System and method for blind fault detection for rotating machinery

• US 8,963,733 B2
• Filed: 02/13/2012
• Issued: 02/24/2015
• Est. Priority Date: 02/13/2012
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Kar, Chinmaya, Sadana, Rajat, Mukherjee, Joydeb
• Primary Examiner(s): Wu, Daniel
• Assistant Examiner(s): Tang, Son M
• Application Number:
  US13/371,576
• Publication Number:
  US 20130207810A1
• Time in Patent Office: 1,107 Days
• Field of Search: 340/686.3, 340/686.1, 340682-683, 702 34- 37, 702 75- 77
• US Class Current: 340/686.3
• CPC Class Codes: G01M 13/02 Gearings; Transmission mechanisms
• CPC Class Codes: G01M 13/021 Gearings
• CPC Class Codes: G01M 13/028 Acoustic or vibration analysis
• CPC Class Codes: G01M 13/045 Acoustic or vibration analysis

Abstract

A system includes more sensors configured to measure one or more characteristics of rotating equipment and a blind fault detection device. The blind fault detection device includes an input interface configured to receive at least one input signal from the one or more sensors. The blind fault detection device also includes a processing unit configured to identify a fault in the rotating equipment using the at least one input signal. The blind fault detection device further includes an output interface configured to provide an indicator identifying the fault. The processing unit is configured to identify the fault by determining at least one family of frequencies related to at least one sensor point, determining an average energy for the at least one sensor point based on the at least one family of frequencies, and comparing the average energy to a baseline value.

Claims

1. An apparatus comprising:

an input interface configured to receive input signals from sensors associated with at least one stage of rotating equipment;

a processing unit configured to identify a fault in the rotating equipment using the input signals; and

an output interface configured to provide an indicator identifying the fault;

wherein the processing unit is configured to identify the fault by;

monitoring multiple families of frequencies in the input signals;

determining at least one average energy based on the multiple families of frequencies; and

comparing the at least one average energy to at least one baseline value; and

wherein the at least one average energy comprises an average energy of the multiple families of frequencies in the input signals from multiple sensors located at a common sensor point and having different measurement orientations.

2. The apparatus of claim 1, wherein the processing unit is configured to determine the average energy of the multiple families of frequencies in the input signals from the multiple sensors located at the common sensor point and having the different measurement orientations.

3. The apparatus of claim 2, wherein the different measurement orientations comprise a vertical orientation, a horizontal orientation, and an axial orientation.

4. The apparatus of claim 1, wherein the input signals comprise signals related to at least one of:

a synchronous energy, a non-synchronous energy, and a shaft energy of the rotating equipment.

5. The apparatus of claim 1, wherein the processing unit is further configured to normalize the at least one average energy with respect to the at least one baseline value.

6. The apparatus of claim 5, wherein the processing unit is further configured to apply at least one of a rule-based fault detection process and a fuzzy rule-based fault detection process to the at least one normalized average energy.

7. The apparatus of claim 1, wherein the processing unit is configured to determine the average energies of the multiple families of frequencies in the input signals from multiple sensors having multiple measurement orientations at multiple sensor points.

8. The apparatus of claim 1, wherein the processing unit is further configured to determine an average energy of the multiple families of frequencies in input signals from multiple sensors located at different sensor points and having a common measurement orientation.

9. A system comprising:

multiple sensors each configured to measure one or more characteristics of rotating equipment; and

a blind fault detection device comprising;

an input interface configured to receive input signals from the sensors;

a processing unit configured to identify a fault in the rotating equipment using the input signals; and

an output interface configured to provide an indicator identifying the fault;

wherein the processing unit is configured to identify the fault by;

monitoring multiple families of frequencies in the input signals;

determining at least one average energy based on the multiple families of frequencies;

comparing the at least one average energy to at least one baseline value; and

wherein the at least one average energy comprises an average energy of the multiple families of frequencies in the input signals from multiple sensors located at a common sensor point and having different measurement orientations.

10. The system of claim 9, wherein the processing unit is configured to determine the average energy of the multiple families of frequencies in the input signals from the multiple sensors located at the common sensor point and having the different measurement orientations.

11. The system of claim 10, wherein the different measurement orientations comprise a vertical orientation, a horizontal orientation, and an axial orientation.

12. The system of claim 9, wherein the input signals comprise signals related to at least one of:

a synchronous energy, a non-synchronous energy, and a shaft energy of the rotating equipment.

13. The system of claim 9, wherein the processing unit is further configured to normalize the at least one average energy with respect to the at least one baseline value.

14. The system of claim 13, wherein the processing unit is further configured to apply at least one of a rule-based fault detection process and a fuzzy rule-based fault detection process to the at least one normalized average energy.

15. The system of claim 9, wherein the processing unit is further configured to determine the average energies of the multiple families of frequencies in the input signals from multiple sensors having multiple measurement orientations at multiple sensor points.

16. The system of claim 9, wherein the processing unit is further configured to determine an average energy of the multiple families of frequencies in input signals from multiple sensors located at different sensor points and having a common measurement orientation.

17. A method comprising:

receiving input signals from sensors associated with at least one stage of rotating equipment;

identifying a fault in the rotating equipment using the input signals; and

providing an indicator identifying the fault;

wherein identifying the fault comprises;

monitoring multiple families of frequencies in the input signals;

determining at least one average energy based on the multiple families of frequencies;

comparing the at least one average energy to at least one baseline value; and

wherein the at least one average energy comprises an average energy of the multiple families of frequencies in the input signals from multiple sensors located at a common sensor point and having different measurement orientations.

18. The method of claim 17, wherein determining the at least one average energy comprises determining the average energy of the multiple families of frequencies in the input signals from the multiple sensors located at the common sensor point and having the different measurement orientations.

19. The method of claim 18, wherein the different measurement orientations comprise a vertical orientation, a horizontal orientation, and an axial orientation.

20. The method of claim 17, further comprising:

normalizing the at least one average energy with respect to the at least one baseline value; and

applying at least one of a rule-based fault detection technique and a fuzzy rule-based fault detection technique to the at least one normalized average energy.

21. The method of claim 17, wherein the input signals comprise signals related to at least one of:

a synchronous energy, a non-synchronous energy, and a shaft energy of the rotating equipment.

22. The method of claim 17, wherein identifying the fault comprises determining the average energies of the multiple families of frequencies in the input signals from multiple sensors having multiple measurement orientations at multiple sensor points.

23. The method of claim 17, wherein determining the at least one average energy further comprises determining an average energy of the multiple families of frequencies in input signals from multiple sensors located at different sensor points and having a common measurement orientation.

24. A non-transitory computer readable medium embodying a computer program, the computer program comprising computer readable program code for:

receiving input signals from sensors associated with at least one stage of rotating equipment;

identifying a fault in the rotating equipment using the input signals; and

providing an indicator identifying the fault;

wherein the computer readable program code for identifying the fault comprises computer readable program code for;

monitoring multiple families of frequencies in the input signals;

determining at least one average energy based on the multiple families of frequencies; and

comparing the at least one average energy to at least one baseline value; and

wherein the at least one average energy comprises an average energy of the multiple families of frequencies in the input signals from multiple sensors located at a common sensor point and having different measurement orientations.