for that item Floating menu example for a measurement wiew Definition Plot Window add in measurements list A Plot Winda CEFAULT i RPM 2 R PM SFR PM 4 R PM Sub Res Add in filters list
42. d a beep to the PC loudspeaker at e Anew AutoDiagnosis checkmark the OPENpredictor main panel menu Tools gt Options gt Beep when AutoDiagnosis message e Anew measurement warning checkmark the OPENpredictor main panel menu Tools gt Options gt Beep when warning OPENpredictor identifies changes in the dynamic behaviour of machines using automated signature see chapter 3 comparison OPENpredictor will issue an AutoDiagnosis Message for identified changes incorporated into the AutoDiagnosis Fault Library For gradually developing faults a prediction will be given This is called Predictive AutoDiagnosis see section 2 3 1 3 For faults with an intermittent character no prediction can be specified so only the fault diagnosis will be available This is called Instantaneous AutoDiagnosis see section 2 3 1 4 To see a list of possible AutoDiagnosis both types 1 Open the Browser click Ts 2 Right click the unit for example plant machine or machine compo nent 3 Select the floating menu View AutoDiagnosis Messages or View Instantaneous AutoDiagnosis Messages to display a list of AutoDiagnosis for the unit selected For identified changes not incorporated into the AutoDiagnosis Fault Library warnings will be issued via the Measurement Warning I ndicators the lamps on the OPENpredictor main panel These warnings have to be investigated manually Rovsing Dy
43. d for the machine state of the warning The time of the measurement The time stamp for a measurement executed by the SPU is given in the SPU The time stamped data is transferred to the OPEN predictor Server The SPU time is synchronised to the OPENpredictor Server clock Machine moment of the warning warning The names are different for all machines Type For example Scalar Spectral Band Harmonic Envelope Profile Additional information e The harmonic which initiated the error 1xRPM Amplitude or 3xRPM Phase e The number of lines in a signature e Spectral band identifier for soectral band warnings Acknowledged Meas Time Info The columns may be moved by clicking the column header and then drag and drop it to a new position by means of the mouse Icons Red Alarm warnings are included Yellow Alert warnings are included Blue System warnings are included 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 20 Menus Menu level 1 Menu level2 Explanation Close the Warning List window Edit Acknowledge All Acknowledge all warnings Acknowledge Acknowledge the warning s selected Selected Filter Columns Hide display the column Right Secondary mouse button floating menus View Browser Opens the Browser showing the measurement causing the warning View Warning Setting Opens the related window with the warning limit set up fo
44. dation ee Confidence Significant Status Not Accepted Accept More Ii Flot Manager Close For details about the fields in the predictive AutoDiagnosis Message Window see section 2 3 1 5 The information provided is Location and Component identify where the fault has been diagnosed Diagnosis identifies what the fault is The numbers in parentheses above the field are internal codes for the text strings displayed Va Prediction identifies Date of Diagnosis the date and time of this AutoDiagnosis How soon the fault is predicted to become serious Nominal Prediction The expected development of the fault using the standard extrapolation algorithm Early Late Prediction The variation to the best estimate using the standard confidence level for the forecast The AutoDiagnosis Message is issued at three Symptom Strength levels indicated by the background colour of the icon Detected As soon an incipient fault is detected by the Auto Diagnosis system the DETECTED message is issued D However it s still too early to predict the date when the fault will become severe with a reasonable confidence Predicted The Symptom Strength has developed to a level where e its history can provide a statistical model for future development and the date at which the fault strength will become severe can be predicted the PREDICTED message Is issued Action The Symptom Strength
45. dence Significant Status Not Accepted Accept Less Browser Plot Manager Close Pending Faults Se ee Mach Section Component Machine Outer Race Defect Detected 2002 11 28 12 00 00 GCK10 APO MUOZ Shaft REB1O0 Cuter Race Defect 2002 11 28 12 00 00 GCK10 APO MUO2 Shaft REBOSO To display a specific AutoDiagnosis Message select it by clicking it 2 3 1 4 Instantaneous AutoDiagnosis IAD messages Instantaneous AutoDiagnosis messages are calculated continuously when ever there is a change in the related parameter s at the relevant machine state s They are mainly intended for the operation people and they often require a fast response To open the window with a list of all activated Instantaneous AutoDiagnosis Messages select the menu Browse gt Instantaneous AutoDiagnosis List on the OPENpredictor Menu Bar The instantaneous AutoDiagnosis message window has fewer fields than the Predictive AutoDiagnosis messages The explanations to the fields are the same as for Predictive AutoDiagnosis messages except the Warning Level field which can have the following messages 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 11 Detected As soon an incipient fault is detected by the Auto Diagnosis system the DETECTED message is issued Action If the Symptom Strength develops to this level the Required ACTION REQUIRED warning is issued At this
46. e EJ Go E Browse EJ Report link Switch to next Mimic originally selected by link this measurement is displayed in the Browser Plot manager selected Report Generate Creates an HTML report with the content of the Mimic window HTML is automatically added to the name typed Open the help file Open the About OPENpredictor window 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 41 2 6 The Browser Window The Browser is used for selecting measurements to be displayed and for displaying details about plant and machine items and measurements To open click the Icon To open close the right side field with the details select menu Options gt Right Part of Browser visible This setting is stored 0x File View Search Browse Options Help JAK Company Carneys Point Turbine HP Section REAR HP JB ACYO02 FFT 2 Company Al State Dependent Setups B E Carneys Point Machine Priority Rate Unit Range From Range Tol Baseline Enabled State Index ERS Turbine 60 Minute 0 0 10 2 0 0 M 5 ERs Operation 60 Minute 10 2 M HAN Keyphaser i m 60 Minute 10 2 Vv H AD N A 60 Minute i 10 2 M SD MAITO2 60 Minute 10 2 M Sg Maut i 60 Minute f 10 2 M E SD Operational PA Tachocheck HDA Load PVA State E S HP Section So TB Skate Thrust E e FRONT HP JB No HP Seal DE Mg HP Shaft Mg HP Blades No HP Seal NDE Ca REAR HP JB HAN ACYT12 HAN ACYT42 aAA a
47. e OPENpredictor system If you for example have not bought the AutoDiagnosis module these functions are not displayed in the OPENpredictor user interface Please disregard them when reading the manual OPENpredictor contains functions that are accessible in this version but not described in any of the manuals delivered with the system Such functions Shall be regarded as non existent as they are only for use by the personnel of Rovsing Dynamics A S its distributors or service partners 1 1 1 Conventions for this Guide The character sequence menu Xxxx gt Yyyy means click on menu item Xxxx and open submenu item Yyyy select menu Xxxx submenu Yyyy Bulleted lists indicate alternatives to be selected from unless other wise specifically indicated or simply a list 1 Numbered lists represent a set of ordered steps to be followed one by one Button name represents a Windows button with the caption Button name 1 2 Key name The key Key name on the PC keyboard Field name The field Field name in a Windows window lt descriptive text gt the lt gt field is to be replaced by the relevant text as described Example menu Filter Column gt lt column name gt could be e menu Filter Column gt Value or e menu Filter Column gt State 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 1 4 1 2 About OPENpredictor OPENpredictor 2 8 0 is an auto
48. e script selected in point 2 The progress of the generation is Shown in the progress bar here marked 0 The generation may take some time depending on the number of warnings and data to be included into the report 7 Click Close to close the window To open the report use sa gt Documents or if that fails open the file defined in Html path for example c OPENpredictor Reports ManagementReport html with the Internet browser for example Microsoft Internet Explorer 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 29 2 4 2 Diagnostic report In the OPENpredictor menu bar select the menu Reports gt Diagnostic report to save an Excel file with the following content Diagnostic Report LI DI DI DI ee ee BETA MAD Shem Turbine Pe ee IU ee eee General Machine Aiallh Cordbion 1 primii and 7 De pamer He gan gah D Autol tagnosis methods II DI DI DI D 1 Journal Bezing 07 07 23 00 59 00 Deanng Waar Radiah Early alate of Gearing Wear is Instantaneous Auk albiar EEE Eee Component HP Shait TOTO Ts Ror Ruka L es Component Date Diagnosis LF Shaft MAA 014 Rear Rub AD LE a DI A Alarm List Campini Alam Warring 10 Journal Dearing 0 1 Coc mpana ni Alam Warring Aled Waring 20 Journal Dearing F 1 Lampit nt Alam Warnings Adler Wamings 40 Journal Dearing Lampit nt Alam Warnings Ader Waring WAD Steam Turbine page lof2 OF 10 11 13 5102
49. eboot of the SPU the SPU and the network must be running Make a Telnet connection to the SPU and send the Ctrl x reboot order 1 Open Telnet Click the Windows Start button Star and select Run 2 Inthe dialog box Run type telnet followed by the IP address of the SPU This address can be found as follow a Inthe OPENpredictor Browser select the menu View gt SPU Definition b The IP address is now found in the Host column of the SPU definition window Ss Type the name of a program Folder document or 7i Internet resource and Windows will open it For you Open telnet 10 0 100 11 Cancel Browse If the system connects properly this opens a DOS window off CA WINNT System32 telnet exe In the case of a failed connection for example network problems to your PC the DOS window is not opened Then use the on site procedure described in section 2 9 4 2 3 At the prompt type Ctrl x press the Ctrl button and keep it down while pressing the X key For some seconds there will be no response When the DOS window closes the reboot procedure has been initiated 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 61 2 9 4 2 On site reboot of the SPU On the RO 2010 module s in the OPENpredictor rack press the Reset button 3 Sata Pressing the button more than 5 seconds will reboot ai the SPU WARNI NG While rebooting no
50. ed 4 Inthe Route MMI window select the menu DataCollector gt Download from Data Collector 5 You are notified when the data has been downloaded Then disconnect the data collector and make sure the battery is being recharged 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 52 Bearing Wear Monitoring special module OPENpredictor uses BDC Bottom Dead Centre measurements for Bearing Wear Monitoring BWM on piston engine bearings A typical application is large ship diesel engines Connected to the general ship alarm system it can give an instant sound alarm for spontaneous bearing damage as well as early warning messages for slowly developing bearing wear 2 9 1 Basic principles The basic idea of the BDC measurements is for each cylinder to place a proximity sensor at the bottom of the crosshead guide just below the BDC point BDC for a piston engine is the position of the piston in which it is closest to the crankshaft When the wear of the bearings is growing each stroke will become slightly longer because of the wear in the bearings at and below the crosshead This means that the lowest position of the crosshead comes closer to this sensor and the change in the data from the proximity sensor over time is a measure for the wear in the crosshead bearing the crank bearing and the main bearings Crosshead Guides Crosshead Bearing Crosshead Sensor position Connecting rod
51. ed point selected point selected Num indicates the keys in the numeric pad section of the keyboard 2 7 5 3 Zooming to fit to the actual data Select the menu Options gt Fit to data or use the buttons lt 4 and or Al 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 48 2 7 5 4 Zooming out by a factor of 1 2 Shortcut Right click inside the curve area of the plot r Zoom 1 2 Icon 22 zon Access select E mark the menu View gt Toolbars gt E Zoom in the appropriate plot sub window Activated clicking anywhere inside the plot will zoom out EJ Zoom 1 2 both axes by a factor of 2 keeping the centre point of the plot Deactivated Clicking inside the plot leads to normal pointer O Zoom 1 2 functions The shortcut will still work 2 7 5 5 Scrolling the selection one grid width using the mouse Right click secondary mouse button the plot sub window outside the curve area itself to scroll the plot approx one grid width in the direction of the arrow displayed the direction away from the curve area In the screenshot below the arrow is shown to the right of the curve area IM Spectrum TR GCK10 CY074 SED1 REB All_states 7 Ho File Options View Report Help 141 1 gt HH RE 24 Independent mode WIS AT Ln dB Joriginal x 2 7 5 6 Cursor position readout Right click secondary mouse button the plot sub window anywhere inside the curve area to show the
52. ed procedure is described below 2 9 2 1 Background In order to convert the measured BDC to wear a number of factors may influence the measurement By far the most important factor is the actual RPM of the machine The BDC baseline normal values includes the curve for correcting the BDC wear measurement for RPM In theory the faster the machine runs due to the inertia of the piston the deeper the piston at BDC will come down towards the crank The BDC correction curve is used to correct the BDC for RPM to its RPM compensated value BDCc To compensate for tilting of the crosshead OPENpredictor is using two transducers one on each side of the crosshead guides The final measured value is the average of these two measurements However if one transducer fails the measured values from the other transducer will be used directly There are four types of BDC measurements in the Browser BDC The raw measurement of each transducer BDCc The measurement corrected for RPM and other if relevant Wear The average of BDCc for the two transducers of the cylinder minus the initial value The initial value compensates for the placement of the sensors Initial wear see below Position Used for adjusting the sensor and sensor validation during opera tion An Alert High on a Position measurement indicates a faulty transducer Initial wear Initial wear is always zero for a new bearing The Initial wear of intere
53. ed starting time describing physical parameter properties in time frequency transient and process domain Examples e A spectrum amplitude versus frequency e A time domain curve for a short time incident for example Orbit or FSA e A vector measured for example during inputs Signature Processing Unit RO2000 19 frame for 1 pcs RO2010 CPU unit 1 to 10 pcs RO2Z020 SPM modules System warning The connection to an SPU is lost Vector Multi dimensional measuring value e g the amplitude and phase of a vibration or the x and y position of a rotor relative to a fixed centre line In OPENpredictor vectors are handled as multiple scalars 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 1 Page 3 1 Index Bold page number Major information about the subject Name 1 4 19 inch rack 2 65 2020 SPM module 2 67 Acknowledge 2 19 Actual Warning lists 2 17 Alarm warnings 2 15 Alert warnings 2 15 Analog Input connectors 2 67 AutoDiagnosis List menu 2 4 AutoDiagnosis 1 6 2 3 2 9 3 1 Recommendation 2 10 AutoDiagnosis lists 2 11 AutoDiagnosis messages 2 9 Beep when warning 2 5 Browser 2 4 2 42 Bulleted list 1 4 Change password 2 2 CM 3 1 Condition Monitoring 1 5 Cooling fans 2 65 Copyrights 1 3 CPM 3 1 Data Server 2 63 Date amp time format 2 50 DEFAULT 2 45 Delete Warnings from list 2 19 Diagnostic report 2 30 Discla
54. ed for a new installation Reset Zero Gap or if a main bearing has been replaced e fa machine part for example a cylinder is selected all BDC trans ducers related to that machine part is reset This is typically used if a crosshead or crank bearing has been replaced e If a transducer is selected this transducer only is reset This is typi cally used if a transducer has been replaced This message Is displayed if Reset Zero Gap is selected The condition is only needed to be true when the OK button is clicked Click OK to proceed Cancel to quit x J Please be sure that the speed is at least 75 of max RPM Cancel Set the start time for the baseline correction curve parameters calcula tion BDC values which are time stamped before this time are not used in the calculation If the correction curve has previously been calculated this date is displayed Previous Baseline Data Default start time is the current time Pa Recalculate Zero Gap Baseline xX Previous Baseline Date 2007 08 02 12 46 37 Start Time for Baseline Calculation 2007 10 19 14 07 50 Cancel a If changing the start time click on the calendar button oF select a date and time as desired and click OK The value should be set to the date and time where reliable measurements with the current bearings and transducer installation started W Recalculate Start Time oO x october 2007 10 11 i 15 17 18
55. eport should cover warnings from the last lt Days gt days comments reports Report options Include AutoDiagnosis recommendations Include AutoDiagnosis Message s not acknowledged acknowledged Html Path Relative path ref OPEN predictor path and the file name of the report html is omitted Preferably use a path on the OPENpredictor Server Change the Html path Report fields Date Include the date and time of the AutoDiagnosis warnings Operation Include these warnings in the Maintenance report Performance RDM Offline System warnings Machine code Include machine code Measurement Include measurement code Machine State Include machine state Measurement Value Include measurement value of the warnings Warning Settings Include warning settings Value examples 0 4 The last warning limit passed Normal The value is now back in the normal range Forecast Time Include Min and Max forecasted time where the fault becomes critical Value 0 No forecast Include warning status for example HIGH2 M Acknowledged Accepted O Not Acknowl Accepted Save the settings selected 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 28 How to generate a Management Report The Management Report is a report which may be generated e g monthly or after a serious warning It is intended for maintenance management The report contain
56. erate several warnings per state but only the most severe warning per state will be shown in the Actual Warning List The value causing the warning is shown in the Value field The default setting is to list the latest warnings first For access see below A measurement will at most appear once per machine state This means that when a measurement has generated warnings of different warning types in the same machine state only the most severe warning type will be shown The default sorting order is by time with the oldest warning first Warning History Lists are Warning Lists with details for all actual and historical measurement warnings All measurements in the warning condition are displayed Historical Warning Lists are for CM specialist use For details see section 2 3 2 6 For access use the menu Browse gt Warning History List IMPORTANT Displaying the Warning History list may take quite some time depending of the number of historical warnings in the database MOS Warning list is a list of transducers where the MOS Maintenance Override Switch flag is set The MOS system is described in section 2 3 5 Select the Actual Warning List to be displayed D OPENpredictor vky rdopol0g on File view Browse Report Tools Help System j Maintenance Mos Operation Offline EY Ta T Ey Y z all a1 11 lar 3 eja o 0 Go e To display all actual measurement warnings click the All warnings Warning List
57. es from third party suppliers 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 1 8 How to use OPENpredictor The user interface is described in section 2 2 It gives access to a number of visualizing tools e Warning messages see section 2 3 When a combination of measure ments over time indicates that a mechanical failure is on its way a warning message appears on the user interfaces either as an Auto Diagnosis message window or as a flashing warning lamp on the user interface main panel The warning system is described in section 2 3 e Reports see section 2 4 Maintenance management reports shift reports plot reports etc e Mimics see section 2 5 Interactive graphics with selected measure ments and alarms e Browser see section 2 6 The browser gives access to the details about each item plant machine transducer etc and each measurement with links to plots AutoDiagnosis per machine and configuration data The Browser is mainly aimed at the condition monitoring specialist e Plot Manager see section 2 7 Data can be presented in a large variety of plots mainly aimed at the condition monitoring specialist Off line data collection optional is described in section 2 8 Restart of the on line data collection system is described in section 2 9 Description of the hardware the intelligent data logger is provided in section 2 10 2008 11 20 OPENpredictor 2 8 0
58. es from third party suppliers are followed carefully Keeping all untrained persons especially children and animals safely away from all equipment and chemicals to be used for the OPENpredictor system Rovsing Dynamics A S its suppliers and subcontractors will under no circumstances accept any liability for any physical or mental injuries any losses or any damage on anybody s property incl personal belongings equipment buildings and their surroundings in the widest sense due to The use of the OPENpredictor system including wrong fault diagnosis or any kind of transducer or transducer system fault and its conse quences Products manufactured by means of systems using the OPENpredictor system The design and manufacturing of third party equipment included in or connected to the OPENpredictor system e The lack of information contained in manuals for the OPENpredictor system and equipment manufactured by third parties incl safety related matters The content incl safety related warnings and instructions of manuals for equipment from third party manufacturers is solely the responsibility of the vendor manufacturer of this equipment Failure to follow or comply with any safety related instruction given in manuals for the equipment used for or connected to the OPENpredictor system on the equipment and in on manuals packages and safety sheets for the consumables incl manuals and packag
59. es of system components with selected measurements and warnings related to the items currently displayed ltaj MimicViewer Steam turbine Data values without warning are green If a measurement shown is in a warning condition the colour of the measured value is the colour for the warning condition red Alarm yellow Alert Coloured buttons are links to other Mimics The colour of the button indicates the colour of the worst measurement on the linked mimic TIPS e f holding the mouse pointer over a data field the time for the measurement is displayed as a tool tip text e For more information about a measurement right click the name of the measurement see section 2 5 2 2 5 1 Opening a Mimic 3 OPENpredictor O x File View Browse Report Tools Help E ie eh System Operation Maintenance Performance Mos Oa an ivco Oo a 2 i6 Jal lai go 0 aien 1 In the OPENpredictor Menu Bar click to select the Mimic Viewer vi Mimic Viewer File View Go Browse Options Report Help B amp R oo NA i 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 37 If a default Mimic has been defined this is immediately shown below the panel see point 3 below 2 Click amp to open a Mimic This opens the Mimic Viewer Open window 46 MimicViewer Open 3 4 Mimic Viewer OVERVIEW ee tale ff l iain i ay n i ie nmin ran M BEHE i j mm di
60. ese above floating menu options will give useful additional information to act upon For the regular operator most often the answer is no except maybe View Browser and Acknowledge selected 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 18 2 3 2 5 Acknowledging and removing a measurement warning To acknowledge a measurement warning use the following procedure In the Warning List window 1 Select the warning s to be acknowledged To select more than one warning hold down the Ctrl add selected or Shift mark end of group keys in the usual way while selecting 2 Select the menu Edit gt Acknowledge selected or the floating menu Acknowledge selected Alternatively all warnings can be acknowledged by selecting the menu Edit gt Acknowledge All A measurement warning is automatically removed When it is acknowledged AND Its value is back within the accepted range OR the machine has moved to another machine state The warning data remains in the historical list To see all current and removed warning data select the menu Browse gt Warning History List WARNI NG The acknowledged mark cannot be removed I MPORTANT When a warning has been acknowledged the Value field for a scalar measurement is no longer the worst data for the parameter From now on the last data for the parameter of the related machine state is displayed in the Value field 2 3 2 6
61. eso H h ll i The image above shows a system overview without measuring values 4 To switch to another Mimic alternative methods Click the link button for the Mimic desired Select the Mimic from the list step 2 3 above Click the P back or forward icon to get the previous or next Mimic previously displayed 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 38 2 5 2 Working with a Mimic Isi MimicViewer Steam turbine File View Go Browse Options Report Help Sen Fe BY i Steam turbine 1MAD 40 C Y001 Overall 1MAD 30 CY001 Overall 1MAD 20 CY001 Overall 1MAD Calculated State No data 1MAD 10 CY001 Overall No data No data 0 um 0 um 1MAD 40 CY002 Overall 1MAD 30 CY002 Overall 1MAD 20 CY002 Overall 1MAD 10 CY002 Overall 33 um No data 0 um 0 um 1MAD 40 CY003 Overall 1MAD 30 CY003 Overall 1MAD 20 CY003 Overall 1MAD 10 CY003 Overall No data No data 0 0 mmis 0 0 mmis 1MAD CS001 Tacho 3000 RPM 1MAD 40 CY001 Gap 1MAD 30 CY001 Gap 1MAD 20 CY001 Gap 1MAD 10 C Y001 Gap 1184 pm No data No data No data 1MAD 40 CY002 Gap 1MAD 30 CY002 Gap 1MAD 20 CY002 Gap 1MAD 10 CY002 Gap No data No data No data No data 1 MAD GRID 0 24 0 ofon 1MAD KVA 4 20mA 758 Mvar Poa ts Yiewer Meters File View Go Browse Options Report Help SEIE hh B Tacho m s so 25 2i o 100 5 Tacho m s Tacho m s Tacho m s Tacho m s P M Tacho Tacho
62. exact position of the cursor in a small sub field Line 1 x axis position For a time axis date amp time see section 2 7 5 7 Line 2 y axis position 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 49 2 7 5 7 The date amp time format The date amp time format refers to the format displayed at the bottom of the window In this case the first part 2003 01 13 12 is fixed for all points and therefore only the part mn s min sec in this case 54 27 is displayed on axis etc If for example the format was 2003 M D the date amp time stamp displayed would have been 01 13 in this case no time If the plot shown is a signature the time format text is replaced by the time of the signature 2 7 5 8 Peak position readout Left click the plot sub window near a peak to set the selected point to the nearest peak value The position is indicated in the plot by border to border dotted orange lines and the position data is shown in the data field to the right of the plot together with other important information about the measurement 8 Scalar Trend TR GCK 10 CY064 Overall A File Options View Report Help ER Shortterm 4 gt Po Note the data field may be switched on off by means of the FE icon 2 7 5 9 Changing data period for a scalar plot window I Scalar Trend Turbine amp File Options wiew Repe Short term d Short term Medium term Long term Previous te
63. for maintenance see section 2 3 5 To see which transducers are not enabled see section 2 3 5 4 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 23 2 3 5 3 Checking changing the position of the MOS and Enabled flags To change the Enabled flag setting you must have Flags rights 1 Inthe Browser right click the transducer AM or SD related to the measurement KA and select the floating menu View Definition lolx File View Search Browse Options 56t Zero Help JAK stRig KPO1 Single stage pump REB110 CY114 Company E K TR E e GCK10 APOOL TestRig E e Operation BE s KPOL Single stage pump E e REB110 WEEN fi Definition H pr i View Definition HDA CPB PA SED Cavitation PA ASL PA SED1 PA SED2 DA SED3 Mg Pump shaft Mg Pump Mg Stage 1 Mg Pump casing Mg Seal NDE g REB120 HAN N A MUO2 Shaft HS MGO1 Gear box Shaft LS Motor SB D z eo 5 Pop This displays the definition for the transducer in the above case je Accelerometer Configuration J i x Name evos o Code TestRig GcK10 cogs SSS Description DA Coupling Ac K ngle boo o 9 Overload tzv F J Serial No sy Enabled IV Sensitivity booo mW EU MOS Flag E ICP Accelerom V SPU spu z Offset fo my Channel No 26 Gain fo z dB Online Ci Offline C Accelerometer
64. ges for this machine Open the Machine States window with a list of machine states of the machine selected during the last week You can change the display period by clicking the Time from to icons and then click Apply 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 43 Set MOS Flag All except Set Reset the MOS flag for the kA Measurement transducer all transducers below this Reset MOS Fla 9 item See section 2 3 5 1 Plot Manager IKA Measurement Add this measurement to the last Add in meas opened Plot Manager window urements list Plot Manager IKA Measurement Add the measurement to the Plot Add in filters Manager Filters list list ll Clear Baseline Set Baseline Machine For specialists only See the OPEN Machine section predictor 2 8 0 manual section 3 3 Machine compo for details nent BR Measurement DEFAULT PR Measurement The default plot script for this para meter with default state if specified in its Range Settings olot scripts gt 2 6 2 1 Displaying AutoDiagnosis messages for a machine component From the browser you can display lists of AutoDiagnosis messages for a specific machine or machine component To open the AutoDiagnosis message window 1 Open the Browser 2 Select the machine or a machine component Click its Be or Me icon 3 Right click the or Ys icon to display the floating menu for the machine component View Def
65. hd Rovsing DYNAMICS Operator s Guide open Version 2 8 0 for Windows Predictive Maintenance Information System Issue 2 2 Rovsing Dynamics A S Marielundvej 41 DK 2730 Herlev Phone 445 4690 7200 Fax 45 4484 6040 www rovsing dynamics dk VAT No DK 1613 9084 Table of Contents Note When using the electronic version of the Guide the page number serves as a link to the section Table of Contents Copyrights amp Trademarks 1 Introduction 1 1 About this Operator s Guide 1 4 1 1 1 Conventions for this Guide 1 4 1 2 About OPENpredictor 1 5 1 2 1 History and background 1 5 1 2 2 Present status 1 6 L223 OPENpredictor main building blocks 1 7 1 3 Disclaimers 1 8 2 1 Opening the OPENpredictor User Interface Application 2 2 2 2 The OPENpredictor Menu Bar 2 4 2 2 1 Menus and their related toolbar icons 2 4 2 2 1 1 Measurement warning List Menus Icon and Lamps 2 5 2 2 2 Customizing the OPENpredictor Menu Bar toolbars 2 6 2 2 2 1 Moving the Warning Indicator toolbars in the OPENpredictor Menu Bar 2 6 2 3 Warning systems 2 8 2 3 1 AutoDiagnosis Messages 2 9 2 3 1 1 How to react on a new AutoDiagnosis warning 2 9 2 3 1 2 Acknowledging and removing an AutoDiagnosis 2 9 2 3 1 3 Predictive AutoDiagnosis messages 2 9 2 3 1 4 Instantaneous AutoDiagnosis IAD messages 2 11 2 3 1 5 AutoDiagnosis message explanation 2 13 2 3 2 Measurement warnings 2 15 2 3 2 1 Measurement warning t
66. hts when the module receives power Run lamp right lamp Lights flashes due to data activity on any of the inputs 8 pcs analogue Input Each analogue input is connected to a fast A D connectors converter The SPM has its own on board Signal processing units which also calculates signatures defined in the measurement set up e g FFT FRF STA calculations Digital transducer signals like tachometer pulses are handled as analogue voltages 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 66 Glossary AutoDiagnosis Automatic Diagnosis methodology developed by Rovsing Dynamics A S It is used for automatically diagnosing potential machinery problems and predicting the time of the final fault Bottom Dead Centre See section 2 9 Condition Monitoring See section 1 2 1 CPM Communication Processor Module RO2010 Module in SPU to control internal and external data communication CM Hz 60 CPM computer Distributed Control System The control system archi tecture of many large plants Event An event is any measurement where its value has passed its Event Window see below The measurement result is time stamped Storage of the event is in the OPENpredictor database Event Window An Event Window is the acceptance range for variations of a parameter where no data transfer or storage is required If the actual measured value stays within the window no data transfer
67. ich Warning List has been selected for example All Warnings or Operation Alarm Warnings The lamps below the menus indicate the selected warning types The actually selected warning is highlighted tn blue To display the parameter signature which caused the warning right click the warning and select the floating menu Plot window Add in measurements list 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 19 The data field columns of the Warning List are Explanation Code A unique number for the warning measurement Warning Type System An SPU has lost the connection See 2 2 1 1 Operation Operator Warning System Maintenance Maintenance Warning system Performance Performance Warning System Severity OVERLOAD UNDERLOAD Result out of range SPU OVERLOAD the transducer voltage output is out of range Level names Alarm High Alert High II Alert High Alert High normal Alert Low Alert Low I Alert Low II Alarm Low Examples Severity High Il Above High II level but below High level Severity Low Below Low level but above Low II level C Not acknowledged EJ Acknowledged A warning is automatically removed from the Actual Warning List if it is acknowledged AND its measurement value is back in its non warning range Measurement Description Description of the measurement Value Unacknowledged the value measured for the warning Acknowledged the latest value measure
68. icking on a measurement Warning Indicator opens the related Actual Warning List see below The Actual Warning List shows only one the most severe alert or alarm per measurement and per machine state run up idle full load etc An alert or alarm for a particular measurement can only be assigned to one group See also section 2 2 2 1 SE All Warnings RDOPOSI RDOPO10g 1O x File Edit Filter Columns Acknowledge All Acknowledge Selected 4 System SYSTEM W 6 System SYSTEM W 7 System SYSTEM W 3196 Offline OVERLOAD 3197 Offline AlarmHigh 3198 Offline lAlertLow 3256 Offline OVERLOAD P M Acc 2006 12 11 10 31 06 PM SPU OVERLOAD al P M Displ 2006 12 11 10 55 32 PM SPU OVERLOAD P M Displ2 2006 12 11 10 55 32 PM spu OVERLOAD HAM TG22 l 252 5 2006 05 15 00 00 00 HAMTG22 O Default scalar Too HAM TG22 55 2006 05 15 00 00 00 HAMTG22 0 Default Is HAM TG22 16 2006 05 15 00 00 00 HAMTG22 OlDefault S HAM TGZ1 200 2006 05 15 00 00 00 HAM TG212 0 Scalar P M Tacho 1011 39 2006 12 19 06 45 13 P M 96 s2 Is nowle IV M M Vv M Iv n 21468 Maintenance HighII 2 3 2 1 Measurement warning types and warning systems OPENpredictor has three types of measurement warnings with related colours Red Alarm Action Required warnings the alarm limit has been passed amp Yellow Alert warnings the
69. imers 1 4 Efficiency reduction warnings 2 15 Electronics 1 7 2 65 Enabled flag 2 63 Ethernet connector 2 66 Existing transducers 1 7 Fit to data 2 48 Graph See Plot Hardware 2 65 Input connectors 2 67 Liabilities 1 4 Login 2 2 Long term maintenance planning warnings 2 15 Main panel 2 4 Maintenance 2 16 Maintenance Override Switch 2 6 2 16 Maintenance warnings 2 15 Man Machine Interface 2 4 Management report 2 5 2 26 2 29 Measurement 1 7 Measurements Statistics report 2 30 Menu Xxxx gt Yyyy 1 4 Mimic 3 1 Mimic report 2 26 2 40 Mimic Viewer 2 4 2 37 Mimics Warnings 2 22 MOS 3 1 MOS flag 2 6 2 23 2 63 MOS Warning list 2 17 MOS warnings 2 6 2 16 2 23 Multiple graph plots report 2 26 Note Reports 2 31 Numbered list 1 4 Off line data collection 2 52 Oil Analysis 2 32 Opening OPENpredictor 2 2 Opening User Interface 2 2 OPENpredictor main panel 2 4 OPENpredictor User Interface panel 2 4 Operation warnings 2 15 Operator Warning System 2 15 Password 2 2 Password change 2 2 PC server 2 66 Peak position data display plot 2 50 Performance warnings 2 15 Plot Manager 2 4 Plot reports 2 26 Multiple 2 46 Single 2 45 Plots 2 4 Navigation facilities 2 48 Peak position data display 2 50 Scroll one grid width 2 49 User defined 2 46 Zoom 1 2 2 49 Zooming 2 48 PMIS 1 5 3 1 Power lamp 2 65 Power supply electronics
70. initian View AutoDiagnosis Configuration View AutoDiagnosis Messages View Instantaneous AutoDiagnosis Messages View Machine States View Mote Reports Set MOS Flag Reset MOS Flag Clear Baseline Set Baseline Collapse All Expand All 4 Select the menu View AutoDiagnosis Messages or View Instantaneous AutoDiagnosis Messages This will open the related AutoDiagnosis list window see section 2 3 1 5 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 44 2 7 Working with predefined plots Each measurement has an associated Default plot called DEFAULT There are many ways to launch a Default plot as described in other sections of this chapter and in section 2 7 4 The most common Default plot is the Scalar Trend plot shown below a Plot Manager p 10 x File Insert Report Option View Window Help SUK Wu M E l B E MA DHE 4 scalar Trend TR GCK10 CY064 Overall All_states File Options View Report Help EJ Short term 1 lw H MEDS u m CO AT OB Cursor point C Zoom 1 2 Gz 2002 01 31 2002 09 15 2003 04 30 2003 12 13 The Plot Manager with a Scalar Trend plot where the yellow Alert line is crossed by the upper prognosis confidence range trend curve To copy the active top plot in black white e g for using in a Word report just press Ctrl c the standard Windows shortcut for Copy For a colour copy press Ctrl d 2 7 1 How to make a Single Plot Report
71. itch list Equivalent to clicking the MOS button in the Tool Bar see section 2 2 1 1 aa ars ge on cre se section 2 4 1 __ mentRepor_ Stesecion nana ment Report See section 0 Report Tools are apa Used with the special module Oil analysis See the Operators Guide section 2 4 6 Routes Open the Route MMI for handling of Routes for off line data collection See section 2 8 Options e Always on top When checkmarked M the MMI main panel always stays on top of the screen in front of all other windows Beep when warning Checkmark M for making a beep in the PC loudspeaker in case of a new warning Beep when AutoDiagnosis message Checkmark M for making a beep in the PC loudspeaker in case of a new AutoDiagnosis Display milliseconds M for displaying milliseconds in tables mimics and plots Else integer seconds are displayed OTA option gt Phase lead Phase lag Sign of phase in OTA measure ments Default Phase lag Unit system Select Metric USA Imperial or SP SP metric with acceleration in G etc Helo Contents Openthe on line help this manual About Display the window with information about the current version of OPENpredictor If a menu is not enabled grey text or if it s not displayed its function is currently not available 2 2 1 1 Measurement warning List Menus Icon and Lamps Measurement warnings and how to work with them a
72. l module Optional module card position for a RO2021 7 9 Serial Port Upgrade with 3 RS232 RS485 serial ports Serial 9 RS232 Serial 7 amp 8 RS485 There is one more unused port on the rear panel Auxiliary There are several possible applications but the ports are typically used for control of a Warning Relay Unit receiving data from a PLC using the Modbus 3 Sata Interface Reset button Pressing the button more than 5 seconds will Reset reboot the SPU see section 2 9 4 2 WARNI NG While rebooting no measurements will be performed g ea It performs a hot boot of the built in CPM nine equivalent to the CPM boot after a power failure Speed 1 Ethernet Activity Off No activity desi Blinking Green Activity proportional to Bg Rovsing bandwidth utilization Speed Off No link Yellow 10 100Base T operation Green 1000Base T operation Fail Yellow Board has a failure After Power On or reset this LED is ON until extinguished by firmware or software Green Board is running and status is OK 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 65 2 10 3 The RO2020 Signal Processor Module SPM The RO2020 SPM executes all defined measurements and transfers results internally to the RO2010 CPM Each RO2020 contains 8 Analogue inputs Power supply for transducers e LED s for operation indication The lamps and inputs are RO 2020 aan 5 Power lamp left lamp Lig
73. level an action is required for example an inspection and or maintenance work The reason for creating this special type of AutoDiagnosis messages is the nature of the development of Instantaneous AutoDiagnosis faults which makes predictions for the time of a serious breakdown impossible Pj Instantaneous AutoDiagnosis Message RDOPOSIMRDOPOIOg ioj x Component Turbine Shaft Location Ht 2 1 STi Turbine Slarm Level Action Diagnosis Rotor Rub IAD LF Vibration measurements on the bearings show some signs of rotor rub or looseness in the rotor elements Inspect auto spectra for fractional order components and check conditions for rotor alignment and eventual expansion bearings Recommendation Date 24 02 07 18 24 02 Status Not Accepted Accept Browser Close Like the Predictive AutoDiagnosis messages clicking More Less will display hide a list of all current Instantaneous AutoDiagnosis messages Pj Instantaneous AutoDiagnosis Message RDOPOsIMRDOPOI1Og oO x Component Turbine Shaft Location Ht 2 1 GT1 Turbine Alarm Level Action Diagnosis Rotor Rub IAD LF Vibration measurements on the bearings show some signs of rotor rub or looseness in the rotor elements Inspect auto spectra for fractional order components and check conditions for rotor alignment and eventual expansion bearings Recommendation Date 24 02 07 18 24 02 Status Not Accepted Acce
74. loating menu 2 43 2 6 2 1 Displaying AutoDiagnosis messages for a machine component 2 44 2 7 Working with predefined plots 45 Zid vi How to make a Single Plot Report 2 2 How to make a Multiple Plot Report 2 7 3 User defined plots 2 7 4 How to open a user defined plot 2 7 5 Navigation facilities of a plot RS RPS BPPP AU AN AN AB 2 7 5 1 Zooming by selecting ideo Zooming moving and scrolling using shortcuts 2 7 5 2 2 7 5 3 Zooming to fit to the actual data 2 7 5 4 Zooming out by a factor of 1 2 2 7 5 5 Scrolling the selection one grid width using the mouse 2 7 5 6 2 7 5 7 2 7 5 8 Cursor position readout The date amp time format 7 5 Peak position readout 2 7 5 9 Changing data period for a scalar plot window 2 8 Off line data collector special module O O O lO O WO COO CMOON DAD UI N N N N N N N N N N N N N N WN IN I N 2 8 1 Uploading the route to the data collector 2 52 2 8 2 Downloading the tour data from the data collector 2 52 2 9 Bearing Wear Monitoring special module 2 2 9 1 Basic principles 2 53 2 9 2 BDC baseline calibration 2 55 2 9 2 1 Background 2 55 2 9 2 2 Reset Zero Gap Recalculate BDC Baseline 2 55 2 9 2 3 Set Initial Wear 2 57 2 9 2 4 Explanation to the baseline calculations 2 58 2 9 2 5 Reset zero gap Recalculate BDC Baseline what happens 2 59 Server starting and rebooting procedures 2 60 2 9 3 Starting closing the OPENpredictor system 2 60 2 9 3 1 Start the Server C
75. ls of cutting off a transducer MOS and not Enabled 2 3 5 1 The MOS flag The MOS flag is used to avoid warnings from a machine or transducer under repair maintenance while the machine is running When the MOS flag is set M SPU relay functions will ignore warnings from measurement related to this transducer AutoDiagnosis Messages are not generated for warnings from measurement related to this transducer Measurement data is stored as usual e Alarms alerts and system overload warnings are not recorded The MOS flag should be set if e The related machine under repair maintenance modification whilst still running may cause false warnings due to noise from tools e The related transducer loop is being tested for a fault e The related transducer loop is being tested or calibrated after repair e The related transducer loop is defective but is still used and is to some extent reliable i e has a periodic fault 2 3 5 2 The Enabled flag If the Enabled flag for a transducer is NOT check marked O no measure ments are transferred to the database at all The Enabled flag should be NOT check marked if The related transducer has been removed or its cable is broken e The related transducer is defective and causes unreliable warnings WARNI NG Even if the Enabled flag for a transducer is NOT check marked the trans ducer is NOT included in the MOS list of transducers marked
76. mance warnings Alarm Click red to display a list of all Performance Alarm warnings Alert Click yellow to display a list of all Performance Alert warnings System Click blue to display a list of all Performance System warnings a Offline Warnings from offline measurements for Oil ll o 0 o Analysis In the Offline group All Click All to display a list of all Oil Analysis warnings Alarm Click red to display a list of all Oil Analysis Alarm warnings EN RDM RDM Reliability Data Management All 4655 0 Alert Click yellow to display a list of all machine stops scheduled and unscheduled System Click blue to display a list of all RDM System warnings eee MOS MOS Maintenance Override Switch Displays the number of transducers where the MOS Flag is set In the MOS group click red to display a list of all MOS marked transducers See section 2 3 5 The number to the right of each warning lamp is the number of actual warnings to be found in the Warning List for this group 2 2 2 Customizing the OPENpredictor Menu Bar toolbars To change which toolbars are displayed in a user interface window select the menu View gt Toolbars there may be further levels Then select or deselect the toolbars as desired The settings are saved per user specified by the User D This means that each user can have her or his own personal toolbar setting 2 2 2 1 Moving the War
77. marks service marks or product names as designated by the companies who market those products The trademarks and registered trademarks are held by the companies producing them Inquiries concerning such trademarks should be made directly to those companies 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 1 3 Introduction OPENpredictor provides information about a wide variety of machinery faults in order to minimise plant operation risk and prioritise maintenance activities OPENpredictor executes AutoMonitoring AutoDiagnosis AutoForecasting and AutoReporting to inform the users of current and potential machine problems The users can pre define reporting both for the daily shift operators for short term action and for maintenance management to prioritise activities Definitions and acronyms see chapter 3 Glossary About this Operator s Guide The contents of this document provide guidance to the plant operators about the actions they may need to execute with the OPENpredictor Predictive Maintenance Information System PMIS Furthermore the managers legally responsible for the use of the system must read and accept the content of section 1 3 Disclaimers and the Copyrights amp Trademarks notice above A comprehensive description for the total system intended for the experi enced Condition Monitoring expert can be found in the User Manual This manual covers all versions of th
78. matic Predictive Maintenance Information System PMIS advancing traditional Condition Monitoring CM to the next level for Predictive Maintenance The system identifies and forecasts potential machinery problems on a wide range of rotating and stationary machinery components typically encountered in power plants and other continuous operating process industries 1 2 1 History and background Historically the experienced and skilled mechanic or engineer would listen to his machines put his hand on the machines to sense its vibrations and kept an eye on simple parameters like flows and temperatures He would then use his experience to judge the machine health and possibly diagnose an existing problem No historic data was present so fault prediction was difficult This created the need to record data in order to manually identify trends over time As technology developed this engineer was supported by Condition Moni toring CM systems that provided registration of condition related measure ments typically vibration values on paper rolls and providing basic alarming in the control system for shutdown actions The tedious routine work to ana lyse enormous amounts of mostly redundant data was typically done by a vibration expert Typically the data investigation was carried out when strange phenomena were encountered on routine plant inspections or when alerts or alarms were identified at the control system Diagnostic analysis to
79. measurements will be User performed ik 2 Console It performs a hot boot of the built in CPM equivalent to Fail the CPM boot after a power failure 0 Speed E 1 Ethernet 0 Activity BK Rovsing DYNAMICS 2 9 4 3 On site power cycling of the SPU 1 Switch off the power for the SPU 2 Wait for the LED s to go off and then wait another 10 seconds 3 Switch on the power for the SPU 2 9 5 Stopping and restarting the Data Server only This procedure is used for example when a MOS flag or Enabled flag has been changed see section 2 3 5 3 1 On the OPENpredictor server start Work Console by clicking its icon on the desktop or in the line with the Windows sa button 2 Close the Watchdog At the prompt normally c work gt type op services stop watchdog and press Enter 3 Close the Data Server At the next prompt type op services stop data and press Enter To restart the data server 1 Start the Data Server At the prompt type op services start data and press Enter 2 Start the Watchdog At the next prompt type op services start watchdog and press Enter 2 9 6 How to verify that the System is operating properly The SPU operation may be verified as follow 3 On the OPENpredictor Server display the Data Server window click the Data Server in the Windows Start button line FE Data Server 2 7 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2
80. nScheduled 2007 07 05 13 13 38 2007 07 05 13 14 06 O UnScheduled To 2007 10 12 14 16 23 Here you can edit four columns e Type Right click the field to select any of the two standard causes o Scheduled o Unscheduled e Cause Right click the field to select any of the three standard causes o External EXT o Failed Whilst Running FWR o Failure To Start FTS e Root Cause When Cause has been selected right click to select a related Root Cause e Comment To enter edit double click the field When a cause has been changed click Recalculate to change the statistics bars accordingly If the Period data have been changed click Update to display the new list of stops 2 4 6 3 The RDM Report In the Menu Bar select the menu Report gt RDM Report to open the RDM Report window giving a survey over the reliability of the machines included in the system 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 34 S RDM Report RDOPOSI RDOPO10g loj x File view Report amp Reliability Repot Downtime List D Surveillance Period Update f Month From 2007 09 12 14 13 02 To 2007 10 12 14 13 02 Ku 2 1 GT1 Mark Main Engine The bars for the machine selected are marked with a medium blue back ground The report displays for one or more machines e Reliability light blue bar
81. namics can offer this analysis as a remote service 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 8 2 3 1 AutoDiagnosis Messages 2 3 1 1 How to react on a new AutoDiagnosis warning AutoDiagnosis Message windows pop up automatically when a potential fault related to a defined AutoDiagnosis has been identified The advised reaction is to follow the recommendation If no recommendation is given nform dependent on the type of fault reported the Operation or Maintenance Department management and seek advice Note the local person in charge of the OPENpredictor system can define the AutoDiagnosis Recommendation messages Consequently neither Rovsing Dynamics A S nor its local representative has any responsibility for the content of these messages There are two types of AutoDiagnosis messages e Predictive AutoDiagnosis messages displayed when a gradually developing fault has been identified and reached a defined fault strength Example A specific vibration pattern during full load combined with a gear lubrication oil temperature See section 2 3 1 3 for a detailed description e Instantaneous AutoDiagnosis messages displayed when a specific parameter for a short period of time has exceeded the warning limit set Example Vibrations due to a rub See section 2 3 1 4 for a detailed description For further details of how to read the fields see section 2 3 1 5 2 3 1 2 Ackn
82. ning Indicator toolbars in the OPENpredictor Menu Bar The Warning Indicator Blocks can become individual windows To transform a Warning Indicator Block into an individual floating window click inside the group except on any button and drag the group out 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 6 P OPENpredictor k rdopoilg a ol x File View Browse Report Tools Help Performance System Mog Operation al o o oc o h0 i 3 es When released it is a separate window and not any longer shown in the Menu Bar Fy e Ge OP Ee Ee a i 2 operation MISI Al 1 3 6 To put it back at the end of the Menu Bar close the separate window by clicking its X button 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 7 2 3 Warning systems There are two types of warning indicators AutoDiagnosis Messages See section 2 3 1 Measurement Warning traffic light type indicators in the Menu Bar with links to Warning Lists see section 2 3 2 Selected measure ment warnings may be shown in Mimics too see section 2 3 4 An overview of AutoDiagnosis messages and measurement warnings is shown in the AutoDiagnosis and Warning Browser see section 2 3 3 I MPORTANT AutoDiagnosis warnings are NOT signalled by the traffic light system To check for them click and F or use the AutoDiagnosis and Warning Browser To sen
83. nsient curves with reference signatures measured under defined machine states Run up Coast Down Idle Low load High Load Full Load etc to identify fault symptoms Data comparison is executed under pre classified operation conditions to compensate for RPM load tem perature etc variations Classification by Machine State is essential to avoid false warnings improve fault identification sensitivity and create realistic forecasts Identified changes in the machine behaviour are then automatically used as basis for AutoDiagnosis and AutoForecasting An AutoDiagnosis prediction is based on complex calculations using many parameters from different sensors Historic measurement data is also available for Auto Diagnosis verification and troubleshooting The measurement results can be presented graphically in real time including warning levels Alert and Alarm for traditional interpretation All informa tion may be included in Shift Reports for short term actions and Management Reports for long term maintenance planning In this way OPENpredictor has automated machine fault identification and prediction stating in clear text which machine problems have been identified and when inspection or maintenance is advised OPENpredictor is conse quently a very useful tool to identify operation risk and schedule corrective actions The information is used to reduce Unforeseen breakdowns Scheduled downtime for
84. omputer and software 2 60 2 9 3 2 Closing down the system 2 60 2 9 4 SPU rebooting procedures 2 61 2 9 4 1 Remote reboot of the SPU 2 61 2 9 4 2 On site reboot of the SPU 2 62 2 9 4 3 On site power cycling of the SPU 2 62 2 9 5 Stopping and restarting the Data Server only 2 62 2 9 6 How to verify that the System is operating properly 2 62 2 10 OPENpredictor System Hardware 2 64 2 10 1 The RO2000 Signature Processing Unit SPU 2 64 2 10 2 The RO2010 Communication Processor Module CPM 2 65 2 10 3 The RO2020 Signal Processor Module SPM 2 66 3 Glossary 4 Index Document information 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 1 2 Copyrights amp Trademarks This manual is copyright 2001 2008 Rovsing Dynamics A S Denmark All rights title and interest in the software hardware and services detailed in this document and all copyrights patents trademarks service marks or other intellectual property or proprietary rights relating thereto belong exclusively to Rovsing Dynamics A S No part of this manual may be reproduced or distributed in any form e g copied transferred printed or transcribed by any manual optical photographic electronic or other means without specific written permission from Rovsing Dynamics A S Denmark OPENpredictor and AutoDiagnosis are trademarks of Rovsing Dynamics A S Denmark All other products or services mentioned in this manual are identified by the trade
85. onsumption is 6 Amps e A separate Cooling Unit mounted below each RO2000 Unit with 3 fans and a Power lamp The Power lamp is connected to 12VDC from the RO2000 power supply which also powers the fans e Various installation dependent accessories Cable terminal blocks relays galvanic isolators etc Lr TTT CULL 1 RO 2000 with one RO 2010 and one to ten RO 2020 2 Cooling unit with Power lamp 19 OPENpredictor rack with one RO2000 Rebooting the SPU is described in section 2 9 4 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 64 2 10 2 The RO2010 Communication Processor Module CPM The RO2010 CPM controls all internal and external data communication from and to the SPU It controls the data communication between the RO2020 Signal Processing Modules SPM and the OPENpredictor Server Each RO2010 contains e Ethernet port e Port to control external relays e Slots for expansion of memory and number of ports e LED s for operation indication Reset button The lamps controls and inputs are RO2010 Ethernet 1 Standard 10 100 Mb s Ethernet connector cs Console 2 Service connector used by Rovsing Dynamics A S personnel when setting up the system SATA 3 Serial ATA interface Auxiliary module Optional module card position May be used for 4 6 reserved a second serial port module see below or e g a PCMCIA card docking station Seria
86. ower failure restart the system completely starting with section 2 9 3 1 followed by rebooting the SPU see section 2 9 4 The OPENpredictor User I nterface on the Client Computers may be started and stopped without restarting any other part of the system 2 9 3 1 Start the Server Computer and software Power up the OPENpredictor Server Computer and login The servers are starting in the correct order as Services which can be checked by means of Windows Control Panel gt Administrative tools gt Services The last item started is the Server Watchdog which e checks continuously whether all Servers needed are running e restarts the Server system correctly in case any Server fails The Servers may be restarted without rebooting the SPU 2 9 3 2 Closing down the system Just close the Server PC the usual way starting with closing Windows 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 60 2 9 4 SPU rebooting procedures The SPU is to be rebooted in three cases e After changing the position of a MOS flag or Enabled flag in order to activate the change After downloading a new configuration If instructed to do so by Rovsing Dynamics service personnel Before rebooting make sure all Servers are running see section 2 9 3 1 above The SPU may be rebooted without restarting the Servers see 2 9 3 1 2 9 4 1 Remote reboot of the SPU To be able to carry out a remote r
87. owledging and removing an AutoDiagnosis When an AutoDiagnosis is acknowledged it remains on the list until the AutoDiagnosis data moves into the next region of severity Detected Predicted Action Required which causes a new AutoDiagnosis When the data Is back in the normal range for example because the problem has been solved the AutoDiagnosis system will automatically detect it and remove the acknowledged AutoDiagnosis messages for this fault 2 3 1 3 Predictive AutoDiagnosis messages Predictive AutoDiagnosis messages are labelled AutoDiagnosis messages They are per standard calculated every 24 hours based on the measurements from the last 24 hours compared with the development in the past They are most often intended for the maintenance people To open the window with a list of all activated predictive AutoDiagnosis Messages select the menu Browse gt AutoDiagnosis List on the OPENpredictor Menu Bar 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 9 Pj AutoDiagnosis Message loan Location TR GCK10 POOL TestRig MUOZ Shaft HS Component REBOIO Diagnosis Outer Race Defect Outer Race Defect symptoms have developed to a state where some action is recommended Prediction Date of Diagnosis 2002 11 28 17 00 00 Prediction of Required Action Level Nominal Prediction 19 Days Early Prediction 15 Days Late Prediction 24 Days Recommen
88. predictor 2 8 0 Operator s Guide Issue 2 2 Page 2 57 fee Initial Wear value Cancel i 4 This message is displayed in the above case the value of DP3F Wear will be set to 50 um and DP7F Wear will be set to 10 um La x Jil Initial Wear set 2 9 2 4 Explanation to the baseline calculations The Baseline calculation takes typically from a few hours to weeks where a sufficient number of BDC measurements must be made in certain defined RPM ranges These ranges are defined in the BDC RPM Range Settings window To open this window 1 Open the Browser Be 2 Select the Main engine amp 3 Right click the machine icon 8 or name and select the floating menu View Definition This opens the Machine definition window 4 Inthe Machine definition window click the BDC Settings button This opens the BDC RPM Range Settings window i 3BDC RPM Range Settings i x Machine Mary Main Engine gt 20 48 19 27 500 1000 10 10 4 20 48 27 34 500 1000 10 10 gt 20 48 34 41 500 1000 10 10 gt 20 48 41 46 500 1000 10 10 48 105 46 60 1500 2000 20 20 48 105 60 74 1500 2000 20 20 48 105 74 88 1500 2000 20 20 48 105 88 100 1500 2000 20 20 gt 48 105 46 60 500 1000 10 10 gt 48 105 60 74 500 1000 10 10 gt 48 105 74 88 500 1000 10 10 48 105 88 100 500 1000 10 10 gt 10 20 10 19 500 1000 10 10 10 20
89. pt Pending Faults Mach Section Rotor Rub I40 LF Action 24 02 07 16 24 02 2 1 GT1 Turbine Turbine Shaft How to get a survey over all AutoDiagnosis messages for a machine see section 2 6 2 1 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 12 2 3 1 5 AutoDiagnosis message explanation i AutoDiagnosis Message ol x Location TR GCK10 APOO1 TestRig MUOZ Shaft HS Component REBOSO Diagnosis 5 11 30 3 Outer Race Defect Outer Race Defect symptoms have developed to a state where some action is recommended Prediction Date of Diagnosis 2002 11 28 12 00 00 Prediction of Required Action Level Nominal Prediction 19 Days Early Prediction 15 Days Late Prediction 24 Days Recommendation Confidence Significant Status Not Accepted Accept Less a Browser Plot Manager Close Pending Faults Mach Section Component 00 00 GCK10 APO MUOZ Shaft REB100 2 00 00 GCK10 APO MUO2 Shaft REBO90 Predictive AutoDiagnosis window The Instantaneous AutoDiagnosis window is similar with the differences specified below Fields buttons AutoDiagnosis message area Field button Identification of the Machine Section with the pending fault Name of the Machine Component with the pending fault Alarm level Detected or Action Required See section 2 3 1 4 for definitions Prediction Line 1 The date time the diagnosis
90. r this measurement Acknowledge Selected Acknowledge the warning selected Plot Window Add in measurements list For CM specialists only Plot Window Add in p y filters list 2 3 3 The AutoDiagnosis and Warning Browser The AutoDiagnosis and Warning Browser is used for getting an overview over where there currently are warnings AutoDiagnosis and or Instanta neous AutoDiagnosis messages In order to open the AutoDiagnosis and Warning Browser select the menu Browse gt AutoDiagnosis and Warning Browser The basic layout is the same as for the normal Browser but the information displayed for each item is here warning oriented je AutoDiagnosis and Warning Browser RDOPOSi RDOPO10g d ol x File Filter Browse Options Ey Mode AutoDiagnosis Warnings IAD Alarms warnings per State Statistic Interval a Week x From 2007 10 11 11 13 18 Machine Sections 0 PAD Warnings 1 IAD Warnings 0 not accepted a ra Ta Secon Fault Level Type Date Section Component KY p yp p Rotor Rub IAD LF Action 24 02 07 18 24 02 Turbine Turbine Shaft e main Engine amp operation AN UPS Power SD operational SO Rpm Slope SD Process Input Mg cylinder 1 Mg cylinder 2 Mg cylinder 3 Mg Cylinder 4 fe El Pena Me Cylinder 5 Mg Cylinder 6 Mg Cylinder 7 Mp Cylinder 8 Mg Cylinder 9 Mg Cylinder 10 Mg Cylinder 11 HA
91. re described in section 2 3 2 Submenus and explanations E All Click to open a list of all actual warnings See section 2 2 2 1 ae System System SPU System warning 1 An SPU has lost the connection In the System group click amp blue to display a list of all SPU system warnings ey Operation Warnings for problems that would require Al 1 3 6 an action within a one or two shift period In the Operation group All Click All to display a list of all Operation warnings Alarm Click red to display a list of all Operation Alarm warnings Alert Click amp yellow to display a list of all Operation Alert warnings System Click blue to display a list of all Operation System warnings 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 5 Maintenance Maintenance Warnings for changes in machine behaviour All o 0 o related to maintenance activities In the Maintenance group All Click All to display a list of all Maintenance warnings Alarm Click red to display a list of all Maintenance Alarm warnings Alert Click amp yellow to display a list of all Maintenance Alert warnings System Click amp blue to display a list of all Maintenance System warnings Performance Performance Warnings related to efficiency reduction or ll o 0 o process problems of a machine In the Performance group All Click All to display a list of all Perfor
92. related machinery and equipment for ease of use If a displayed measurement Is in a warning condition the status Is indicated by the colour for the warning type red yellow blue see section 2 3 2 1 See the example in the lower left corner of the Mimic viewer If the colour of a button is different from green it relates to a Mimic with one or more measurement warnings at a more detailed Mimic level The colour of the button indicates the worst warning type indicated on the related Mimic Note Only warnings on scalar measurements e g Over all vibration are reflected in the colour of the buttons in the Mimics Further information on Mimics including Mimic warning indications is found in section 2 5 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 22 2 3 5 Maintenance Override Switch MOS The number next to the MOS lamp indicates the number of transducers which are marked for maintenance To display a list of transducers marked for maintenance click the mos lamp or use the menu Browse gt MOS Maintenance Override Switch MOS Settings a oj x File Transducers SPU Server Channel No Enabled Comment C3081 Tacho HS TestRig GCK10 CS081 SPLI1 To display the transducer in the browser right click the transducer and select the floating menu View Browser The Maintenance Override Switch MOS is used when measurements are irrelevant or unreliable There are two leve
93. ria Ala Relay Machine Work Alarm Rela 2 5 1 1 To export the data to another text file e g including the date in the file na me tip use the yyyy mm dd format click the Report Generate button DG 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 30 2 4 4 Note Reports If using the Movipack module for offline data collection see section 2 8 Note Reports displays stored standard notes or notes typed in on the module Note Reports are accessible from the Browser Right click a Machine Ma chine Part or Transducer and select View Note Reports on the floating menu For a Machine or Machine Part a Note Report looks like this S Note Report RDOPOSI RDOPO10g ome Hitachi 2 1 MP 16 28 2007 09 12 12 34 56 0il spil S O For a Transducer a Note Report looks like this S Note Report RDOPOSI RDOPO10g oe KI 2007 09 12 12 34 56 0il spil S O Click amp to print the Note Report Click HEI to save the Note Report as an HTML file By means of the Period functions you can select the period for which the reports are displayed 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 31 2 4 5 Oil Analysis special module Oil Analyses is a tool used in some installations for reading and recording oll data The measurement is defined as a server source loxi File View Search Browse Report Options Set
94. rm Next term In the icon tool bar of most scalar plot windows there is a drop down list with five choices 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 50 e Short term Reloads the data using the period Short term defined for the Plot Manager menu View gt Settings gt View settings field Time Base e Medium term Reloads the data using the period Medium term defined for the Plot Manager e Long term Reloads the data using the period Long term defined for the Plot Manager e Previous term Load the data of the period prior to the actual period and with the same length of period In case of no more data a message is displayed instead e Next term Load the data of the period just after the actual period and with the same length of period The drop down list may be hidden displayed by de selecting the menu View gt Toolbars gt Selection 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 51 2 8 Off line data collector special module Some installations of the OPENpredictor system use off line data collection by means of a hand held data collector Various types are used It could for example look like this For the handling of the data collector and the data collection procedures please refer to the user manuals for the data collector Before collecting the data the route must be loaded into the data collector
95. s the current warning history of the entire plant The content selected should reflect the detailed needs of the plant maintenance management The report is saved in the directory specified as an html format file The directory should be on the OPENpredictor Server 1 Inthe OPENpredictor Menu Bar select the menu Report gt Management Report iol xi Report Management El ana Ar for s6 days Managemen Report Comments 1 1 days shift report Report Options MV Comments M AutoDiagnosis Alarms MV Recommendations Report only warnings not acknowledged Html Path C OPENpredictor Reports ManagementReport html Report Fields M Date V Offline Warnings IM Measurement Value MM Operation Warnings V System Warnings M Warning Settings MM Maintenance Warnings MM Machine Code MM Forecast Time M Performance Warnings MM Measurement MM Warning Status IM RDM Warnings V Machine State V Acknowledges close 2 In the Report drop down list Management J select the script for Management Reports in the above example Management there may be several others for example After fault 3 Check Select the number of days the report is to cover 4 Insert the relevant Report comments 5 If relevant make other amendments to the window For details about the fields see section 2 4 1 1 Shift Report Fields 6 Click Generate to generate the report and to save the list of contents to th
96. s within the Plot Manager window The HTML file contains all plots and all relevant data for evaluating the plots AE File Insert Report Option View Window Help SE ee bts OH OB ke 4a te TE ES a ce HE A g t 1 In the Plot Manager main window not the individual plot e Select the menu View gt Toolbars gt Advanced toolbar and then click the MA icon or e Select the menu Report gt Generate This opens a Save As box 2 In the Generate report Save box select a name with the extension HTML and click Save 3 To open the report use Asa gt Documents or if that fails open the file Html path for example C OPENpredictor Reports xxxx html with the Internet browser for example Microsoft Internet Explorer 2 7 3 User defined plots It is possible to create other predefined plots for easy data presentation The CM specialist may have predefined Scripts under a dedicated name to display measurement data e g Run up Gas turbine This would present all Bode diagrams for all the bearings without having to request the data per bearing Most predefined plots are used for advanced Condition Monitoring data analysis to be made by the maintenance engineer or vibration specialist However several types of plots are also useful for analysing plant operation for example displaying actual load output power and relationships between parameters e g Load temperature and efficiency Please
97. sent status The present OPENpredictor Predictive Maintenance Information System PMIS Version 2 8 0 provides AutoDiagnosis which eliminates the need for periodical data analysis to be done by the Condition Monitoring specialist as the data evaluation and interpretation is completely automated The tasks left to the CM specialists are reduced to system control evaluation of war nings and AutoDiagnosis Messages with fault predictions and ultimately the maintenance planning System operation can be taken over by the operators of the machinery When an AutoDiagnosis Message appears on the PC screen a machine problem is identified For gradually developing problems the Predictive AutoDiagnosis Message identifies approximately when the problem will become serious days weeks or even months ahead This makes it possible to plan corrective tasks on that specific component to the best economical period or ultimately during a planned stop For changes in the dynamic behaviour of the machine where no experience exists yet a warning will be issued without AutoDiagnosis Message in order to minimise operation risk For vibration experts all the traditional tools for manual machine analysis are present such as Multiple Trend Analysis 3 D AS AutoSpectrum Waterfall plot Nyquist analysis Orbit and Shaft Centre Line analysis OPENpredictor automatically compares actual values and signatures i e vibration spectra and tra
98. st here is the wear at the time the Initial wear is entered into the database If for some reason which could be a severe mechanical problem the cross head comes too close inserted limit value to the transducer an Alert High on the BDC raw measurement is released The machinery must then be inspected a s a p to find out if the alarm was caused by a transducer problem or a mechanical problem 2 9 2 2 Reset Zero Gap Recalculate BDC Baseline Purpose To clear the correction curve parameters and to initiate calculation of the parameters starting from a time entered by the user e Reset Zero Gap the correction curve is calculated from new values only must be carried out each time a sensor or bearing part has been replaced or a sensor may have been moved e Recalculate BDC Baseline the correction curve is calculated using old parameters as preliminary values should only be carried out on recommendation from Rovsing Dynamics in case of too many false alarms In both cases an Initial wear value may be inserted if known The time it takes to make the calculation of the correction curve and consequently the baseline depends a lot on the operation conditions of the machine The system needs a certain amount of data at various different RPM value bands It may take from a few hours to a few weeks 1 Inthe Browser right click on a Machine Machine Section Machine Component or Transducer and e Select the menu Rese
99. t Zero Gap or Recalculate BDC Baseline as indicated above 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 55 in x File View Search Browse Report Options Set Zero Help IATA Company Maersk Main Engine Cylinder 1 a Transducers KJ Rom od Ham Name code Descrinti Type Enabled MoS Flag SPU Ser Chann E4 Maersk DP1A Maersk M PR6424 0 Displacement Probe v L BDC SPU 1 EQS Main Engine DP1F Maersk M PR6424 0 Displacement Probe Vv D ppc SPU 2 amp Operation Meg E Me Cylinder View Definition A Mg Cylinder View AutoDiagnosis Configuration Ng Cylinder wiew AutoDiagnosis Messages Mg Cylinder Mg Cylinder View Instantaneous AutoDiagnosis Messages My Cylinder View Note Reports 4 Mg Cylinder Mg Cylinder Recalculate BDC Baseta z notion MO ao p XM Cylindet Ah Reset BDC correction curve when sensors or bearing parts have been replaced KAN Set Initial Wear Soe end N Cylinder Set MOS Flag Reset MOS Flag fined Mg Cylinder Mg Cylinder Mg Cylinder Clear Baseline SE ao Set Baseline XY Hitachi Collapse All Expand All Eg Plots l e fa machine is selected all BDC transducers related to that machine is reset This is typically us
100. time based maintenance tasks 6 Repair and maintenance costs For further information about the philosophies behind OPENpredictor and Condition Monitoring basics etc see the OPENpredictor User Manual chapter 2 General system description and 7 Bibliography 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 1 6 1 2 3 OPENpredictor main building blocks The OPENpredictor PMIS system typically consists of A variety of transducers mounted on inside the machines converting physical parameters to electrical signals from which health information will be extracted Existing transducers pre mounted on the equipment are used as far as possible Signal Processing Units SPU for processing transducer signals into fault selective signatures The signal from a single transducer is often transformed into many dedicated signatures for example amplitude and phase for harmonics Autospectrum Envelope Spectrum etc to enhance fault detection sensitivity and selectivity Identified changes in these signatures are transferred to the OPENpredictor Server for storage and automated interpretation by AutoDiagnosis Methods e The OPENpredictor Server This is a PC operating on Windows 2000 Pro 2003 Server or XP Pro It receives processed data from the SPUs Data is saved in an Oracle relational database The OPENpredictor system software runs on the Server in English e The User Interface Applica
101. tions UIA running on Windows 2000 Pro 2003 Server or XP PC workstations for displaying warnings predictions and AutoDiagnosis Messages etc The UIA is available in different languages 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 1 7 1 3 Disclaimers The OPENpredictor system is only intended for providing information about machinery faults under development Rovsing Dynamics A S its suppliers distributors and subcontractors will under no circumstances accept any liabilities for any mental or physical injuries any losses or any damage on anybody s property incl personal belongings equipment and buildings and their surroundings in the widest sense due to the use of any part of the system It is the full and sole responsibility of the corporation organization person in charge of the use of the equipment to ensure that each person using OPENpredictor has been properly trained This responsibility includes Giving sufficient instructions to all relevant persons concerning all safety related matters in general and in particular as described in manuals for the equipment on the equipment and in on manuals packages and safety sheets for consumables incl manuals and packages from third party suppliers Ensuring that all safety related instructions given in manuals for the equipment on the equipment and in on manuals packages and safety sheets for consumables including the manuals and packag
102. ts data Oil Data Sheet RDOPOSiI RDOPO10g ioj xj File Edit Report e DX DO Machine Ham TG21 x No of Samples per Sheet le x Surveillance Period Update j Year v From 2006 10 06 15 54 19 To 2007 10 09 15 54 19 quipement date arriv e au labo labo d analyse type d huile constructeur puissances poids total de I huile date dernier appoint date du dernier traitement aspect Oil service event g cm cSt HAM TG21 Oil Viscocity 100 viscosit cin matique 100 C cSt HAM TG21 Oil Viscosity index indice de viscosit HAM TG21 Oil Acid No indice d acidit mg KOH g HAM TG21 Oil x Temperature point d clair C HAM TG21 Oil x Test test de desemultion HAM TG21 Oil Particles comptage de particules ppm HAM TG21 Oil x Property propri t anti rouille 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 32 To insert a new data column date select the menu Edit gt Insert Oil Report Ctrl N or click the L button You will be prompted for a date To copy a previous data column select the menu Edit gt Copy Oil Report Ctrl C You will be prompted for a date and time Please note the button Now To delete a new data column select the menu Edit gt Delete Oil Report Ctrl X or click the S button and select the date of the record to be deleted
103. was made Line 2 Always Prediction of Required Action Level Line 3 If possible The nominal time from now where the problem is predicted to become severe Line 4 As line 3 but the earliest predicted time Line 5 As line 3 but the latest predicted time The earliest and latest time depends on the confidence level set for the calculation The values may be negative Recommen The text in this field is user defined possibly entered by the dation local system administrator The intention is to tell the plant operator which action to take in case of a specific fault diagnosis at a particular AutoDiagnosis Message level Confidence A statistical classification for the confidence of the diagnosis Levels e None e Low e Significant e High Accepted by User ID of the person who accepted the message or Not accepted not acknowledged Click to accept acknowledge by the person logged in Click to display the Browser with the item selected which initiated the AutoDiagnosis Plot Manager Click to display a plot showing the history of the symptom development and a prediction with statistical confidence levels of further development Open Close the Pending Faults list see below Close the AutoDiagnosis window 1 Only in the Predictive AutoDiagnosis window Only in the Instantaneous AutoDiagnosis window 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 13 Columns
104. word max 32 characters AD Recommendation V and repeat it in Confirm ok cane Password Click OK to change the Password 3 In the login window click OK to continue 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 2 4 When the Password session has been completed correctly the OPENpredictor Menu Bar opens this may also take some time PE OPENpredictor vky rdopol0g Oj x File View Browse Report Tools Help System Maintenance Mos Operation Offline FOET E 7 a a nolle ame se Al o o o 5 Check for new measurement warnings see section 2 3 2 If any traffic lights ar flashing click E for opening the warning list 6 Check for new AutoDiagnosis messages see section 2 3 1 Select Y menu Browse gt AutoDiagnosis list for Predictive AutoDiagnosis AND Y menu Browse gt Instantaneous AutoDiagnosis list for Instantaneous AutoDiagnosis IMPORTANT Autodiagnosis messages are not indicated trough the warning traffic lights Tip To see a short explanation of an icon hold the mouse pointer over the icon for a short time ils Help System Operation 3r M Lsystem Warnings SPU and others Important Do NOT close the FRoorenpredictor Work Console window shown below as this will terminate the OPENpredictor User Interface Applica tion OPENpredictor uses among other things this window for display ing
105. y list Submenus Performance Maintenance Alarm System All See section Note Some menus and tools available with certain specialist user login Menu Submenu 3 level submenus and explanations Performance Offline RDM MOS Toolbar icon All Warnings list Operation Offline RDM System All 2 2 1 1 rights are only shown in the User Manual section 5 1 Menus related to Close the OPENpredictor application System warning group items to be Browse E Warning Menu Complete Warning History List Deeper submenu level e g Alert AutoDiagnosis Opens the AutoDiagnosis and Warning and Warning Browser see section 2 3 3 Browser Browser aa Open Open the Browser see section 2 6 Find Open the Browser Find window When an item is selected the Browser opens with the item selected ty Mimic Viewer Open Open the Mimic Viewer See section 2 5 R Find Open the Mimic Viewer Find window When an item is selected the Mimic Viewer opens with the item selected must then be selected See section 2 7 AutoDiagnosis Open the Predictive Auto Diagnosis List List Contents see section 2 3 1 5 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 2 4 Instantaneous Open the Instantaneous Auto Diagnosis AutoDiagnosis_ List Contents see section 2 3 1 5 List E MOS Maintenance Override Sw
106. ypes and warning systems 2 15 2 3 2 2 Measurement warnings overview table 2 16 2 3 2 3 How to react on a new Measurement warning 2 16 2 3 2 4 Opening a Warning List 2 17 2 3 2 5 Acknowledging and removing a measurement warning 2 19 2 3 2 6 Reading Warning list details 2 19 2 3 3 The AutoDiagnosis and Warning Browser 2 21 2 3 4 Measurement warning indicators in Mimics 2 22 2 3 5 Maintenance Override Switch MOS 2 23 2 3 5 1 The MOS flag 2 23 2 3 5 2 The Enabled flag 2 23 2 3 5 3 Checking changing the position of the MOS and Enabled flags 2 24 2 3 5 4 How to see which transducers are switched off 2 25 2 4 Reports 2 26 2 4 1 How to generate a Shift Report 2 27 2 4 1 1 Shift Report fields 2 28 How to generate a Management Report 2 29 2 4 2 Diagnostic report 2 30 2 4 3 Measurements Statistics report 2 30 2 4 4 Note Reports 2 31 2 4 5 Oil Analysis special module 2 32 2 4 5 1 Importing Oil report data 2 33 2 4 6 Reliability monitoring special module 2 34 2 4 6 1 Menu Bar indicator 2 34 2 4 6 2 The Downtime List 2 34 2 4 6 3 The RDM Report 2 34 2 4 6 4 The Machine Reliability Report 2 35 2 4 6 5 RDM machine Info 2 36 2 5 Mimics 2 37 2 5 1 Opening a Mimic 2 37 2 5 2 Working with a Mimic 2 39 2 5 3 How to make a Mimic Report 2 40 2008 11 20 OPENpredictor 2 8 0 Operator s Guide Issue 2 2 Page 1 1 2 5 4 Mimic menus and related toolbar icons 2 41 2 6 The Browser Window 2 42 2 6 1 Item Measurement Selector 2 42 2 6 2 F

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