PowerNode: Motor Health Management

PowerNode: Motor Health Management

Architecture is as follows:

Edge Connectivity

The GPG Controller located at the industrial premises automatically triggers periodic oscillographies in the motor IEDs if the motor is running. Additional data (temperatures, vibration, electrical data) can also be automatically retrieved if available.

Oscillographies are transferred to the Service Portal through a secure remote connection.

PowerNode: Motor Health Management supports GE and non-GE IEDs. For non-GE IEDs, an evaluation will need to be carried out.

Service Portal

Motor data received from the industrial site is processed and stored in the Service Portal infrastructure.

When a potential fault is detected, the analytics engine automatically opens a case to be reviewed by our managed services team.

The Service Portal also provides a web interface to customers and the managed services team where they can see the asset status overview and details for each monitored asset.

Managed Services

The managed services center receives all potential failures detected by the service portal. A team of experts validates the data, provides recommendations to address the detected problem(s), and supports the site maintenance team.

PowerNode: MHM Service Portal Web Interface

GE’s PowerNode Motor Health Management uses a cloud-based application to store and display data for analytics and monitoring.

Site Map

Overview of the location of all monitored sites and assets of a company. Locations of an asset with potential issues will be highlighted in orange or red.

Plant Layout

View the status of an asset by navigating to a specific zone. Assets can be organized into four hierarchical levels for easy access.

Asset Details

View current and historical data for each asset and failure type to validate a potential motor failure.

Performance Analytics

Monitor the performance of your assets with a set of dashboards that display the status of the assets by failure type, and a confusion matrix that displays the failure detection accuracy.

List of Failure Modes

Electrical Signature Analysis (ESA)

• Used to detect various failure modes in a rotating machine by analyzing stator current and voltage signals.
• ESA systems rely upon Fast Fourier Transformer (FFT) analysis, much like vibration analysis.
• ESA fault detection algorithm uses FFT computation of the current signal to detect fault conditions at vibration frequencies related to the corresponding fault condition and computes peak magnitudes with respect to the baseline peak magnitudes (healthy mode of the motor without misalignment).

Machine Learning (ML)

Being part of artificial intelligence, ML algorithms can improve automatically through experience and using data.

GE’s ML algorithms can automatically detect and classify healthy and unhealthy motor operating conditions (unsupervised clustering).

The algorithms consider multiple parameters derived from the current and voltage readings (frequency, power, speed, rate-of-change, etc.) to increase accuracy of pure ESA analytics.

Secure Gateway at the Plant

• Secured data transfer between IEDs and gateway through standard communication protocols
• Malware protection software, white-listing, and hardening are all implemented

Secure Communication from Plant to Cloud using 3rd Party Rail (3PR)

• All external communications between the WAN router and the GE data repository are secured using encrypted tunnels. No control system or management ports will be exposed on the outside interface of the WAN router.
• Strong encryption standards to protect the privacy of the communication between the plant and GE over public networks.
• Inspect inbound/outbound traffic at the edge of the GE network.

Security at the Cloud

• All the endpoints of the cloud are secured by proper authentications and firewall implementations.
• The data files that are uploaded from the GPG are stored in a folder that is exclusively assigned to a customer. Access to this folder is given only to designated users through appropriate authentication.

Managed Serivces

The managed services provided by GE are the core value of Motor Health Management. These services save the customer the unnecessary pain of being exposed to the analytic algorithms while they are still in the process of being fine-tuned, thus avoiding unnecessary mis-operations. They also provide recommendations with regards to the detected failures in the form of prescriptive analytics.

The Managed Services team performs three main actions:

• Service 1: Review and validate the incipient failure of the motor. Prepare and send recommendations of actions to be taken by the site maintenance team to address the problem.
• Service 2: Support the site maintenance team to investigate and correct the problem.
• Service 3: If failures are missed or incorrectly detected, the managed services team performs an investigation and performs modifications of asset parameters and/or performs enhancements to the failure detection algorithms to increase failure detectability.

Electrical motors operate under different load conditions depending on the application. A continuous improvement process can adapt failure detection to your specific operating conditions.

Reduce unplanned downtime

PowerNode: Motor Health Management solution uses advanced diagnostics and prognostics to ensure you can plan your actions before the asset fails, avoid unplanned downtime, and reduce O&M costs.

Make the most of your IEDs

No additional sensors are required. The system uses protection and control relay data and existing communication infrastructure to minimize cost of deployment and installation impact.

Leverage GE's managed services

Our managed services team will accurately interpret the results and guide you in making the right decisions.