The ISO 13381-1 Standard's Failure Prognostics Process Through An Example
The ISO 13381-1 Standard's Failure Prognostics Process Through An Example
through an example.
Diego Tobon-Meja, Kamal Medjaher, Noureddine Zerhouni
Sensor type
Accelerometer
Accelerometer
Ohmeter
Accelerometer
Accelerometer
Accelerometer
Accelerometer
Accelerometer
Pressure
Pressure
Component
Bearing 1
Bearing 2
Stator
Shaft
Shaft
Bearing 1 pump
Bearing 1 pump
Impeller pump
Subsystem
System
AC Motor
Hydrostatic bearing
Pumping System
Centrifugal pump
Seal
alarm alert
trip
(1)
The trip, or the shut-down value, specifies the value that the
parameter/descriptor reaches when the component must be
fixed without any exception. Normally, this value is lower than
the real break value and can be understood as the security
factor in strength of materials. This value can be defined from
standards, manufacturers guidelines or by experience. In the
pumping system, the FMECA sheet contains also a column to
take into account these values, (see the red colored column in
tables 2 and 3).
V PROGNOSTICS PROCESS
In the same as the ISO, some researchers and industrials are
aware of the importance of prognostics in the CBM policy and
this pushed them to make some efforts in their standardization.
For example, the cooperation between scientists and industrials
has enabled the development of a standard platform to build a
CBM software [9], called "Open Systems Architecture for
Condition-based Maintenance". In this platform the
2.
The second step consists in the identification of the
influence factors between the existing failure modes. To
perform this operation the prognostics system can use the
"effects on" column in the FMECA analysis (see tables 2 and
3) to find the relations between the FMs. Once this operation
is performed for the pumping system, by using the diagnostic
4.
The last step in the pre-processing process consists in
determining the potential future failure modes, their
initiation criteria and the failure definition set points. For
example, in the pumping system the old maintenance
histories data can be used to find the most probable future
failure modes. For this, the prognostics system can proceed
by similarity study and analysis (similar diagnosed failure
modes with their associated monitoring values) on the
previous recorded situations to find the potential future
failure modes. The result of this step is shown in the green
box of figure 6.
Existing failure modes prognostics process
During this step the following operations are made:
1. The first step of this process aims at identifying the
actual condition of the overall system, and the severity of the
existing failure modes. For this, the prognostics system will
classify the failure modes from the most severe to less severe.
To perform this quantification, the system measures the
distance between the actual descriptor value with its
respective trip value, and the smallest distance defines the
most sever failure mode. For example, in the pumping
system if the prognostics system displays in the same
window (using scales factors) the descriptors "D1" and "D4"
which have the trends showed in the figure 7, the system
concludes that the outer race break FM in the bearing 1 of
the AC motor (M_B1_1) is more severe at the present time
than the oil degradation FM in the hydrostatic bearing (HB).
This is because the distance between its current value and its
trip value is shorter than the descriptor "D4".
2. The next step is the time projection of the
parameters/descriptors into the future. For this purpose, the
standard presents projection and extrapolation as trending
tools. The basic difference between trend extrapolation and
trend projection is that projection requires the estimation of
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