On-Line Predictive Condition Monitoring System For Coal Pulverizers

On-Line Predictive Condition Monitoring
System for Coal Pulverizers

Application of Wireless Technology
Technical Report
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EPRI 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA
800.313.3774 650.855.2121 askepri@epri.com www.epri.com
On-Line Predictive Condition
Monitoring System for Coal
Pulverizers
Application of Wireless Technology
1004902
Final Report, October 2003
Cosponsors
SmartSignal Corp.
901 Warrenville Road Suite 300
Lisle, IL 60532

Principal Investigator
A. Wolosewicz

Dynegy Midwest Generation
2828 N. Monroe St.
Decatur, IL 62526

T. Wheeler

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SmartSignal Corp.

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iii
CITATIONS
This report was prepared by
SmartSignal Corporation
901 Warrenville Road
Lisle, IL 60532
A. Wolosewicz
2828 N. Monroe St.
Decatur, IL 62526
Principal Investigator in charge of eCM
TM
installation
T. Wheeler
Principal Investigator in charge of wireless sensor installation
B. Baldwin
This report describes research sponsored by EPRI.
The report is a corporate document that should be cited in the literature in the following manner:
On-Line Predictive Condition Monitoring System for Coal Pulverizers: Application of Wireless
Technology. EPRI, Palo Alto, CA; SmartSignal Corp., Lisle, IL; and Dynegy Midwest
Generation, Decatur, IL: 2003. 1004902.

v
PRODUCT DESCRIPTION

This report discusses how the combination of two new technologies (equipment predictive
monitoring software and wireless technology vibration sensors) provides more information for
early detection of coal pulverizer failures than conventional vibration analysis alone. Early
warning before failure, from several hours to as much as several days, allows maintenance staff
to plan proactive maintenance under the best possible scenario versus continually reacting to
upset conditions and performing unscheduled maintenance under emergency conditions.
Results and Findings
This is the first EPRI-sponsored (partial) demonstration of on-line monitoring (OLM) to assess
equipment condition from signals obtained from plant components during operation. This
requires the processing of several signals, some from the component under examination but most
from surrounding equipment/systems that have a high degree of correlation. The project results
have shown that vibration magnitude data can be modeled with correlated process variables to
detect failures with early warning. Initially in this study, currently available process variable
signals were used to model and monitor a coal pulverizer. The results identified a need to
consider vibration signals in order to capture more failure modes. Vibration signals provided by
a wireless network, in combination with the existing process signals, significantly increase the
ability to provide valuable early warning. Results also indicate the ability to differentiate
between sensor anomalies (that is, drift, sensor failure, and the like) and mechanical faults, such
as those from the bearings on the pulverizer and motor.
The combination of vibration signals and process variables, when monitored by the predictive
monitoring system, increases the number of detectable failure modes from 11% to 46%. The
value proposition is that the technology was capable of achieving up to 12 hours early warning of
impending failure.
Challenges and Objectives
The ability to accurately predict equipment failure from on-line signals to plan maintenance
and/or repair remains a challenging problem facing the power industry. Successful prediction can
lead to increased efficiency, lower operation and maintenance (O&M) costs, and increased
reliability. The objectives of this effort were to:
Demonstrate the on-line ability to combine wireless vibration signals with other process and
equipment signals to warn of anomalous equipment conditions
Demonstrate the ability to operate under plant operating conditions
Applications, Values, and Use
The system used in the demonstration is a commercially available, enterprise software solution
that provides real-time asset health monitoring for large industrial assets such as combustion

vi
turbines, jet engines, diesel engines, pumps, electric motors, and pipeline flow meters. The
product has been specifically designed to allow operators to monitor fleets of equipment in real
time and easily scales to plant-wide or fleet-wide applications. This technology has been
successfully demonstrated in the United States in commercial airline operations and maintenance
by providing the earliest possible warning of deteriorating conditions in jet engines across
various manufacturers.
EPRI Perspective
A class of highly advanced, model-based equipment condition monitoring software systems have
been developed and deployed in several industries for continuous health monitoring. These
provide early detection of signal anomalies and enable timely disposition of asset condition
without incurring costly corrective maintenance or failure. Coupled with advances in wireless
technology that are enabling measurement of heretofore difficult-to-access signals, OLM
capabilities offer the potential for more reliable detection.
EPRI has initiated projects in 2003 to leverage previous work done in implementation of these
technologies for instrument calibration reduction. These advanced technologies utilize powerful
pattern recognition methods that use either causal or model-based mathematical models to detect
out-of-range conditions. Typically, they consider multiple process signals obtained from the
plant historian. However, some consider other non-quantitative inputs, such as operator rounds
information and nondestructive evaluation (NDE) data as well as other non-periodically obtained
signal information (for example, vibration data). While not demonstrated yet, these technologies
have the potential to significantly improve condition-based assessment and are likely to have a
large impact on plant reliability and availability. The vision is to see equipment condition
monitoring software applied on entire fleets so that there are measurable reductions in
maintenance, improved reliability, and increased customer and investor confidence.
Approach
The system determines if equipment operation is significantly different from normal operation
and, if so, then guides the analyst to finding the problems. First, an empirical model is created
from normal operational data on some equipment or system. During real-time operation, samples
of data for the system are compared to the model estimates (of expected normal behavior) to
determine whether the current state is normal. Finally, a suite of incident rules built to capture
expected fault mode signatures is applied to guide the analyst to the likely fault modes and the
amount of degradation. The underlying technology involves proprietary algorithms in a step-by-
step mathematical approach. The methodology is an engineering-based method used to identify
critical pieces of equipment where early warning of failure could prove financially beneficial by
allowing operators to shift from unplanned maintenance to planned maintenance, by reducing
maintenance duration, or by increasing the interval between maintenance activities.
Keywords
On-line monitoring (OLM)
Equipment condition monitoring
Wireless network
Early warning fault detection
Vibration
Failure analysis

EPRI Licensed Material
vii
ABSTRACT
This report discusses how the health monitoring of a coal pulverizer is significantly enhanced
when vibration signals are added to a model of existing process variables. Two new
technologies, SmartSignal eCM
TM
predictive monitoring software and wireless vibration sensors,
are utilized to achieve the goal. Systems analysis indicates that the combination of process
variables and vibration signals increases the number of coal pulverizer failure modes, detectable
through early warning, by a factor of four to six (46%) versus modeling on process variables
alone (11%) or vibration signals alone (7%). Providing early warning of failures can allow time
for proactive or scheduled repairs, resulting in substantial financial benefit to maintenance and
operations.

ix
CONTENTS
1 INTRODUCTION ................................................................................................................. 1-1
2 SMARTSIGNAL ECM SOFTWARE..................................................................................... 2-1
2.1 Overview................................................................................................................... 2-1
2.2 SmartSignal eCM Software Architecture ................................................................... 2-3
2.3 Underlying SmartSignal Technology ......................................................................... 2-5
2.4 SmartStart Methodology............................................................................................ 2-9
2.3.1 Value Analysis.................................................................................................2-11
2.3.2 System Analysis ..............................................................................................2-14
2.3.2.1 Process Decomposition.............................................................................2-15
2.3.2.2 Process Behavior Analysis ........................................................................2-16
2.3.2.3 Fingerprint Charts......................................................................................2-17
2.3.3 Data Analysis ..................................................................................................2-19
2.3.4 eCM WorkBench Application Development .....................................................2-19
2.3.4.1 eCM Model Testing ...................................................................................2-20
2.3.4.2 Rule Testing ..............................................................................................2-20
3 MERGING ECM WITH WIRELESS VIBRATION TECHNOLOGY....................................... 3-1
3.1 Pulverizer Value Analysis.......................................................................................... 3-1
3.1.1 Description of Pulverizer Function .................................................................... 3-1
3.1.2 Benefits of Early Warning of Pulverizer Failure................................................. 3-3
3.2 Pulverizer System Analysis ....................................................................................... 3-4
3.2.1 Coal Pulverizer eCM Models with Original Process Variable Sensors .............. 3-5
3.2.2 Coal Pulverizer eCM Models with Added Vibration Sensors ............................. 3-9
3.3 The Wireless Vibration Network ...............................................................................3-11

x
4 RESULTS............................................................................................................................ 4-1
4.1 Case A Results: Models on Initial Process Variables ................................................ 4-1
4.2 Case B Results: Models with Vibration and Process Variables.................................. 4-5
5 CONCLUSIONS .................................................................................................................. 5-1
5.1 Technology Shows Promise for Coal Pulverizers ...................................................... 5-1
5.2 Wireless System Obstacles and Lessons Learned.................................................... 5-2
5.3 Technology Works - Reliability of Signal Is an Issue ................................................. 5-3

xi
LIST OF FIGURES
Figure 2-1 Overview of the SmartSignal eCM Process............................................................ 2-1
Figure 2-2 Architecture of the SmartSignal eCM Software ...................................................... 2-3
Figure 2-3 Estimate of a Dynamic Response Surface Based on Exemplars............................ 2-8
Figure 2-4 Auto-Associative Modeling of Stator-Winding Temperatures.................................. 2-9
Figure 2-5 The SmartStart Methodology Process...................................................................2-11
Figure 2-6 Early Warning Value Hierarchy .............................................................................2-12
Figure 2-7 Frequency Pareto Chart of Pulverizer Failure Modes............................................2-14
Figure 2-8 Process Decomposition ........................................................................................2-15
Figure 3-1 Schematic of Coal Pulverizer ................................................................................. 3-6
Figure 3-2 Frequency of Pulverizer Failure Modes: Breakdown by Available Signals.............3-10
Figure 3-3 Data Flow from Wireless Vibration Network ..........................................................3-11
Figure 3-4 Roller Bearing Vibration Sensor Installation ..........................................................3-12
Figure 3-5 NCAP Transmitter Installation...............................................................................3-13
Figure 3-6 Antenna and Access Point Installation ................................................................3-133
Figure 4-1 Bowl Differential Pressure: 11/22/02 to 11/25/02.................................................... 4-2
Figure 4-2 Current: 11/22/02 to 11/25/02 ................................................................................ 4-3
Figure 4-3 Bowl dP (L) and Current (R): 12/6/02 to 12/10/02 .................................................. 4-4
Figure 4-4 Base Pressure (L) and Bowl Differential Pressure (R): 1/16/03 to 1/25/03 ............. 4-5
Figure 4-5 Base Pressure (L) and Bowl Differential Pressure (R): 1/16/03 to 1/25/03 ............. 4-7
Figure 4-6 WatchList Results: VIBPOINT 5-8, 05/017/1/03................................................... 4-8
Figure 4-7 WatchList Results: VIBPOINT 1-4, 6/128/27/03..................................................4-10
Figure 4-8 WatchList Results: VIBPOINT 5-8, 06/128/27/03 ................................................4-11
Figure 5-1 Cumulative Failure Mode Pareto Chart of Catchable Failures................................ 5-2

xiii
LIST OF TABLES
Table 2-1 Fingerprint Chart for Baldwin Unit 3 Pulverizer 3A..................................................2-18
Table 3-1 Effect of 12 Hours of Early Warning of Pulverizer Failure........................................ 3-4
Table 3-2 Signal List for Enhanced Model............................................................................... 3-8

1-1
1
INTRODUCTION
This report discusses how the health monitoring of a coal pulverizer is significantly enhanced
when vibration signals are added to a model of existing process variables. Two new
technologies, SmartSignals eCM
TM
predictive maintenance software and wireless network with
vibration sensors, are utilized to achieve the goal. Systems analysis indicates that the
combination of process variables and vibrations signals increases the number of detectable coal
pulverizer failure modes by a factor of four over modeling on process variables alone or
vibration signals alone. Providing early warning on failures can allow time for proactive or
scheduled repairs, resulting in substantial financial benefit to maintenance and operations.
The purpose of this report is to:
Provide detailed technical information on how SmartSignal eCM predictive monitoring
software detects the earliest sign of physical deterioration in a pulverizer
Explain how continuous wireless vibration monitoring can improve pulverizer performance
The combination of wireless vibration technology and predictive monitoring software will
substantially improve power plant performance. By early detection of pulverizer problems, plant
operations, engineering, and maintenance staff can plan proactive maintenance under the best
possible scenario versus continually reacting to upset conditions and performing unscheduled
maintenance under emergency conditions.
The SmartStart methodology is used as a framework to explain how the combination of wireless
vibration technology and SmartSignal eCM predictive monitoring software work together.
SmartSignal eCM software has demonstrated to be a platform for continuous asset management
and has proven to be successful monitoring coal-fired plants.
In any process or equipment, fundamental physical laws such as conservation of mass, energy,
and momentum govern the systems operation and tie together the complex set of relationships
between sensor readings. As equipment degrades or failure begins, the system physically
changes. For example, as bearings wear, excess friction increases bearing temperature and
vibration and ultimately reduces overall system efficiency. When bearing temperature or
vibration exceeds traditional monitoring thresholds, permanent damage could have already
occurred. Early warning of failure provides maximum value when it detects the earliest signs of
deterioration before permanent damage has occurred.
SmartSignals eCM technology analyzes historical data and constructs high fidelity, empirical
models of normal, expected equipment and process operation. During real-time operation, eCM
compares estimated sensor values to actual real-time data collected from the equipment. This
comparison identifies developing failures much earlier then conventional technologies.

Introduction
1-2
Many factors prevent conventional mathematical and statistical models from accurately revealing
the complex relationships between sensors. First, equation-based mathematical modeling fails for
all but the simplest system even under normal, steady-state operating conditions because the
equations that describe the physical process quickly become too complex. Second, as the process
moves from one state to another, transient behavior further complicates analytical techniques.
Finally, random process variance and sensor measurement error obscure deterministic physical
relationships. Computationally, first principle models simply become impractical for most real-
world applications
While some catastrophic failures occur too quickly to avoid, most failures develop over time and
disrupt the equipments normal sensor relationships. This impending failure changes how
process variables move with relation to each other in very subtle ways. Frequently, the change
progressively grows until either the equipment fails or a safety system detects a threshold
violation and shuts down the unit.
SmartSignal eCM detects abnormal equipment behavior within the variability of normal
operation and well within existing threshold alarm limits. The key is calculating residual values
by subtracting the estimates generated by an eCM model from the actual real-time sensor values.
Analysis of the residuals identifies very subtle process deviations well within the normal
threshold alarm limits and detects the earliest possible signs of equipment malfunction. The alert
feature of the system detects deviations from normal operation without reacting to the normal
process or system variation. SmartSignal eCM diagnoses failure modes, based on a pattern of
high or low residuals, which is unique to each failure mode. Therefore, we refer to this as a
fingerprint or signature unique to the pattern of residuals.
This report explains the value proposition of these two technologies in the coal pulverizer
application, discusses the workings of the system, and shows examples of the two technologies
working together to provide actionable and valuable information.

2-1
2
SMARTSIGNAL ECM SOFTWARE
2.1 Overview
SmartSignals eCM V. 2.5 is an enterprise software solution with a browser-based, graphical
user interface (GUI) that provides real-time asset health monitoring for large industrial assets
such as combustion turbines, jet engines, diesel engines, pumps, electric motors, meters, and, in
fact, almost any instrumented mission-critical asset with installed sensors. Moreover, the product
easily scales to plant-wide or fleet-wide applications.
As eCM receives raw data (known as actual signals) in real time from the data source, it
generates expected values (known as estimate signals) using eCM models built from historical
data of the equipment. eCM determines for each sensor whether the actual values deviate
significantly from the estimates and, if so, produces an alert. Alerts are passed through user-
configurable rules that determine whether to create an incident and automatically notify users
that this asset must be watched. Rules can also be used to diagnosis the cause of the incident and
classify it according to severity and confidence of diagnosis. This focuses the attention of
engineers and analysts on only those components and systems with developing problems. A
graphical representation of this process is shown in Figure 2-1.

Figure 2-1
Overview of the SmartSignal eCM Process

SmartSignal eCM Software
2-2
To start, eCM collects a history of data samples for all of the sensors in an eCM model. Next,
eCM automatically creates an empirical model of normal performance of the asset based on the
normal historical data. Unlike conventional threshold monitoring techniques, the eCM empirical
model generates an estimated value for each sensor that would be characteristic of normal
operation. Each sensor estimate is based not only on that sensors history but also on how that
sensor interacted with every other sensor value. The result is a data-driven personality profile
of each asset. Then, in real time, the software effectively removes the effect of normal operation
by subtracting the estimated values from the actual values to generate residual values. If the
equipment is running normally, the resulting residuals should be small and evenly distributed
around zero. Equipment faults show up as spikes or trends in the residuals.
eCM compares the residuals using a patented statistical technique. If significant deviations are
found, the equipment is running abnormally, and the eCM issues an alert. These alerts are fed
into the diagnostic rules engine that analyzes the pattern of alerts to see if this is a known pattern
or if it meets the preestablished criteria for being promoted into an item on the WatchList
and/or notifying an analyst. (These criteria are set up during the SmartStart methodology phase.)
Information about the incident is fed back into the eCM database, and all the critical information
can be sent back to the control system.

2-3
2.2 SmartSignal eCM Software Architecture

Figure 2-2
Architecture of the SmartSignal eCM Software
The server computer receives data and performs state estimation and alerting. The results are
viewable through web browsers connected via internet/intranet to the WatchList Manager
TM
. The
eCM WorkBench
TM
tool is used for initial offline system setup.

2-4
1. WatchList Manager
eCM end user interface:
Focuses attention on failing assets
Provides quick access to critical diagnostic and sensor data
Provides exception driven data
Provides asset event reports
Provides fleet summary reports
Provides historical views
Provides asset event logs
Web based
IBM MQ middleware
Secure access
User configuration and management
2. eCM Database
Repository for real-time data and configuration information:
Asset hierarchy
Models
Diagnostic rules
Signal data
Alerts and incidents
User permissions and roles
3. eCM Run-Time Engine
Key analytical component:
Generates signal estimates and residuals
Applies rules
Triggers incidents
Provides real-time operation, 24 hours a day, 7 days a week

2-5
4. eCM Data Feeds
Real-time data connectivity
Bi-directional data transfer
Easy integration of data and incidents to:
Control systems
Historians
Enterprise-level business systems
5. eCM WorkBench
Provides eCM engineer setup environment
Allows the user to develop models and rules
Provides data visualization and analysis
Provides offline model testing
Provides runtime configuration
This platform for asset management has led to solutions for detecting, alerting, and classifying
failures for actionable early warning of failure in components such as boiler feed pumps and
recirculation valves, steam turbines, condensers, boilers, and electrostatic precipitators.
The SmartStart methodology first uses a value analysis to identify critical pieces of equipment
where early warning of failure could prove financially beneficial by shifting unplanned
maintenance to planned maintenance, by reducing maintenance duration, or by increasing the
interval between maintenance activities. Next, during a systems analysis, key failure modes are
linked to available sensors to help the engineers design the SmartSignal eCM models. Finally,
during a data analysis, SmartSignal models based on historical sensor readings are built and
tested to determine their efficacy as a fault detection tool.
2.3 Underlying SmartSignal Technology
The core of SmartSignals commercial eCM software comprises a unique modeling technology
called a similarity-based model (SBM). In contrast to first principle modeling techniques, it is
entirely empirical, that is, data driven. The model is built from sets of exemplars or historic data
observations that sufficiently characterize normal or desirable operation of the monitored
equipment. In contrast to parametric modeling techniques (like polynomial regression, Kalman
filters, or neural networks), no assumption about the analytical form of the solution is imposed.
The model is capable of making reasonable, if not exacting, estimates of proper equipment
behavior globally by means of a proprietary form of similarity-based regression.

2-6
The two primary requirements of the technology are:
1. Good historic data truly representing the equipment free from fault
2. Sufficient historic data
Both of these requirements are hallmarks of all empirical techniques. However, SmartSignal has
developed tools for data cleansing to address requirement 1 and adaptive bootstrapping
techniques for implementations where sufficient data are not available at first to address
requirement 2.
The SmartSignal modeling technology is based on using a similarity operation on two
observation vectors. The result of the similarity operation is a similarity score (a scalar) for the
comparison of the two observation vectors. The similarity operation is akin to the vector dot or
inner product and can be extended to matrix operations where a scalar similarity score is
rendered for each combination of a row from one matrix and column from a second matrix.
Accordingly, an estimate vector of estimated sensor values y
est
is determined from:
w D y
est
Eq. 2-1
where:
D is a state matrix of the aforementioned exemplars characterizing normal operational states
w is a weighting vector derived from:
(
(
,
\
,
,
(
j
N
j
j w
w
w
1
) (
Eq. 2-2
( ) ( )
in
T T
y D D D w
1
Eq. 2-3
Here, y
in
is the current actual observation vector, comprising sensor data. The similarity operation
is indicated by the symbol (which is not meant here to designate the Kronecker Product as it is
sometimes used in literature).
The similarity operator for use in the above equations meets the following criteria:
Similarity is a scalar range, bounded at each end.
The similarity of two identical inputs is the value of one of the bounded ends.
The absolute value of the similarity increases as the two inputs approach being identical.
The similarity operation can be a vector operation or can be an element-to-element operation that
is averaged across the vectors being compared. For example, one vector-to-vector similarity

2-7
operation that can be used is based on the Euclidean distance in n-space (where n is the number
of sensors in the observation):
1
1
2
) ( 1 ) , (
N
n
n n
y x y x S
Eq. 2-4
An example of an element-to-element similarity operation that can be used is:
( )
+
N
n n
n n
R
y x
N
y x S
1
1
2
1
1
) , (
Eq. 2-5
The D matrix of exemplars is created from a large set of historic reference data covering the full
dynamic range of the equipment. The selection of exemplars is extremely efficient, and
SmartSignal has developed a number of proprietary techniques for this. All such selection steps
are one-pass processes, in contrast to iterative training algorithms that characterize parametric
approaches like neural networks. Consequently, they are both extremely fast as well as
deterministic. The number of exemplars required is dependent on both the number of sensors in
the model, as well as the dynamic variability of the equipment in normal operation. However, a
general rule of thumb provides for the selection of a number of exemplars no less than two times
the number of sensors. It is not uncommon to model a 5060 sensor system with 200300
exemplar observations.

2-8

Figure 2-3
Estimate of a Dynamic Response Surface Based on Exemplars
As can be seen in Figure 2-3, an unknown dynamics surface is empirically mapped by exemplars
(shown in blue), using the SmartSignal modeling technology. An estimate (shown in red) is
generated as a weighted combination of the exemplars. The contributions (shown in green along
each contributing exemplar) can be both positive and negative.
In the classic inferential mode common to most modeling approaches, where estimates are made
for variables that are not in the input vector, the D matrix comprises two subsets: one of input
exemplars and one of corresponding output exemplars. Equations 2-1 and 2-3 above become:
w D y
out est

Eq. 2-6
( ) ( )
in
T
in in
T
in
y D D D w
1
Eq. 2-7
Advantageously, the modeling technique is also capable of generating estimates in what we call
the auto-associative mode, where all outputs are also inputs (Equations 2-1 and 2-3). This is a
critical advantage (and somewhat unorthodox in the modeling world) for the common situation
where the instrumented variables of the equipment represent a mix of the causes and effects of
the physics that drive the equipment. It ameliorates the need to determine causes, effects, and
feedback, and reduces the degree of ill-posed problem caused by many-to-one state issues. In
addition, the auto-associative mode enables monitoring of variables that are comprised solely of
responses (for example, stator winding temperatures or vibration signal spectral features).

2-9
Figure 2-4 shows an example of an auto-associative model used to monitor 81 stator-winding
slot temperatures of a generator. The first eight temperatures (in blue) are plotted along with the
corresponding auto-associative estimates (in red). The temperature signal in the upper left plot is
drifting by 5F (2.8C) over the length of the signal due to a simulated fault in the winding. The
model estimate indicates what the temperature readings should be based on the auto-associative
SBM. A clear deviation from the actual signal and the estimate is first evident when the drift has
only progressed to about 1 to 1.5F (0.6 to 0.8C). The deviation becomes greater over time,
indicating the presence of drifting temperature signal.

F = (C 9/5) + 32
Figure 2-4
Auto-Associative Modeling of Stator-Winding Temperatures
Four parallel sensors. The X-axis represents samples (measured once per minute). The Y-axis
represents temperature (in F). The top left figure shows the signal deviating from the estimate.
The three other signals have overlapping signal and estimate.
2.4 SmartStart Methodology
The SmartStart methodology assists the user to develop valuable, actionable, and accurate
equipment condition monitoring. SmartSignal delivers focused, robust applications that span
wide operating ranges and require minimal ongoing maintenance.

2-10
The SmartStart methodology emphasizes repeatability and completeness. Repeatability
minimizes rework as eCM spans different applications across a fleet of assets. The SmartStart
methodology consists of four phases:
1. Value analysis - Asset owners need to mitigate their most costly failures and problems.
Value analysis develops a list of valuable, actionable failures that, if detected early, will
substantially reduce an owners expenses and increase revenue. This is done by creating a
value pareto chart with failure modes prioritized by value, which takes into account severity
and frequency and ensures that the project focus is on high value opportunities. Thus, the
eCM solution will reduce expenses and increase revenue.
2. System analysis - The goal of system analysis is to break down complex equipment and
processes into manageable subsystems that can be modeled to the accuracy needed to detect
the failures identified by value analysis. To do this, engineers who implement eCM solutions
must understand their equipment. Analyzing equipment according to engineering principles
provides a base level of familiarity to build successful models. In addition, expert interviews
provide the information necessary to identify failure fingerprints that will be useful in
providing diagnostic advice to operators.
3. Data analysis - eCM models require historical data that explain normal equipment behavior.
The data should represent the complete operating range to provide a highly efficient model.
SmartSignals eCM WorkBench includes many tools to help visualize and extract normal
operating data.
4. eCM WorkBench application development - The analysis stages provide the decision
points necessary to build models and rules to detect early warning of failure. The eCM
WorkBench provides an efficient model and rule-building tool that allows users to test the
theories they developed while analyzing the system.
As illustrated in Figure 2-3, the results of each phase of the SmartSignal methodology help to
focus and refine the effort in subsequent phases. For example, identifying valuable actionable
failures in the value analysis helps to define which area of the plant needs to be analyzed. Only
the data associated with equipment models of interest would be considered. Using the SmartStart
process analysis methodology to reduce project scope through each stage, the application
engineer can confidently implement an eCM predictive monitoring system to provide valuable,
actionable advice for operators.

2-11

Figure 2-5
The SmartStart Methodology Process
Information is gathered from operating, finance, maintenance, and engineering. A value analysis
reveals the most valuable faults to catch. A system analysis identifies which signals and systems
can be modified. The data analysis proves which faults can be seen with early warning and which
financial savings can be achieved.
2.3.1 Value Analysis
A value analysis is the first step of the SmartStart methodology process. The end result of value
analysis is the value pareto chart. The value pareto chart lists valuable, actionable fault modes
that, if detected early with eCM technology, will quantifiably improve financial and operational
results. Constructing the value pareto chart requires three steps.

2-12
1. First, identify the type and frequency of failure modes for a given piece of equipment from
historical reliability data.
2. Next, calculate the value of mitigating each failure mode, multiply by its frequency, and
order the failure modes by value.
3. Finally, since the efficacy of eCM is limited by sensor availability, drop the failure modes
that existing sensors cannot detect. It is also considered that some failure modes are unable to
provide early warning before failure (such as lightning strike) and are disregarded.
Value calculations must include not only readily apparent charges but also hidden costs such as
lost production. The early warning value hierarchy (Figure 2-6) provides a framework for
calculating all the value associated with identifying an impending failure.

Figure 2-6
Early Warning Value Hierarchy
Early warning can be broken into catastrophic failure or minor failure and deterioration. These can
be further broken into maintenance or operations effects and eventually to actual dollars.

2-13
Effective eCM implementations deliver value when they detect equipment failure and emerging
problems early enough for equipment operators to change their maintenance and operations
practices. Altering business processes increases operational revenue and decreases maintenance
expense. Early warning of failure and equipment condition monitoring achieves these
improvements through the following mechanisms:
Reduce the catastrophic failure rate - Recognizing imminent catastrophic failures in time
can avoid costly repairs and reduce collateral damage to other parts of the machine or nearby
equipment.
Reduce the minor failure rate and gradual deterioration - Detecting minor failures and
gradual loss of functionality can increase equipment efficiency and profitability.
Shift unplanned downtime to planned downtime - Early detection of a fault frequently
offers the choice to correct a problem during a regularly scheduled downtime or a more
desirable time or place than an unplanned event.
Extend the major overhaul interval - Interval extension is possible when operations has
confidence that the system can catch catastrophic problems early enough and maintenance
can become truly condition based with minimal risk.
Reduce the maintenance duration - Early warning technology reduces the preparation,
troubleshooting, and repair time required to complete maintenance activities on a piece of
equipment by focusing attention on the failing elements.
Achieve the operational excellence - In the best organizations, maintenance and operations
departments work together to achieve the maximum return on equipment investment.
Once the value of each failure mode is calculated, the value pareto chart can easily be created.
An example for a frequency pareto chart for a coal pulverizer is shown in Figure 2-7. This
incorporates information about the failure modes and also the frequency of occurrence,
completing Step 1 as described above. To determine the value pareto, multiply the frequency of
failure by the number of failures by the cost per failure to achieve a dollar cost, and rearrange by
priority (highest to lowest). Finally, those failure modes that could provide early warning
through eCM are identified. The final value pareto chart gives the priority list of failure modes to
identify, therefore also prioritizing equipment or processes that should be monitored to provide
the greatest financial benefit.

2-14

Figure 2-7
Frequency Pareto Chart of Pulverizer Failure Modes
Based on an EPRI report
1
, scaled on total failures sum to 100%. For example, shaft problems
occur more frequently than mill fires.
The value pareto chart guides the implementation. It also serves as the basis for return on
investment (ROI) projections during the project approval process. The value pareto chart drives
creation of the models. It focuses the application engineer on building models to detect early
warning of failures with the highest value.
2.3.2 System Analysis
The next step of the SmartSignal methodology is system analysis. In system analysis, the
application engineer divides large systems and processes into smaller components that can be
effectively modeled and determines how to use the output of these models to define and
annunciate failure modes. Since eCM technology works most effectively when analyzing sensors
that have strong deterministic relationships, this technique enables excellent modeling of
extremely complex systems.

1
Derdiger, J. A., Bhatt, K. M., and Siegfriedt, W. E. Component Failure and Repair Data for Coal-Fired Power
Units, Coal Mill Application, pp, 226. EPRI, Palo Alto, CA: Oct. 1981. AP-2071.


2-15
System analysis provides three deliverables:
1. Process decomposition - Block diagrams that show how to divide equipment and processes
into easily modeled components.
2. Process behavior analysis - Categorization of the operation into distinct modes and sensors
into independent random variables, independent control variables, and dependent variables to
guide modeling technology choices.
3. Fingerprint charts - Table that links failure modes with expected residual patterns. Since
each failure mode has a unique, identifying combination of residuals, SmartSignal calls the
table that relates failure modes to residuals the fingerprint chart.

Figure 2-8
Process Decomposition
The user defines the primary step(s) involved to achieve the primary equipment goal(s) and any
auxiliary systems to support the primary steps.
2.3.2.1 Process Decomposition
Process decomposition defines the overall process goal and the inputs and outputs of energy,
mass, and momentum. The process is broken down into primary and auxiliary stages. The raw
inputs flow through the primary stages to create the final product, while auxiliary stages provide
support for the primary stages. Around each stage, the engineer defines a control volume

2-16
bounded by the laws of conservation of mass, momentum, and energy. Within each stage, the
engineer identifies the principal inputs, products, mass, and energy flows, and the associated
sensors.
Operating on the primary and auxiliary stages, the composition process continues recursively
until each of the existing sensors are associated with each stage. In the process decomposition,
gaps in sensor measurements necessary to effectively model a primary or auxiliary stage are
identified. Sometimes, sensors are too expensive, or a sensor interferes with correct functioning
of the process. When this occurs, proxy variables can account for key missing sensor
measurements. Proxy variables substitute for the value of the missing sensors and correlate
strongly with the key variable of interest.
2.3.2.2 Process Behavior Analysis
Process behavior analysis strives to understand process dynamics. By understanding such things
as which sensors measure the primary inputs or independent variables, and which sensors
measure the dependent variables, the application engineer can configure many of the eCM
modeling features such as modes, adaptation, and model-style.
Commercial equipment rarely runs in one operational mode. Process plants commonly move
through startup, part-load, and shutdown conditions as their normal cycle. Frequently, the
available historical data cannot represent the full range of operating conditions for a given piece
of equipment. For example, if only winter data were used when the model was created, the
ambient temperature in the summer can represent a whole new operating state. In these cases, the
eCM model must recognize when a new process state has been reached and adapt its model
accordingly. The difficulty, of course, is distinguishing between a developing fault condition and
a new process state. SmartSignal eCM incorporates many strategies to ensure that the system
does not mistake a fault condition for a new operating condition. Correctly classifying the model
sensors into the appropriate variable types is crucial to successful runtime adaptation.
Independent variables are external and represent input into the system. Sometimes, they can have
no direct correlation to each other and can assume any value within their allowable range.
Independent variables break down into control variables and random variables. A control
variable typically responds to a set point on an automatic controller.
Dependent variables are system outputs. Note that in some cases variables can be dependent in
one stage and independent in another. The physical laws governing the process and the state of
the independent variables define the dependent variables.
Once the types of variables that a model contains are understood, developing adaptation
strategies is much simpler. For example, imagine a process model that runs very accurately
throughout winter and spring and begins to falter in the summer. By comparing the range of the
ambient pressure and temperature used to train the model to the current ambient conditions, it
should quickly become apparent that the equipment has entered a new operating regime and the
models must be augmented. In addition to adaptation strategies, understanding variable types can
help the user choose the type of eCM model best suited for the application.

2-17
SmartSignal eCM employs two distinct model types: auto-associative and inferential. Auto-
associative models generate an estimate for every independent and dependent input signal as a
function of every sensor whether it is independent or dependent. While auto-associative models
do not require a distinction between independent and dependent variables, variable groupings
require strong sensor relationships. When key independent variables are unavailable from sensor
measurements, auto-associative models provide the best results. Inferential models use measured
independent sensors to generate the complex set of estimates for the independent and dependent
variables. If the application engineer confidently accounts for all the independent sensors and
uses high quality data, then inferential models can provide very accurate results.
2.3.2.3 Fingerprint Charts
SmartSignal models generate alerts when the residual value (the difference between the
measured and estimated signal value) is statistically significant, that is, varies significantly from
zero. Different failure modes will result in unique patterns of shifting residuals and alert events.
If the actual value of a signal is greater than (less than) the estimate, then the residual value is
positive (negative). Information captured in a fingerprint chart could help to troubleshoot
problems based on residual patterns. For example, an increasing positive residual in a
temperature sensor on a bearing could indicate overheating due to excessive rubbing. However, a
high residual in a temperature sensor combined with a low residual in lube oil flow could
indicate a problem with the lube oil pump.
Information that is captured in a fingerprint chart can be incorporated into the diagnostic portion
of the eCM software to pass the information to the analyst. Expected residual patterns can be
used to define eCM rules that generate an eCM incident. The SmartSignal rule engine interprets
which residual shifts and alerts are significant enough to notify the operator of an incident and
provide a preliminary diagnosis. Operators are notified of the incident through the eCM
WatchList, which displays incidents that might require action to prevent a specific failure mode
from occurring. The process in which alerts escalate to incidents virtually eliminates nuisance
and false alarms from appearing on the WatchList.
Table 2-1 shows how a fingerprint chart relates failure modes to incidents in the pulverizer.
Developing fingerprint charts requires expert interviews to complement analysis of the
engineering data and drawings. In expert interviews, the people who have expert knowledge of,
and experience with, the equipment are consulted for how the equipment operates and how it
fails.

2-18
Table 2-1
Fingerprint Chart for Baldwin Unit 3 Pulverizer 3A
OSI PI
TM
Tag
Name Description Units
Grinding
Problems
Sensor
Plugging
BAQ1331 Opacity PCT
BYC5109 Cold air damper demand PCT
BYC5115 Hot air damper demand PCT
BYF2085I Coal flow KLBH
BYF2145I Air flow KLBH
BYI1091 Amps AMPS +
BYP1072 Air differential pressure INWC
BYP1134 Bowl differential pressure INWC + / - +
BYP1147 Base pressure INWC -
BYS5097 Feeder speed demand PCT
BYT1145 Inlet air temperature DEGF
BYT1515 Fuel air temperature DEGF
BYZ1109 Cold air damper driver position PCT
BYZ1115 Hot air damper driver position PCT
FDRASPD Feeder A speed PCT
Notes: PCT = percent
KLBH = kilopounds per hour (1 lb = 0.45 kg)
AMPS = amperes
INWC = inches of water column (1 in. = 2.54 cm)
DEGF = F = (C 9/5) + 32
Process decomposition and behavior analysis provide the application engineer with sufficient
background to interview an expert technician, operator, or engineer to determine how the likely
failure modes would manifest themselves in terms of the process variable shifts. During the
expert interview, the application engineer seeks to translate the experts internalized
troubleshooting process and operating rules of thumb into the fingerprint chart format so that the
rules can be programmed after the models are built.

2-19
2.3.3 Data Analysis
After system analysis has identified which models are best suited to detect crucial failure modes,
data analysis identifies and prepares predefined normal data for building eCM models. To build
models that provide early warning of failure with minimal false alerts, application engineers
require reference data that represent normal or consistent states of the process or equipment. Raw
data can consist of time stamped sensor readings over a period of days, weeks, or months,
depending on the cycle time of the process.
SmartSignal eCM includes a number of tools to help identify and capture normal data. The use
of the four features described below helps prepare reference data that will result in models that
provide early warning of failure:
1. The application engineer can use filtering tools to eliminate abnormal data spikes and
compressed data. For example, self-calibrating instruments can spike through the high and
low ranges at regular intervals and interrupt otherwise normal data. The filter tools remove
data that exceed a fixed number of standard deviations on either side of the average, that lie
outside some threshold values, or that drop out into non-numeric values. Some data
historians compress data into flat signals or piecewise linear blocks that reduce the data
fidelity. The filter tool can automatically delete these sections if the application engineer
believes they obscure the data.
2. The application engineer uses graphing tools to ensure that data represent normal operation.
Time series graphs plot each sensor value against time. A selection tool provides a
mechanism to remove blocks of data that are not normal based on visual inspection of the
trends.
3. The WorkBench application or software also includes correlation tools to help ensure that the
variable grouping produced during process decomposition did not miss any key relationships.
The Pearson correlation tool calculates the Pearson correlation coefficient of every variable
against every other variable over the entire time series.
4. Using a wizard, an application engineer can define rules that sort incoming data into one or
more distinct operating modes. Data grouped by modes are often easier to model. For a
power generation combustion turbine, the full load-operating operating mode could include
data only when the power output exceeds 100 MW. In another example, full load power is
defined as greater than 90% maximum load; part load power is 30 to 90% power; and power
less than 30% is unit off.
2.3.4 eCM WorkBench Application Development
Value analysis, system analysis, and data analysis provide the sensor groupings, the raw data,
and the background for building and testing models and rules. Using this information, the
application engineer uses eCM WorkBench to build models based on normal data obtained
during the data analysis step.

2-20
The application engineer builds the initial models and rules in eCM WorkBench and tests the
output to determine whether the variable groupings, the dependent versus independent, and
inferential versus auto-associative model choices accurately represent the process.
2.3.4.1 eCM Model Testing
With the initial models in hand, the application engineer uses eCM Workbench model testing
tools to determine whether the models will enable early warning of failure with minimal false
alerts. The first test tool runs the model over a set of test data. WorkBench provides time series
plots of the residuals for all the sensors and displays indications of alerts and incidents based on
the rules. If the initial model does not achieve the desired accuracy, the application engineer
should double check that the reference data represented normal operation. The application
engineer can consider adding or deleting variables from the model or changing the model type.
The application engineer can use the simulated disturbance tool to determine whether the model
responds to changes as expected. To aid in the model troubleshooting process, eCM WorkBench
includes a tool to add a gradual drift, to add a step change, or to add a constant to one, some, or
all of the sensors in the model. The simulated disturbance tool provides a good mechanism for
determining abilities and limitations of a model to detect signal deviations. For example, the
application engineer can test if a 5F (2.8C) temperature shift of an input variable produces a
statistically significant residual. The engineer can test the amount of deviation that will be
annunciated by eCM, which can be linked to how much early warning a model can provide.
Refining eCM models is typically an iterative process. An application engineer can tune the
accuracy of a model by a number of different methods. Examples include increasing the amount
of reference data, adding or deleting sensors, attempting different model types, employing
adaptation strategies, changing run-time parameters, and so on.
Once the application engineer is satisfied with the new models fidelity, the next step is selecting
the algorithms and sensitivities that will be used to analyze residual signals and, in turn, generate
alerts. The key consideration is that the model is sufficiently accurate, and the alert logic
sufficiently sensitive, to provide early warning of failures defined in the value pareto chart .
2.3.4.2 Rule Testing
Process behavior analysis and the fingerprint chart development lay the groundwork for incident
rules. The application engineer uses the WorkBench rule editor to translate the fingerprint chart
into rules that interpret the residual signals and alert events to generate incidents that will appear
on the WatchList. During the model testing process, the application engineer also checks that the
rules operate as expected. The simulated disturbance tool provides a good method to vary
sensors in a controlled manner and investigate whether the rules operate according to the design.
SmartStart methodology was used to develop the pulverizer model philosophy. This philosophy
was to detect grinding problems caused by roller journal bearings seizing and insufficient
fineness of coal leaving the pulverizer. Also, this philosophy included the early detection of
motor problems relating coal grind rate to current draw and motor vibration. In the value

2-21
analysis, the value drivers were determined to be roller bearing outage interval extension, sensor
plugging duration reduction, and motor problems shifted from unplanned to planned outages.
The system analysis broke the equipment and process into easily developed models. Fingerprint
charts were developed to capture residual patterns, and so they can be incorporated into eCM
incident rules, which will generate eCM incidents to the WatchList. In data analysis, the raw data
from time stamped sensor readings are prepared for building eCM models. Tools with the eCM
software are applied to filter the data to eliminate abnormal data spikes. Once the sensors were
grouped, the initial models were built and tested. During the iterative process of refining and
testing the eCM models that were built, it was realized that motor failure bearing and lubrication
temperatures did not correlate with the other process variables to predict grinding problems.
These sensors were removed from the model.
The eCM models ran with 15 sensors for about six months. In the six-month project review, the
determination was made that the modeling was capable of predicting some failure modes and
that significantly more failure modes could be detected if vibration sensor data were applied to
the modeling. Secondary models were developed including the vibration sensor utilizing wireless
technology to transmit the signal. The project is still in the iterative stage of model testing. The
preliminary model rules utilizing the vibration sensor are being monitored for their capability to
predict failure. As more experience is gained the eCM rules will be modified to enhance failure
detection.

3-1
3
MERGING ECM WITH WIRELESS VIBRATION
TECHNOLOGY
The SmartSignal eCM technology was applied to process variables in a coal pulverizer, creating
models for equipment condition monitoring. To provide more comprehensive predictive
condition monitoring system for the pulverizers, eCM was then merged with wireless vibration
technology
3.1 Pulverizer Value Analysis
The pulverizer is a critical asset that serves two main purposes:
The pulverizer reduces large chunks of coal into particles suited for combustion.
The pulverizers provide contact between the coal and hot air to dry out the coal.
Coal is delivered to the plant at a 1.5 to 2.0 in. (38.1 to 50.8 mm) size and is reduced to 0.75 in.
(19.1 mm) top size in a coal conditioner. The 0.75 in. (19.1 mm) coal enters the pulverizer with
hot air and is reduced to the consistency of face powder. The output of the pulverizer is a two-
phase mixture of hot air transporting pulverized coal to the (boiler) burners.
3.1.1 Description of Pulverizer Function
In a pulverizer, raw coal is moved over a grinding ring by centrifugal force. Coal is passed under
spring or hydraulically loaded rollers. It is pulverized by a combination of rolling, crushing, and
attrition. Partially ground coal passes over the edge of a rotating bowl and is entrained in the
rising hot air stream, flash dried, and carried upward toward a classifier. The larger coal particles
are thrown out, or dropped out, of the stream to fall back into the bowl. The smaller particles and
fine material enter the classifier tangentially through a number of circumferentially located
openings. Externally adjusted vanes, located within the periphery of the classifier, impart a
spinning action to the coal/air mixture. The more spin imparted, the finer the product leaving the
pulverizer. Material that is oversized is rejected by the classifier and returned to the bowl for
further grinding. The fine material is carried out of the pulverizer by the air stream and into the
furnace for combustion. Approximately 75 to 80 % of the classifier input is returned to the
pulverizer body where it mixes with the incoming raw coal. This circulation produces some pre-
drying of the raw coal and reduces the average particle surface moisture in the flash drying zone.
This enables the pulverizer to handle coal of varying moisture content without reduction of
pulverizer capacity or classification efficiency up to the limitation of the hot air supply. Foreign
materials in the coal fall through or spill over through an annulus around the rotating bowl and
are rejected from the lower housing of the pulverizer.

Merging eCM with Wireless Vibration Technology
3-2
Fine grinding of coal is necessary to ensure complete combustion of coal in the furnace for
maximum boiler efficiency. However, coal can be ground too finely, resulting in the use of
unnecessary amperage (or power). Also, the coal could not be ground finely enough, which
could result in boiler plugging, coal pipe plugging, and/or carbon carryover or delayed ignition
due to incomplete combustion. The coarser the coal is ground without plugging, the greater the
efficiency of the pulverizer and the combustion process. Furthermore, the combustion process is
more efficient if the fineness increases with increasing burner elevations. This is true because of
the decreasing time for combustion as the elevations increase. Units where low nitrous oxide
burner nozzles with over-fire air systems are utilized are more sensitive to coal sizing for proper
combustion.
In many plants, environmental constraints and economics dictated the use of low sulfur Powder
River Basin (PRB) sub-bituminous coal instead of the substantially higher heat content of the
original bituminous coal required for plant design targets. The characteristics of PRB coal have
several ramifications on plant operations. Its lower heat or Btu content and high moisture content
requires that for the same amount of steam and power output, the plants boiler requires more
coal than the original plant design. This requirement also affects the sizing of the air heater and
other heat recovery sections of the furnace, which could result in not enough hot air being
available.
The temperature of the coal and air mixture from the pulverizer to the burner is important.
Generally, 155 to 160F (68.3 to 71.1C) is recommended as coal pipe temperature for high
moisture coals. Some plants that switched to PRB sub-bituminous coal are unable to reach this
temperature due to insufficient hot air being available from the air heater. As a consequence, this
puts a greater load on the coal pulverizers to keep up with coal demand. The lower heat content
coupled with excessive moisture could further limit pulverizer throughput exceeding the capacity
of the hot air used for drying in the pulverizer. The higher moisture content in the coal results in
additional load on pulverizer capacity to the extent that enough coal cannot be delivered to the
furnace to maintain full load.
Low coal pipe temperatures are common, and when coal gets wet in handling and storage, the
problems get worse. Low coal pipe temperature contributes to carbon carryover and upper
furnace slagging. For example, plants that historically operated on three coal pulverizers and
kept one pulverizer in reserve now require the fourth pulverizer to run in order to maintain power
output. The original design or pulverizer selection basis was one full spare with remaining
pulverizers operating at a 90% capacity level. This makes it more likely that any upset in a
pulverizer will reduce coal production to the point that a unit is forced to reduce power output.
The pulverizers have become a critical piece of plant equipment, and their operating availability
a capacity limiting constraint for the plant.
In addition to the lower Btu content, PRB coal is much softer than the coal the plant was
designed to burn. This has the positive effect of extending the useful life of the rollers in the
pulverizers. Historically, the rollers have been the most frequent cause of pulverizer failures, and
a plant could plan around certain number of operating hours before a roller would need to be
replaced. While the rollers were being replaced, the plant could perform other needed
maintenance during the down time.

3-3
Now because of the longer life of rollers, pulverizers are experiencing a greater frequency of
unexpected shutdowns due to other causes. Plant personnel have not as yet developed the tools
for early detection of these new failure modes. In fact, the relative scarcity of sensors in the
pulverizers and extremely harsh environment inside the pulverizers make this job very difficult
and one ideally suited for these new technologies.
3.1.2 Benefits of Early Warning of Pulverizer Failure
A SmartSignal eCM system could provide the key benefits of shifting unplanned repairs to
planned and also reducing the duration of repairs. The plant can then experience both
maintenance expense reduction and revenue improvement. The calculations in Table 3-1 show
how 12 hours of early warning of pulverizer failure provides annual benefits of $100,000 at a
600 MW unit such as Unit 3 of the Baldwin Energy Complex. Consider a roller journal bearing
failure that occurs on a Tuesday morning in July around 6:00 AM. The unit must be immediately
derated. The maintenance team must scrounge for replacement parts and scramble to repair the
problem with whatever maintenance crew is available. Consider the same failure with 12 hours
of early warning, annunciated on Monday at 6:00 PM. The plant could requisition parts from the
warehouse, schedule the proper craftsmen to do the repair on the night shift, and take the
derating during nonpeak power periods.

3-4
Table 3-1
Effect of 12 Hours of Early Warning of Pulverizer Failure
Expected Benefits Per Incident for a 600 MW Unit

Reduce Maintenance Expense
Reduce work-hours by optimizing logistics and scheduling
15 work-hours at $50/hour $ 750

Increase Revenue by Shifting Maintenance to Nonpeak Production
12 hours at 600 MW versus 12 hours at 510 MW $ 21,600

Total $ 22,350

Expected Annual Benefits for a 600 MW Unit

Mean Time Between Failure (Year) 0.5
Number of Mills per Units 6
Peak Fraction 37%
Annual Expected Value of 12 Hours Early Warning $ 97,938
One incident could save $22,000; yearly benefit for a plant is nearly $100,000.
3.2 Pulverizer System Analysis
The six Raymond Bowl pulverizers of Unit 3 at the Baldwin Energy Complex are CE-Raymond
Model 923 RP pulverizers. They use a three-roller system to produce pulverized coal suitable for
combustion. Each pulverizer is sized to grind 126,000 lb/hr (47,028.4 kg/hr) of Midwestern Sub-
bituminous coal with a Hardgrove Grindability of 56 to fineness such that 70% of a sample will
pass through a 200 mesh screen. The percentage on 50 mesh should not exceed 1.5% because
oversized coal will contribute to poor combustion, affecting nitrous oxide output, slag, and high
carbon carryover. As discussed earlier, the actual capacities are affected by the coal moisture and
grindability.

3-5
3.2.1 Coal Pulverizer eCM Models with Original Process Variable Sensors
During the SmartSignal eCM implementation kickoff meeting, Dynegy Midwest Generation
(DMG) pulverizer specialists explained the key failure modes experienced at the Baldwin Energy
Complex. Based on the sensors available, the joint SmartSignal-Dynegy team estimated that
SmartSignal eCM could provide early warning of failure modes that represent about 11% of
pulverizer breakdowns, primarily grinding element problems and motor problems. All of the
grinding element failure modes, and half of the motor failure modes, can be detected early using
the original process variable set.
The fingerprint chart in Table 2-1 lists the sensors used in each model and associates failure
modes with expected residual deviation patterns. Each failure mode is illustrated as having a
unique, identifying combination of residual patterns, which were the basis for the original
pulverizer model. Grinding problems have characteristically high amperage residuals and can
have high or low pulverizer bowl differential pressure residuals. Sensor plugging is characterized
as a high residual on bowl differential pressure and a low residual on base pressure. Figure 3-1
shows a schematic diagram of the pulverizer and the roles of the process variables.

3-6

Figure 3-1
Schematic of Coal Pulverizer
The goal of the designed model was to detect subtle shifts in current draw and/or bowl
differential pressure that would signal roller bearing failure, loss of grinding efficiency, or other
mechanical problems with the pulverizer that could impact the viability of that pulverizer and
possibly cause a derate of the unit. Detection of these problems hours or days in advance would
enable Baldwin personnel to perform any additional tests or maintenance during off-peak hours
and minimize the risk of losing generation capacity.
From the beginning, it was understood and accepted that the diagnostic capability of such a
model was limited by several factors. The quality of the pressure, flow, and temperature readings
was suspect given the harsh sensor environment of the pulverizer. As time went on, it became
clear that plugging of the pressure impulse lines resulted in a reading that was not reliable. The

3-7
ability to have confidence in subtle shifts in bowl differential pressure diminished, and each
incident had to be first reviewed as a possible line plug that needed purging. In fact, the majority
of the incidents detected by the SmartSignal eCM monitoring platform were acting as sensor
validation because they were, in fact, pressure tap line plugs that needed to be manually purged.
There was one incident that preceded a roller seizing by several days, but there were two
mechanical failures on the pulverizer that did not provide any warning.
The original sensors used in the model consisted of the first 15 signals shown in Table 3-2.
Temperature sensor data were available from the motor inboard and outboard bearings as well as
from the lubrication system. While bearing temperatures and lube system operation can provide
information to prevent motor and worm gear failures, they were not part of the primary coal
pulverizer system (see Figure 2-7 regarding primary versus auxiliary systems). These
temperature signals did not directly correlate to the process variables used in the initial coal
pulverizer model and do not contribute to predicting grinding problems or reduction of fineness
problems. In absence of vibration sensor information, motor bearing temperatures and
lubrication sensors operate independently of the system that predicts grinding efficiency or
mechanical problems, which were the primary goal of the model.

3-8
Table 3-2
Signal List for Enhanced Model
Tag OSI PI Tag Name Description Units
1 BAQ1331 Opacity PCT
2 BYC5109 Cold air damper demand PCT
3 BYC5115 Hot air damper demand PCT
4 BYF2085I Coal flow KLBH
5 BYF2145I Air flow KLBH
6 BYI1091 Amps AMPS
7 BYP1072 Air differential pressure INWC
8 BYP1134 Bowl differential pressure INWC
9 BYP1145 Base pressure INWC
10 BYS5097 Feeder speed demand PCT
11 BYT1145 Inlet air temperature DEGF
12 BYT1515 Fuel air temperature DEGF
13 BYZ1109 Cold air damper driver position PCT
14 BYZ1115 Hot air damper driver position PCT
15 FDRASPD Feeder A speed PCT
16 VIBPOINT-1 Motor outer bearing in./s
17 VIBPOINT-2 Motor inner bearing in./s
18 VIBPOINT-3 Worm drive inner bearing in./s
19 VIBPOINT-4 Worm drive outer bearing in./s
20 VIBPOINT-5 Vertical shaft lower bearing in./s
21 VIBPOINT-6 North roller vibration g
22 VIBPOINT-7 South roller vibration g
23 VIBPOINT-8 East roller vibration g
Notes: PCT = percent
KLBH = kilopounds per hour (1 lb = 0.45 kg)
AMPS = amperes
INWC = inches of water column (1 in. = 2.54 cm)
DEGF = F = (C 9/5) + 32

3-9
The key piece of information that was missing that could have helped detect these failures and
differentiate between sensor issues and mechanical faults was vibration information from the
bearings on the pulverizer and motor. The original model development for monitoring the
pulverizers was done in coordination with DMG experts and engineers on-site at the Baldwin
facility. With the scarcity in available sensors on the pulverizers, nearly all of the available
sensors were used to build a model capable of monitoring each pulverizer and its driving motor.
The pulverizer value drivers are:
Detecting grinding problems, such as roller journal bearing seizing and insufficient fineness,
to gain interval extension between pulverizer overhauls
Detecting motor problems relating coal grind rate to current and motor vibration to shift from
unplanned to planned maintenance
Detecting sensor plugging of the pressure differential signal to avoid operational impact and
unnecessary derate
Early warning on motor vibration problems cannot be diagnosed based only on the process
variables listed in Table 2-1.
3.2.2 Coal Pulverizer eCM Models with Added Vibration Sensors
DMG Engineering recognized the need to include mechanical vibration data along with the
available process parameters for the coal pulverizer model after the failure to detect a cracked
vertical shaft on one of the pulverizers. The original pulverizer design does not include vibration
instrumentation to support continuous monitoring. Although vibration data were routinely
collected and analyzed through the use of portable hand held instruments on a quarterly basis,
this provides only a snapshot view of current conditions and does not provide real-time
correlation with other process parameters or historical trends associated with dynamic operating
conditions.
The need for continuous vibration data on the pulverizer gearbox and roll journals is essential to
identifying key failure modes and degraded performance associated with items such as excessive
roll clearances or unequal loading of the rolls. One coal pulverizer was targeted for a pilot study
in a tailored collaboration with EPRI to evaluate the use of wireless vibration technology.
Figure 3-2 is a breakdown of the failure modes identified in Figure 2-7, demonstrating the
proportion of each failure mode that can be detected with early warning for various model
configurations. For example, for shaft problems (which make up 18% of all pulverizer failures),
only a small amount of shaft problems can be detected by vibration signals alone, and none by
the process variables alone, but nearly half of shaft problems can be detected with eCM models
that incorporate both vibration and process variables. Therefore, eCM models that combine the
two signal types are much more capable of providing early warning of failures than models made
by either signal type. The sum total amount of failure modes detectable by vibration signals
alone is 7%, the total by (original) process variables alone is 11%, and the total failure modes
detectable combining vibration signals and process variables is 46%.

3-10

Figure 3-2
Frequency of Pulverizer Failure Modes: Breakdown by Available Signals
A review of the project after six months concluded that while the current approach had promise,
significantly more failure modes could be detected if additional sensor data were available and
could be used in the model, particularly vibration sensors. At this point, it was decided to utilize
a wireless vibration network provided by 3e Technologies, Inc. (3eTI) to continuously monitor
vibration on key pulverizer components. Table 3-2 illustrates the vibration sensors (Tags #16-23)
that were added to the pulverizer and drive motor. After the eight wireless vibration sensors were
installed, SmartSignal developed a secondary pulverizer model that was the original model plus
the eight additional sensors.
The monitoring project began on 5/01 and has been collecting data at five-minute intervals ever
since. The analysis that follows is on data that were collected between 5/16 at 9:00 AM and
05/18 at 9:00 AM. The modeling used data collected between 05/01 and 05/13 as a reference
during periods of indicated stable behavior. For the next month, the SmartSignal model
monitored the performance of the pulverizers, but with the exception of a temporary increase in
roller vibration and an increase in motor current in all the pulverizers, there were no mechanical
incidents with the pulverizer.

3-11
3.3 The Wireless Vibration Network
A cost-effective solution with a short implementation schedule was needed to fit the timeline of
the SmartSignal pilot project. DMG Engineering evaluated the use of contemporary wireless
technologies for transmitting vibration information to their data archive/historian software.
Research of the various wireless technologies available included Bluetooth, IEEE Standard
802.11b, and 900 MHz systems. Following the evaluation of several commercial systems, DMG
selected the IEEE 802.11b wireless standards that indicated better signal strength and range
within a power plant environment, as well as providing nearly real-time data transfer capabilities.

Figure 3-3
Data Flow from Wireless Vibration Network
The application of wireless vibration network and sensors involved adding:
Vibration sensors from Wilcoxon Research
Data collecting sensors (Wireless I/O Node) from 3eTechnologies, Inc. (3eTI)
Wireless technology (transmits data from a parabolic antenna) from 3eTI
Wireless Access Point system receiver 3eTI
Wireless Gateway (forwards data to plant OSI PI historian) from 3eTI
SmartSignal eCM (retrieves data from plant historian and performs analysis)
DMG Engineering selected the 3eTIs network capable application processor (NCAP) system
that operates at 2.4 GHz with a 100 mW signal having a range of up to 300 ft (91.44 m).
Wilcoxon 786A general purpose accelerometers were hard wired via armored cable to the eight-
channel NCAP transmitter that provides both power and signal conditioning for the sensors.
Vibration accelerometers were installed on each of the three-roll journal trunion shafts, inboard
and outboard worm bearings, lower vertical shaft bearing, and the motor inboard and outboard
bearings utilizing an epoxy/pad mount (Figure 3-4). The Access Point wireless system receiver
utilizes an ethernet connection with the plants local area network (LAN), where a dedicated

3-12
desktop computer receives the data and provides an interface with the plant OSIsoft PI Data
Archive server. DMG utilized installation services of the wireless system by 3eTi, including a
signal strength survey to determine the optimum location for the Access Point and configuration
of the NCAP transmitter.

Figure 3-4
Roller Bearing Vibration Sensor Installation
The NCAP transmitter was mounted on a structural I-beam (Figure 3-5) within a few feet of the
pulverizer, and the Access Point was mounted approximately 270 ft (82.30 m) away in a
maintenance shop with a nearby ethernet connection (Figure 3-6). The eight channels within the
NCAP were individually configured to provide proper signal conditioning, data sampling rates,
units of measure, and frequency range for the application. The NCAP was configured to provide
an update of vibration magnitudes at 30-second intervals in support of the 1-minute scanning
frequency of the data archive program. The eight inputs to the NCAP were installed with the
capability to install a portable vibration analyzer/data collector to obtain additional diagnostic
data if needed.

3-13

Figure 3-5
NCAP Transmitter Installation

Figure 3-6
Antenna and Access Point Installation
4-1
4
RESULTS
This section is divided into presenting and discussing the results from the original model
configuration (Case A) with process variables and from the enhanced configuration with process
variables and eight vibration signals (Case B).
4.1 Case A Results: Models on Initial Process Variables
The initial eCM model was built on data available from the Baldwin plant data historian (OSI PI
system). The data were extracted from 5/1/02 through 5/13/02. Test data for model testing were
collected from 5/1/02 through 5/24/02. Incident rules were designed to trigger incidents for
grinding problems and sensor plugging. These rules were based on patterns of deviations
indicated in the fingerprint chart (Figure 3-2) where a grinding problem is identified by an
increase in pulverizer amps and a significant increase or decrease in bowl differential pressure,
and sensor line plugging is identified by an increase in bowl differential pressure while there is a
change in base pressure.
Prior to the start of eCM monitoring, the rolls on Pulverizer 3A needed adjustment. Operators
had observed deterioration in coal fineness and heard noise coming from the rolls contacting the
bowl. The rolls were adjusted on 10/25/02.
Monitoring of Baldwin Unit 3 Pulverizer 3A began on 11/02. Data were received from a live
feed from the plant historian at 5-minute intervals and processed by the eCM Run-Time Engine
in real time. The modeling results are stored in the eCM database and are viewable through the
eCM WatchList Manager. On 11/22/02, eCM began annunciating incidents on the WatchList.
Significant residuals were registering on Pulverizer 3A motor current draw; at the same time
there were high residuals on bowl differential pressure. These abnormal conditions persisted for
7.5 hr before readings returned to normal. Figure 4-1 shows the bowl differential pressure for the
period the 11/22 to 11/25/02.

Results
4-2

Figure 4-1
Bowl Differential Pressure: 11/22/02 to 11/25/02
The top chart shows the actual values (dark) and estimates (light). The bottom chart shows the residuals.
The Y-axis is pressure (actual/estimate range 0 to 10, residual range -6 to 3) in units of INWC. The X-axis
is the sample number (range 0 to 4300). The X marks at the top of lower figure indicate alerts, and the
black diamonds indicate incidents.

Results
4-3

Figure 4-2
Current: 11/22/02 to 11/25/02
The top chart shows the actual values (dark) and estimates (light). The bottom chart shows the
residuals. The Y-axis is current (actual/estimate range 0 to 110, residual range -80 to 20) in
amps. The X-axis is the sample number (range 0 to 4300). The X marks at the top of lower
figure indicate alerts, and the black diamonds indicate incidents.
Figures 4-1 and 4-2 are images from the eCM WatchList Manager sensor views for the bowl
differential pressure and current, respectively. In the bottom chart of Figure 4-1, high residuals
are visible on bowl differential pressure between samples 1000 and 1400. Alerts begin around
sample 1000, and the persistence of alerts triggers incidents beginning around sample 1200.
Similarly, the bottom chart of Figure 4-2 indicates a high residual on pulverizer amps with
subsequent alerts and incidents. For the next few days following this abnormal period, the signals
returned to normal with some occasional alerts on differential pressure (occurring on Saturday
and Sunday). This is visible in Figure 4-1 around samples 2400, 3800, and 4000. No immediate
action was taken based on the intermittent nature of the subsequent alerts.
In the investigation of the abnormal conditions on Pulverizer 3A, there were no significant
deviations found in any of the other five pulverizers during the same time period. This indicated
that a coal change or process change was not a likely cause of abnormal deviations. Potential
roller bearing failure diagnosis was not verified because signals returned to normal.

Results
4-4
On Monday, 11/24/02, during routine walk-around monitoring, the operator heard noise coming
from Pulverizer 3A. The pulverizer was taken out of service, and an internal inspection was
conducted. The in-place inspection of the east roller revealed that the roller was not turning and
the dust seal was leaking oil. The roller was replaced with an overhauled roll, the spring preload
was adjusted, and the mill was returned to service.

Figure 4-3
Bowl dP (L) and Current (R): 12/6/02 to 12/10/02
The Y range on bowl dP is 5 to 9 (actual) and 0 to 2 (residual) units of INWC. The Y range on
current is 73 to 93 (actual) and -4 to 4 (residual) units of amps. The X range has 5700 samples.
On 12/6 and 12/8/02, slight positive residuals were seen in the Pulverizer 3A bowl differential
pressure and an increase in residuals on pulverizer motor amps (see Figure 4-3). The operator
investigating Pulverizer 3A provided a diagnosis that there was likely a motor rub, audible to the
operator again during walk-around monitoring. An outside contractor, who was called in to
investigate the incident, further identified the incident as an eccentricity problem on 12/10/02.
The problem was determined to not be severe enough to require repair at that time.
On 12/16/02 the vertical shaft (from the gear drive to the bowl) broke. Determination was made
that roll tension might not have been tight enough. The pulverizer was subsequently overhauled.
The overhaul included replacement of the vertical shaft and the worm gear, and all three rolls
were removed and replaced with overhauled units.
During the pulverizer system analysis (see Section 3.2), we discussed how accurately predicting
grinding problems was hindered due to frequent sensor line plugging. An example of sensor line
plugging was seen shortly after Pulverizer 3A was returned to service on 1/23/03 from the

Results
4-5
overhaul. Figure 4-4 shows the base pressure and bowl differential pressure for 1/16/03 to
1/25/03. High residuals were seen on bowl differential pressure, and a change in base pressure
was observed. The signal characteristics of bowl differential pressure and base pressure changed
significantly over the course of 10 days from 1/16 through 1/25/03.

Figure 4-4
Base Pressure (L) and Bowl Differential Pressure (R): 1/16/03 to 1/25/03
The Y range on base press is 20 to 27 (actual) and -2 to 0.5 (residual) units of INWC. The Y
range on bowl dP is 4 to 10 (actual) and -1.5 to 1.5 (residual) units of INWC. The X range has
11,000 samples.
Note that in Figure 4-3 the range of the noise (signal variation) on the bowl differential pressure
increased from about 0.25 to nearly 2 INWC. The noise on the base pressure signal decreased
from 5 to 0.5 INWC. The diagnosis in this incident was probable pressure sensing line plugging.
The sensing lines were manually purged.
4.2 Case B Results: Models with Vibration and Process Variables
The wireless vibration sensors system was installed on Pulverizer 3A in the end of 4/03. A new
model was developed for Pulverizer 3A, and live data began flowing to the eCM run-time engine
with results viewable in the WatchList Manager on 5/1/03.
The model continued to run without reporting any system incidents. There were two issues with
the data quality of the wireless sensor system that have hindered full utilization of the vibration
sensors. The first was a vibration sensor problem with the east roller vibration reading
inaccurately high, which was fixed in mid-July. The second problem was due to interference

Results
4-6
between the wireless transmitter and receiver. The result was periods of flat readings from the
sensors that are not useable as reference data and reduce the reliability of the diagnostic logic.
Both of these issues are discussed below.
The wireless monitoring models were rebuilt in mid-August removing all data prior to the south
roller vibration sensor being repaired. Additionally, the data were manually filtered to remove
the periods of lost signals. This model is currently up and processing data. But, since then, there
have not been any mechanical failures with the pulverizer.
Figures 4-5 and 4-6 illustrate vibration data received from 5/1/03 through 7/1/03. Most vibration
levels are within about 0.2 in./s (5.08 mm/s) or 1 g. The period in the middle of the figures
(samples 650010,500) represents a time when the unit was out of service. The east roller
(VIBPOINT-8) saw an elevated vibration magnitude reading from 5/1 through 6/11

as a result of
a sensor problem. The signal was inaccurately registering a value between 10 and 20 g. Note that
even with one sensor failing by reporting (erroneous) readings too large by an order of
magnitude, the model demonstrates robustness in maintaining accuracy in the remaining sensor
estimates within a threshold of 0.1 in/s (2.54 mm/s) and 0.1 g.

Results
4-7

Figure 4-5
Base Pressure (L) and Bowl Differential Pressure (R): 1/16/03 to 1/25/03
In the figure, the dark line (behind) is the actual value. The overlying light line (on top) is the
model estimate. The red X indicates any samples with alerts. The X range is from 0 to almost
88,000. The Y range is approximately 0 to 0.4 in./s (0 to 10.16 mm/s).

Results
4-8

Figure 4-6
WatchList Results: VIBPOINT 5-8, 05/017/1/03
The X range is from 0 to about 88,000. The Y range on VIBPOINT-5 is 0 to 0.6 in./s (0 to
15.24 mm/s), on VIBPOINT-6 is 0 to 1.8 g, on VIBPOINT-7 is 0 to nearly 2.8 g, and on
VIBPOINT-8 is 0 to 35 g.

Results
4-9
Figures 4-7 and 4-8 illustrate vibration data from 6/12/03 through 8/27/03 for the same vibration
signals. Every sensor had a significant number of dropouts and lost signals and these are most
clearly visible in the signals VIBPOINT-5 and VIBPOINT-7 of Figure 4-8. Signal loss hinders
the ability to diagnose failures. For example, consider the south roller vibration sensor
(VIBPOINT-7, third chart of Figure 4-8). Toward the end of this period, the analyst can see the
beginning of an increase in vibration magnitude. However, the signal was lost for the remainder
of the period shown, so clear diagnosis of a growing deviation is not possible.

Results
4-10

Figure 4-7
The X range is from 0 to about 22,000. The Y range is approximately 0 to 0.4 in./s (0 to 10.16
mm/s).

Results
4-11

Figure 4-8
The X range is from 0 to about 22,000. The Y range on VIBPOINT-5 is 0 to 0.6 in./s (0 to
15.24 mm/s). The Y range tics on others are 1 g apart.

Results
4-12
Individually, process variables and vibration signals provide limited information about plant
operation and enable engineers and operators to assess plant health and plan accordingly.
However, there are a lot of failure modes that are not clearly, if at all, identifiable in either of
these sensor classes. The strength of building one model that looks at the behavior of both sensor
classes is that vibration anomalies can be referenced against process changes (and vice versa) to
enable a much higher degree of confidence in making a critical decision.
These vibration patterns seen could be differences in roll clearance. As this is a new observation,
there is a need to gain confidence before calling for the shutdown of this pulverizer for
maintenance. This pulverizer is being monitored closely to determine if these vibration spikes
will trigger an incident indicating a trend to failure.
Prior to this experiment, Pulverizer 3A returned to service from overhaul on 1/23/03; therefore,
the tests were performed on a newly overhauled machine. Since that date, the unit has not
experienced an extensive amount of run hours. Also, since the addition of vibration sensors to
the system, there has not been a significant amount of reliable signal data on the system, due in
part to frequent signal loss, weak signals, and sensor plugging. Moving forward, engineering
interest lies in monitoring performance as run hours increase, as well as the potential for failure.
Sufficient data on the system have not yet been acquired to fully validate the incident rules.
Recently (after the latest results shown), the antenna system was changed to a different model.
This resulted in some signal improvement. Differences in the vibration patterns among the three
rolls (with the north roll vibration signal as reference) have been routinely occurring, and spikes
in vibration amplitude are being observed. Local readings on Pulverizer 3A have been compared
with other pulverizers and show higher than average activity on Pulverizer 3A. Based on these
observations, Pulverizer 3A is being monitored closely because the current belief is that the
roller tension could need to be adjusted and that is the cause for the periodic increases in
vibrations.
Resolving signal reliability is the final step to gain confidence for detecting, alerting, and
classifying failures for actionable early warning of failure in the pulverizers using the vibration
signals with wireless technology. Based on observed trends when data are received, the value
proposition of achieving 12 hours of early warning for pulverizer failure is achievable.

5-1
5
CONCLUSIONS
5.1 Technology Shows Promise for Coal Pulverizers
Success was demonstrated for the SmartSignal technology and SmartStart methodology in
application to coal-fired plants. This has led to solutions for detecting, alerting, and classifying
failures for actionable early warning of failure in components such as boiler feed pumps and
recirculation valves, steam turbines, condenser efficiency, boilers, and precipitators. Knowledge
capture has been achieved in the implementation of rules that trigger incidents to the WatchList.
It was understood and accepted that the diagnostic capability of modeling a pulverizer could be
limited by several factors. The quality of the pressure, flow, and temperature readings was
suspect given the harsh sensor environment of the pulverizer. Plugging of the pressure impulse
lines resulted in readings that were not reliable. The ability to confidently diagnose subtle shifts
in bowl differential pressure was diminished because each incident had to be first reviewed as a
possible line plug that needed purging.
The majority of the initial incidents detected by SmartSignal eCM monitoring were in fact
pressure tap line plugs that needed to be manually purged. There was one incident that preceded
a roller seize by several days, but there were two mechanical failures on the pulverizer that did
not provide any warning because the necessary signals were not yet monitored.
The key piece of information that was missing and that could have helped detect these failures
and differentiate between sensor issues and mechanical faults was vibration information from the
bearings on the pulverizer and motor. Key points are that:
Only a small percentage of mill failure modes (10%) can be detected by monitoring process
variables and vibration.
A larger percentage of mill failure modes (46%) can be detected by monitoring process
variables and vibration data.
Project results so far have shown vibration magnitude data can be modeled and correlated
with process variables.
Figure 5-1 is a pareto chart that demonstrates the increased capability to sense failure with the
addition of the wireless network as compared to the original configuration (with 11% of failure
modes) and all possible failure modes. The addition of a vibration system increased the number
of catchable failure modes to 46% (see Section 3.2.2 and Figure 3-2 for the breakdown). This
chart demonstrates that SmartSignal monitoring, enhanced by using a wireless vibrations
network, enables the ability to catch nearly half of all failure modes before they occur.

Conclusions
5-2

Figure 5-1
Cumulative Failure Mode Pareto Chart of Catchable Failures
5.2 Wireless System Obstacles and Lessons Learned
There were two primary problems that were experienced from the onset following the 3eTI
wireless technology installation. First, an erroneously high vibration reading, on the order of ten
times higher, was being obtained from one of the pulverizer roll trunion shafts. A portable
vibration analyzer was utilized to compare signals from all three rolls locally with that observed
in the data archive program and confirm the problem.
Troubleshooting revealed a suspected sensor cable anomaly. The cable was replaced and the
signal was reduced considerably but still indicated a magnitude that was approximately double
the locally obtained reading. More in-depth troubleshooting performed by the plant
instrumentation and control (I&C) technicians revealed a missing ground screw on the channel
PC card. Replacement of the ground screw corrected the problem.
The second problem encountered was an unreliable wireless signal that transmitted
intermittently.
The NCAP transmitter was verified to be functioning properly, but the diagnostic log for the
Access Point revealed a weak signal. 3eTI provided DMG with a directional antenna to channel a

Conclusions
5-3
more concentrated signal for the Access Point. Although the new antenna did help reduce the
frequency and duration of signal loss, the problem was not completely remedied. DMG
encountered an increasing number of interruptions over the course of the next two months. 3eTI
mobilized an engineer to troubleshoot the system and optimize its performance. Troubleshooting
revealed a faulty Access Point, and a follow-up signal strength survey revealed the original
location of the Access Point had a marginal signal. The Access Point was replaced by 3eTI, and
its location was moved to a point approximately 40 ft (12.19 m) closer to the NCAP transmitter.
In addition, the flat directional antenna was replaced with a parabolic antenna to further focus the
signal from the NCAP.
5.3 Technology Works - Reliability of Signal Is an Issue
SmartStart methodology was used to develop the pulverizer model philosophy. This philosophy
was to detect grinding problems caused by roller journal bearings seizing and insufficient
fineness of coal leaving the pulverizer. This philosophy also included the early detection of
motor problems relating coal grind rate to current draw and motor vibration. In the value
analysis, the value drivers were determined to be roller bearing outage interval extension, sensor
plugging duration reduction, and motor problems shifted from unplanned to planned outages.
The system analysis split the equipment and process into easily developed models. Fingerprint
charts were developed to define residual patterns that will be developed into eCM rules that will
generate an eCM incident to the WatchList. In data analysis, the raw data from time-stamped
sensor readings were prepared for building eCM models. Tools with the eCM software were
applied to filter the data to eliminate abnormal data spikes. Once the sensors were grouped, the
initial models were built and tested. During the iterative process of refining and testing the built
eCM models, it was realized that motor failure bearing and lubrication temperatures did not
correlate with the other process variables to predict grinding problems. These sensors were
removed from the model. The eCM models ran with 15 sensors for about six months. In the six-
month project review, determination was made that the modeling was capable of predicting some
failure modes and that significantly more failure modes could be detected if vibration sensor data
were applied to the modeling.
Secondary models were developed, including the vibration sensor utilizing wireless technology
to transmit the signal. The project is still in the iterative stage of model testing. The preliminary
model rules utilizing the vibration sensor are being monitored for their capability to predict
failure. As more experience is gained, the eCM rules will be modified to enhance failure
detection.

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This agreement will be governed by the laws of the State of California as applied to transactions taking place entirely in California
between California residents.
8. INTEGRATION
You have read and understand this agreement, and acknowledge that it is the final, complete and exclusive agreement between you
and EPRI concerning its subject matter, superseding any prior related understanding or agreement. No waiver, variation or different
terms of this agreement will be enforceable against EPRI unless EPRI gives its prior written consent, signed by an officer of EPRI.

On-Line Predictive Condition Monitoring System For Coal Pulverizers

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On-Line Predictive Condition Monitoring System For Coal Pulverizers

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On-Line Predictive Condition Monitoring

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