Expert Systems and Automation

Mike Johnson P.E. Measurements

(Vib, Oil, IR, US)
I believe expert systems and automation can selectively improve vibration analyst
efficiency; however, cannot completely replace a human. This sketch summarizes the
procedure most analyst use for condition monitoring of rotating machinery. Without an Screening
Expert System the screening, diagnostics, and report writing steps require a human to (Smooth or Rough?)
“imagine, discover, learn, and prioritize” the data into meaningful information, which can
be overwhelmingly time consuming if done to the same level as possible with an Expert
System. Here are some of my thoughts for each step. Diagnostics
(What is wrong?)
Measurements – With portable data collection systems, use of a stud mounted integrated
triax accelerometer produces excellent quality repeatable narrow band vibration
measurements in all three axes at every test location. Human error and collection time are Report Writing
reduced when compared to using a magnet mount single axis sensor. Installed (online) (& Distribution)
systems produce large volumes of data that must be screened, diagnosed, and condensed
into an actionable report. The Expert System is just as effective with processing measured
data from an online system as from a portable system.

Screening – This is where the Expert System (narrow band screening) really shines over
conventional wisdom of broadband screening. A survey of 100 machines sorted by Expert
System severity provides a much better prioritization of machine condition than a list
sorted by overall vibration or band alarms. Most who argue for the broadband alarm
technique do not fully understand how narrowband screening works. From an efficiency Good
standpoint this area is where the Expert System gives about 1/3 of its bang for the buck. Engineering
Practice + Filters
Diagnostics – Ok, the machine is rough, now what is wrong? Is the problem inside the
motor, gearbox, pump, within the foundation, or related to a process problem? What is
(are) the root cause(s) for the abnormal vibration? The Expert System can suggest specific Repair Decisions
diagnoses through early recognition of patterns in the data unique to a given fault model.
• Run to failure
Careful review is necessary because the Expert System uses logic that sometimes produces
• Component repair
overlapping diagnoses that a qualified manual analyst can pick-and-choose from.
• Overhaul
Diagnostic efficiency is where the Expert System gives another 1/3 of its bang for the buck.
• Replace
Report Writing – This is where the Expert System provides the last 1/3 of its bang for the buck. The Expert System
report writer is pre-populated with the automated diagnostic results. This eliminates the need for an analyst to write
the report from scratch. The machine owners use the analyst reviewed report, along with good engineering practice
and other considerations (cost of repair, cost of failure, budget, history, manpower, redundancy, mission, safety,
planned outage, etc.) to make the final repair decision.

CONCLUSION
Trio and ExpertALERT represent the technology; with which come efficiency gains. These gains are well proven if:

• The database is setup and fine-tuned with a mature average plus sigma baseline.
• Measurements are made correctly using pre-defined repeatable test conditions.
• Analyst reviewing the data understands the machine and the meaning of the measurements.
• Analyst includes well-articulated comments to go with the diagnoses and recommendations.

The efficiencies gained by using the Expert System are about evenly split across screening, diagnostics, and report
writing. The Expert System on its own is not suitable to fill the vacuum left by a retiring worker.