Standardization And Generalization Approach On Equipment Monitoring Method As A Basis For Reliability Analysis Using Gauge Parameters And Kks Hirarchy Structure
1_Introduction + EAM Vocabulary + how to navigate in EAM.pdf
Automatic Condition Monitoring Method
1. STANDARDIZATION AND GENERALIZATION
APPROACH ON EQUIPMENT MONITORING
METHOD AS A BASIS FOR RELIABILITY ANALYSIS
USING GAUGE PARAMETERS AND KKS HIRARCHY
STRUCTURE
Dimas Kaharudin
Satrio Wahyudi
To improve the overall generating unit reliability, asset operator should have the right decision in terms maintenance. Therefore, reliability analysis, coupled with accurate information representing the condition of the emergence of units (Condition based maintenance) is needed, either in general or specifically.
Process of monitoring and collecting information about the latest condition of the equipment is called Equipment Monitoring.
The typical equipment monitoring methods tends to had many difficulties.
In general, the process of monitoring equipment is conventionally done by two methods, namely the manual method based on the data / records are obtained through a patrol check on a non critical equipment, and real-time method using a sensor that is connected directly to the display control room for the critical equipments. The reason why those equipments require realtime monitoring is because the function and condition of those equipments should always be monitored at all times so that the operator can immediately take action in case of warning / danger to the equipments.
The typical equipment monitoring methods tends to had many difficulties.
But that condition is not always true, the equipment that is monitored manually (non realtime) can be critical too. These equipments are monitored manually just because by nature, they are not possible to be monitored in real-time manner. For example, this is happen when compatibility between equipment and realtime sensor monitoring is low, or because of realtime sensor installation on the equipments is not feasible from engineering and financial standpoint.
Equipments that is considered as a critical but not realtimely monitored, has the potential to miss by the observation of asset operator. When combined with the fact that the amount of equipment that fall into this category is not few, it can leads to higher risk of fatal hidden failure. In fact, the management needs of such information as part of the decision-making. This will culminate in the maintenance to be less effective, and reduces the overall reliability. For this reason, it requires method of monitoring equipment for equipment not covered by the realtime system monitoring. This monitoring method must meet certain rules so that feasible to implement.
The first one is, to judge its condition, it needs many technical term and expertise. So it will be too technical.
Common equipment monitoring method tends to be too difficult to be understood for non technical person, for example, management team, which position here are as a decision maker,
Common solution for this problem is by using engineer as a bridge from technical perspective to management perspective.
Typically, this solution is OK. But it can leads to another problem, the first is
Highly depends on person & expertise
Information losses, subjective, time consuming
HUMAN : root of all error
SUBJECTIVE : like doctor, judging equipment condition can be subjective. One person may said its ok, and other may say it dangerous. It’s natural because of human influence and oppinion
EXPERTISE / COST : like doctor too, judging equipment condition needs expertise and experience. And those are not cheap. Especially if it is done by consultant or professional. So typical equipment condition monitoring by expert can be costly
LOYALITY : if equipment condition monitoring is not done by consultant, that is done by company employee, it doesn’t means that there is no problem about cost. That is still there. Train people so they can do an complex equipment monitoring is not simple and needs time. and not cheap. And highly trained employee sometimes got a problem with the loyality. And if they leave, you must train another person from scratch again and the process repeat
TOO MANY EQUIPMENT : if it is ok with problem 1-3, there is another latent problem that somewhat harder to solve. That is equipment number. In a typical power plant, equipment that needs to be monitored can be as high as 10 thousand item. Monitoring those number of equipments by human is absolutely not practical. Because it will be
TIME CONSUMING :
FIDELITY LOSS: and if it forced to be done by human, there is highly likelihood that in the process there is a fidelity losses.
FIDELITY LOSS : loss of information because of human processing, non digital process, different understanding, etc
To compensate some of this drawback, many company are invested in such a sophisticated & computerized device to monitor the equipment. This tools are called CEM
FAST
Still need an engineer & individual
Ideal form of equipment monitoroing
The typical equipment monitoring methods tends to had many difficulties.
The next problem is the complexity of the monitoring equipment. Because the amount of equipment and measurement parameters are numerous, so we need a method of monitoring equipment that is easier and less resource needed to do than conventional methods, both by strategic management as well as another such as the tactical engineer, operator, or technician. The issues on how to design and implement a method to solve the above problems are the topics to be discussed in this paper.
Can be used in all layer
NO INFORMATION LOSSES : from real world data to percentage, there must be such a complex processing. Despite that, the method must no compromise of information losses. It means, the process can be traced back so we still know where the percentage came from.
In order for a method of quantifying the condition of equipment can met those goals, there are several requirements that must be met. Among them are:
For going to that goal, we describe the requirement. That is :
Objective
Not all Health and Performance variables can be easily measured. There is a possibility that the variable is not quantified by the standard. For example are the smell, sound, color, turbidity, and etc. Quantify something that was not previously quantified could lead to differences of opinion in points of view. For that, it takes the method of assessment is objective. It means, whoever do quantification, the end result is relatively the same or have a relatively small deviation.
Factual
The value for the quantification of the Performance and Health should be based on facts that occurred in the field. Or in other words, is the result of observation and measurement, not on assumptions or estimates.
Quantitative
The facts that were used as a basis for condition quantification must be calculable. That means the fact must be measurable and quantifiable. Conversely, the fact that has qualitative nature should be avoided and converted into quantitative facts first before used, because qualitative facts have a tendency to hard to be processed.
Traceable
Stakeholder of equipment monitoring results is varied, ranging from technicians, operators, engineers to top management. Each consumer has the characteristics of different needs. Technicians need information that is detailed for tactical maneuver. Top management needs information in a general view and conclusive. The Engineer requires information that has both strategic and tactical nature. Methods of equipment monitoring and assessment should be able to meet all these needs. That is capable of displaying information in general view, but if necessary, can be traced to the fundamental and detailed information.
Automatable & Realtime
Assessment and quantification method should be programmable / computer friendly. It means the method could be programmed to produce realtime calculation. This is important because the ability of Engineer and the asset operator to monitor and quantify the properties manually without the help of automation is very limited, whereas the number of equipment to be monitored is vast.
Simple / mudah
The Method of quantification should be easy to learn and to implement. The simpler formulas and algorithms used, the shorter the time spent on knowledge transfer process
To overcome the complexity and the high efforts in monitoring equipment, process monitoring should be made more simple and uniform. Simplicity is done by making a particular variable which is sufficient to describe the properties of equipment in general or in detail, while Generalization is done by making a simple variable that has the same units for all the equipment so those variable become comparable. Therefore, the variable must be a quantitative variable. The variable to describe the performance and health of the equipment is designed as a positive real numbers, with the scale value of 0 ≤ x ≤ 100 and the unit of percent (%). By using these variables, judging health and performance of particular equipment is enough to just mentioning these variable in percent, without mentioning other technical variables such as corrosion, vibration, rpm, etc.
It means, that whether types of the equipment, it must
Percentage represent health & performance
For example: A motorcycle has declared 90% health and 10% performance. That means that bike is physically fine, but the function is not. Because motorcycles main output, that is performance, is not in a good condition. Notes that both the Health and the Performance are expressed in the same units of %. This led to comparing of that both variables are become easy and the idea behind that value is imaginable even with person without technical knowledge.
This is the goal
Kita bahas dulu yang pertama, yaitu gauge based monitoring
Gauge based monitoring adalah, menggunakan sebuah pengukuran / gauge sebagai basis perhitungan peta pembangkit untuk menghasilkan angka kondisi maupun performance
Apabila dalam satu peralatan terdapat lebih dari satu parameter ukur / gauge, maka gauge tersebut kita beri bobot sesuai dengan tingkat signifikansi gauge tersebut terhadap perfomance / kondisi peralatan yang sedang diukur
Contoh:
Pada motor, terdapat dua gauge yang berhubungan dengan kondisi / kesehatan
Vibrasi dan korosi. Karena vibrasi lebih signifikan mempengaruhi kondisi motor daripada korosi
Maka vibrasi diberi bobot lebih besar daripada korosi
Dengan menggunakan batasan-batasan tadi, maka kita bisa menentukan berapa nilai % dari peralatan yang dimaksud
In addition to weight, in each gauge is also defined its functional nature of the influence to the equipments. For example, if one gauge’s value shown in the broken indication and the equipment can not function, regardless of other gauge is still in good health, such a gauge is flagged as a mandatory. Otherwise, not mandatory. These properties are determined at this step.
LOOKS like that equipment monitoring using this method is more simpler & easy to understand than conventional complex equipment monitoring, but this is still distance from perfect. Because there is another problem facing
Selanjutnya kita akan membahas parent child relationship
The main function of KKS is for structure and identificate equipments. Because the KKS has been mature and commonly used in the power plant field on the world, the structure of the KKS is an attractive option to be used as the basis for monitoring equipment. Normally, KKS it self can not be used to monitor the equipment because there is no variable that states the equipment condition on the KKS system. To obtain this monitoring function, one or more variables must be added in the structure of the KKS. That variable is equipment condition.
The next stage after adding the equipment condition variable in the structure of the KKS, another variable must be added to represent a logical relationship between each equipment so those equipment will influences each other and not mutually exclusive in term of equipment condition. It means, equipment condition which is categorized as child will affect the condition of its parent equipment. This relationship is important to be defined because in the real world, the function of equipments is not independent but interrelated with one and another. Relations between the logic of this equipment have been represented by KKS tree structure itself.
In addition to these relationships, as well as gauge, every device also has different dominanity level from each one and another for its parent equipment. This difference is characterized by variable weight. Not only that, the mandatory nature of the relationship is also apply on KKS structure in the relatively the same manner as mandatory variable in the gauge. So, Mandatory variable is also required on this KKS structure.
Illustrative example is a motorcycle. A motorcycle engine (parent) consists of piston, cylinder block, valves, spark plugs, and so on (child). When the condition of the pistons and spark plugs changed from normal to warning, then this change of conditions will impact on the condition of the bike as a whole. Because the piston is considered more critical than the spark plug, the piston will be more influential in the whole system condition changes than the spark plugs does.
Basis yang kedua untuk menentukan kondisi adalah dengan menggunakan metode parent child relationship
Parent child relationship adalah penyusunan equipment secara hirarki, dengan bentuk tree sebagai hubungan antar equipment dengan parent / child-nya.
Setiap child equipment, berdampak langsung pada kondisi parent equipmentnya. Namun tidak berdampak pada equipment sebaya / sesiblingnya
Nilai signifikansi perubahan kondisi child terhadap parentnya dilambangkan dengan bobot
Child yang sangat signifikan terhadap parent, akan diboboti lebih tinggi daripada part lain yang tingkat signifikansinya rendah
Contohnya adalah:
Dalam sebuah motor. Magnet dinilai lebih tinggi daripada casing
Sehingga apabila terjadi perubahan kondisi pada magnet, maka akan signifikan mempengaruhi kondisi motor pada keseluruhan daripada perubahan nilai kondisi pada casing
Apabila terjadi perubahan kondisi pada child equipment, maka perubahan tersebut akan di propagasi / diteruskan ke paretnya. Sehingga akan menyebabkan kondisi parentnya menjadi terpengaruh sesuai dengan perubahan yang ada pada child equipment
Can be used in all layer
Agar lebih terbayang, mari kita membuat sebuah ilustrasi tentang model ini pada sebuah contoh kasus
MISALNYA KITA MEMPUNYAI SEBUAH MOTOR LIST SUB EQUIPMENENT BERIKUT INI
PERTAMA-TAMA,
KITA SUSUN BERDASARKAN HIRARKINYA MENJADI SEPERTI INI
---
TAHAP BERIKUTNYA ADALAH, MENENTUKAN BOBOT MASING-MASING EQUIPMENT TERSEBUT SESUAI DENGAN SIGNIFIKANSI TERHADAP PARENTNYA
Pembobotan dihitung secara proporsional, sehingga berarpapun total jumlahnya, tidak mempengaruhi perhitungan
Misalnya: diboboti 4 4 4 4 adalah sama saja dengan diboboti 10 10 10 10
---
LALU KITA MULAI MENDAFTARKAN MASING-MASING GAUGE SESUAI DENGAN FUGNSINYA
GAUGE UNTUK KONDISI DAN GAUGE UNTUK PERFORMANCE DIPISAHKAN
GAUGE INI KITA DAFTARKAN TERMASUK DENGAN BATASAN-BATASAN OP RANGE, WARNING RANGE DAN DANGER RANGE-NYA
---
KEMUDIAN, SAMA SEPERTI SELANJUTNYA
KITA MEMBERI BOBOT PADA MASING-MASING GAUGE TERSEBUT SESUAI DENGAN TINGKAT SIGNIFIKANSINYA TERHADAP KONDISI / PERFORMANCE SECARA KESELURUHAN
---
KETIKA PETA PEMBANGKIT TELAH JADI, MAKA TAHAP SELANJUTNYA DAN SETERUSNYA, KITA TINGGAL MELAKUKAN PENGUKURAN SEPERTI BIASA, BAIK DILAKUKAN PADA SAAT PATROL CHECK, OVERHAUL, PREDIKTIF, ATAU PENGUKURAN-PENGUKURAN RUTIN LAINNYA
KETIKA ADA DATA PENGUKURAN MASUK, MAKA AKAN DIHITUNG DENGAN MENGGUNAKAN BATASAN-BATASAN TADI SEHINGGA MENGHASILKAN SEBUAH ANGKA %
ANGKA % INI KEMUDIAN AKAN DIPROPAGASIKAN KE PARENT DAN SETERUSNYA SEHINGGA AKAN MENGHASILKAN SEBUAH POTRET PETA PEMBANGKIT YANG UTUH. MULAI DARI GLOBAL VIEW, HINGGA KE VIEW PALING SPESIFIK. TERGANTUNG SEJAUH MANA KITA MENDAFTARKAN PERALATAN DAN GAUGE KE DALAM PETA PEMBANGKIT
SAMPAI DISINI, ADA YANG DITANYAKAN?
SEMAKIN DETAIL YANG KITA DAFTARKAN, SEMAKIN DETAIL PULA INFORMASI YANG BISA KITA PEROLEH DARINYA
Every indinvidual equipments condition, in any level of KKS, is calculated using gauge parameter and its child equipment
Kita bahas dulu yang pertama, yaitu gauge based monitoring
Gauge based monitoring adalah, menggunakan sebuah pengukuran / gauge sebagai basis perhitungan peta pembangkit untuk menghasilkan angka kondisi maupun performance
Objective
Not all Health and Performance variables can be easily measured. There is a possibility that the variable is not quantified by the standard. For example are the smell, sound, color, turbidity, and etc. Quantify something that was not previously quantified could lead to differences of opinion in points of view. For that, it takes the method of assessment is objective. It means, whoever do quantification, the end result is relatively the same or have a relatively small deviation.
Factual
The value for the quantification of the Performance and Health should be based on facts that occurred in the field. Or in other words, is the result of observation and measurement, not on assumptions or estimates.
Quantitative
The facts that were used as a basis for condition quantification must be calculable. That means the fact must be measurable and quantifiable. Conversely, the fact that has qualitative nature should be avoided and converted into quantitative facts first before used, because qualitative facts have a tendency to hard to be processed.
Traceable
Stakeholder of equipment monitoring results is varied, ranging from technicians, operators, engineers to top management. Each consumer has the characteristics of different needs. Technicians need information that is detailed for tactical maneuver. Top management needs information in a general view and conclusive. The Engineer requires information that has both strategic and tactical nature. Methods of equipment monitoring and assessment should be able to meet all these needs. That is capable of displaying information in general view, but if necessary, can be traced to the fundamental and detailed information.
Automatable & Realtime
Assessment and quantification method should be programmable / computer friendly. It means the method could be programmed to produce realtime calculation. This is important because the ability of Engineer and the asset operator to monitor and quantify the properties manually without the help of automation is very limited, whereas the number of equipment to be monitored is vast.
Simple / mudah
The Method of quantification should be easy to learn and to implement. The simpler formulas and algorithms used, the shorter the time spent on knowledge transfer process
Objective
Not all Health and Performance variables can be easily measured. There is a possibility that the variable is not quantified by the standard. For example are the smell, sound, color, turbidity, and etc. Quantify something that was not previously quantified could lead to differences of opinion in points of view. For that, it takes the method of assessment is objective. It means, whoever do quantification, the end result is relatively the same or have a relatively small deviation.
Factual
The value for the quantification of the Performance and Health should be based on facts that occurred in the field. Or in other words, is the result of observation and measurement, not on assumptions or estimates.
Quantitative
The facts that were used as a basis for condition quantification must be calculable. That means the fact must be measurable and quantifiable. Conversely, the fact that has qualitative nature should be avoided and converted into quantitative facts first before used, because qualitative facts have a tendency to hard to be processed.
Traceable
Stakeholder of equipment monitoring results is varied, ranging from technicians, operators, engineers to top management. Each consumer has the characteristics of different needs. Technicians need information that is detailed for tactical maneuver. Top management needs information in a general view and conclusive. The Engineer requires information that has both strategic and tactical nature. Methods of equipment monitoring and assessment should be able to meet all these needs. That is capable of displaying information in general view, but if necessary, can be traced to the fundamental and detailed information.
Automatable & Realtime
Assessment and quantification method should be programmable / computer friendly. It means the method could be programmed to produce realtime calculation. This is important because the ability of Engineer and the asset operator to monitor and quantify the properties manually without the help of automation is very limited, whereas the number of equipment to be monitored is vast.
Simple / mudah
The Method of quantification should be easy to learn and to implement. The simpler formulas and algorithms used, the shorter the time spent on knowledge transfer process
Objective
Not all Health and Performance variables can be easily measured. There is a possibility that the variable is not quantified by the standard. For example are the smell, sound, color, turbidity, and etc. Quantify something that was not previously quantified could lead to differences of opinion in points of view. For that, it takes the method of assessment is objective. It means, whoever do quantification, the end result is relatively the same or have a relatively small deviation.
Factual
The value for the quantification of the Performance and Health should be based on facts that occurred in the field. Or in other words, is the result of observation and measurement, not on assumptions or estimates.
Quantitative
The facts that were used as a basis for condition quantification must be calculable. That means the fact must be measurable and quantifiable. Conversely, the fact that has qualitative nature should be avoided and converted into quantitative facts first before used, because qualitative facts have a tendency to hard to be processed.
Traceable
Stakeholder of equipment monitoring results is varied, ranging from technicians, operators, engineers to top management. Each consumer has the characteristics of different needs. Technicians need information that is detailed for tactical maneuver. Top management needs information in a general view and conclusive. The Engineer requires information that has both strategic and tactical nature. Methods of equipment monitoring and assessment should be able to meet all these needs. That is capable of displaying information in general view, but if necessary, can be traced to the fundamental and detailed information.
Automatable & Realtime
Assessment and quantification method should be programmable / computer friendly. It means the method could be programmed to produce realtime calculation. This is important because the ability of Engineer and the asset operator to monitor and quantify the properties manually without the help of automation is very limited, whereas the number of equipment to be monitored is vast.
Simple / mudah
The Method of quantification should be easy to learn and to implement. The simpler formulas and algorithms used, the shorter the time spent on knowledge transfer process
Basically, system can generate the result in real time manner. The challenge is how to supply the system with the realtime data
Basically, system can generate the result in real time manner. The challenge is how to supply the system with the realtime data
Can be used in all layer
Can be used in all layer
Can be used in all layer
Can be used in all layer
Can be used in all layer
Can be used in all layer
NO INFORMATION LOSSES : from real world data to percentage, there must be such a complex processing. Despite that, the method must no compromise of information losses. It means, the process can be traced back so we still know where the percentage came from.
From raw data into condition, there is no human involved. Just for entry data and first setup
So there is little expertise needed, therefore, low cost
Ideal form of equipment monitoroing
The typical equipment monitoring methods tends to had many difficulties.
The next problem is the complexity of the monitoring equipment. Because the amount of equipment and measurement parameters are numerous, so we need a method of monitoring equipment that is easier and less resource needed to do than conventional methods, both by strategic management as well as another such as the tactical engineer, operator, or technician. The issues on how to design and implement a method to solve the above problems are the topics to be discussed in this paper.
Quantification method described in the previous section above is to calculate the condition of the one equipment only. That quantification process is done until the majority or all of the equipment that is necessary to be monitored its condition. The end result of this process is a complete list of equipment with its conditions value in units of %. This information still requires processing again in order to be used for decision making process by engineers and asset management. Therefore, this information is still considered raw and so it is difficult to be used to answer crucial questions such as where the unreliability tend to occur & congregate, what happens if an equipment suddenly failure, then which generating unit are the most ready and reliable to operate, and so on. To answer these questions, it needs a grouping mechanism that those equipment are structured into a specific relationship that is informative, logical, and meet the rules specified in section 2.3.
