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SmartSensor recommendations

Overview

The SmartSensor Recommendations provides a list of automatic text recommendations for the expert users to follow. The recommendations are based on the analysis of KPI values and thresholds in the reporting period.

Recommendations are computed only for the Motor Assets.

Each recommendation has a recommendation text and the importance level. The Importance level might be either LOW or HIGH, with the idea that the low importance recommendations should be handled within 4-6 months, while the high importance recommendations should be handled under 3 months.

General algorithm

Each recommendation is based on a single timeseries data derived from the Asset KPI. The only exception is the UrgencyLevel recommendation, which is based on the combination of two Asset KPIs.

The timeseries we use for the recommendation is the range (report_start_date - 7 days) to report_end_date

The recommendation is based on the following logic:

  1. Get the timeseries data, required by the recommendation.
  2. Optional. Filter it with motor running signal.
  3. Normalize the timeseries, so its values are in the range [0, 1].
  4. Calculate the time spent in alarm and warning states.
  5. Check if time spent in alarm state is above the alarm limit. If so return the HIGH Importance.
  6. Check if time spent in warning state is above the warning limit. If so return the LOW Importance.

Recommendations general algorithm

Recommendation details used in Fleet Report

Temperature

KPI

  • Skin Temperature (KPI_ID = 4)

Filtering

  • No filtering

Limits

  • Warning Limit = 10 %
  • Alarm Limit = 10 %

Texts

  • Low Importance = Perform a thermographic inspection during the walkdown inspection.
  • High Importance = Perform a thermographic inspection during the walkdown inspection.

TemperatureEnvironmentalIndex

KPI

  • Skin Temperature (KPI_ID = 4)

Filtering

  • Motor is not running

Limits

  • Warning Limit = 20 %
  • Alarm Limit = 20 %

Texts

  • Low Importance = Motor is not designed for ambient conditions
  • High Importance = Motor is not designed for ambient conditions

VibrationOperationalIndex

KPI

  • Overall Vibration (KPI_ID = 8)

Filtering

  • Motor is running

Limits

  • Warning Limit = 15 %
  • Alarm Limit = 15 %

Texts

  • Low Importance = Perform detailed remote analysis to verify high vibration causes - Generate Asset Report or Perform detailed vibration analysis on site
  • High Importance = Perform detailed remote analysis to verify high vibration causes - Generate Asset Report or Perform detailed vibration analysis on site

VibrationOperationalOtherIndex

KPI

  • Overall Vibration (KPI_ID = 8)

Filtering

  • Motor is running

Limits

  • Warning Limit = 10 %
  • Alarm Limit = 10 %

Texts

  • Low Importance = Check gearbox vibrations. Check driven equipment vibrations
  • High Importance = Check gearbox vibrations. Check driven equipment vibrations

VibrationEnvironmentalIndex

KPI

  • Overall Vibration (KPI_ID = 8)

Filtering

  • Motor is not running

Limits

  • Warning Limit = 10 %
  • Alarm Limit = 10 %

Texts

  • Low Importance = Reduce foundation transmitted vibrations. Rotate shaft every two weeks
  • High Importance = Reduce foundation transmitted vibrations. Rotate shaft every two weeks

MisalignmentOperationalIndex

KPI

  • Simple Misalignment (KPI_ID = 66)

Filtering

  • Motor is running

Limits

  • Warning Limit = 15 %
  • Alarm Limit = 15 %

Texts

  • Low Importance = Perform detailed remote analysis to verify high vibration causes - Generate Asset Report. Check for misalignment, soft foot and vibrations coming from coupled load.
  • High Importance = Perform detailed remote analysis to verify high vibration causes - Generate Asset Report. Check for misalignment, soft foot and vibrations coming from coupled load.

BearingReliabilityIndex

KPI

  • Bearing Condition (KPI_ID = 27)

Filtering

  • Motor is running

Limits

  • Warning Limit = 10 %
  • Alarm Limit = 20 %

Texts

  • Low Importance = Perform detailed remote vibration analysis to verify bearing defects - Generate Asset Report
  • High Importance = Replace bearings

RegreasingReliabilityIndex

KPI

  • Regreasing Advice (KPI_ID = 65)

Filtering

  • Motor is running

Limits

  • Warning Limit = 30 %
  • Alarm Limit = 30 %

Texts

  • Low Importance = Regrease bearings or update the date of regreasing
  • High Importance = Regrease bearings or update the date of regreasing

VFDVibrationOperationalIndex

KPI

  • Overall Vibration (KPI_ID = 8)

Filtering

  • Motor is running
  • Motor is connected to VFD

Limits

  • Warning Limit = 10 %
  • Alarm Limit = 10 %

Texts

  • Low Importance = Change speed to reduce structural vibrations
  • High Importance = Change speed to reduce structural vibrations

UrgencyLevelTest

Logic

This one has a custom logic. First we calculate the position on the urgency matrix at the beginning and the end of the reporting period.

There are three recommendations states, all with High importance:

  1. If the both positions are outside the Alarm Limit Radius, and the end position is worse than the start position, we return the recommendation Alarm Worsening

  2. If the end position is outside the Alarm Limit Radius, and the start position is outside the Warning Limit Radius, we return the recommendation Warning to Alarm

  3. If the end position is outside the Alarm Limit Radius, but the start position is OK, we return the recommendation OK to Alarm

KPI

  • Total Stress (Internal KPI, used on Urgency Matrix)
  • Reliability Index (Internal KPI, used on Urgency Matrix)

Filtering

  • Motor is running

Limits

  • Warning Limit Radius = 50 %
  • Alarm Limit Radius = 95 %

Texts

  • OK to Alarm = Ensure spare bearings are in stock
  • Warning to Alarm = Ensure spare motor is available
  • Alarm Worsening = Replace motor at the next outage

Recommendation details not used in Fleet Report

FanGrille

KPI

  • Skin Temperature (KPI_ID = 4)

Filtering

  • Motor is running
  • Motor application is FAN

Limits

  • Warning Limit = 15 %
  • Alarm Limit = 15 %

Texts

  • Low Importance = Clean fan grille
  • High Importance = Clean fan grille

TestCheck

KPI

  • Overall Vibration (KPI_ID = 8)

Filtering

  • Motor is running

Limits

  • OK Limit = 90 %

  • Texts

  • Low Importance = Everything is OK, and all data is present.

  • High Importance = Everything is OK, and all data is present.