Rotating machinery condition monitoring presentation for Linked In RATS group - Rotating And...

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tradition. knowledge. responsibility.11.05.2017

tradition. knowledge. responsibility.

Experts in Condition Monitoring and Predictive Maintenance

RATS

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The Business Case for RATS

• GOLD service clients get a GOLD service product.

• Save on Engineer Time / Costs –use Predictive Maintenance to plan Interventions

• Modern, and developing solutions.

• In house CM / PM experts to use and draw on.

• Improve offer during tenders / competitions.

• Industry 4.0 / IoT credentials.

• Your branding not Koncar.

Richard Brooks – Business Development

Condition Monitoring [email protected]

UK Desk +44 33 022 30 604UK Cell + 44 7971 513 184

mailto:[email protected]

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tradition. knowledge. responsibility.tradition. knowledge. responsibility.

Electrical Engineering Institute has…

Integrated Management System:

ISO/IEC 17025 ISO/IEC 17065

ISO 9001 ISO 14001

OHSAS 18001

Accredited Laboratories and Certification Body

Quality Management System

ISO 9001HRN EN ISO/IEC 17025 HR EN ISO/IEC 17065

EnvironmentalManagement System

OHSAS 18001

Health and Safety Management System

ISO 14001

The Institute has the status

of a private scientific and

research organization.

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Field test and diagnostics

Power and measuring transformers

Generators and motors

Switchgear equipment

Energy efficiencyElectromagnetic

compatibilityElectromagnetic fields

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How we can improve RATS operations?

Full range condition monitoring systems

Solutions are modular and expandable with add-ons for demanding users and basic configurations for most important values (e.g. vibration, displacements, etc.). Machines can be integrated and systems installed flexibly in each factory.

Improved asset management

The condition monitoring platform can be expanded with advanced elements like automated report, machine efficiency calculations and other tools that can extended life time of expensive and critical rotating machines.

Lower costs for preventive

maintenance

Single system with detailed overview of many machines and operations. This means that preventive maintenance (e.g. site tests) are done when needed based on real demand.

Extensive range of site

diagnostic tests

With more than 50 years of experience, we offer preventive maintenance tests for all types of motors, generators and power transformers.

Competitive pricing levels

Compared to competitors in the same area our prices are ~ 60-70% cheaper similar products. We integrate into OSI Soft etc.

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We work with major clients – globally.

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MACHINE CONDITION MONITORING

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Advanced predictive maintenance system

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Front end of the system

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System configuration

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EMCM (EXPERT MOTOR CONDITION MONITORING)

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EMCM (EX APPLICATIONS)

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Upgrade existing systems

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Integration of rotating machine with end applications

HYDRO POWER PLANTS

HYDRO AND TURBO GENERATORS

INDUCTION MOTORS

STEAM TURBINES

COMPRESSORS

PUMPS

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Full flexibility for the operators from many locations

Focus on important issues that e.g. motor, compressor and gearbox have

Almost any value can be monitored and captured with our sensors

The control cabinet selection according to customers’ field requirements with HMI onsite access

Unlimited users, easy graphical analysis, reports and data management

Customized interface with all applications monitored and prestented on one interface

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HMI onsite user screens possibilities

» Calculation of Smax» Orbit calculation» Orbit filtration» Orbit 3D (orbits on several planes)» Position of shaft center (on-line)

» Position of shaft center in dependency of rotating speed

» Alignment of a generating unit» Trends (with restrictive class

grouping)» Alarm/emergency stop

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Diagnostic possibilities

» Calculation of Smax» Orbit calculation» Orbit filtration» Orbit 3D (orbits on several planes)» Position of shaft center (on-line)» Position of shaft center in dependency

of rotating speed» Balancing of a generating unit» Trends (with restrictive class grouping)» Alarm/emergency stop

The system performs standard calculations for signal processing. These calculations are then used as a basis for diagnostic functions that report to users information on machine status. Some of the standard calculations include:

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Some of the graphs available within the system

» Bar display (bar)» Transients display» Timeline (multi-plot)» Event (trend) representations (multi-plot)» Spectral display (2D and 3D)» Orbit representation (2D and 3D)» Polar and linear representation for sensors of air gap (minimum, maximum,

average, rotor shape)» Display of the system alarms (active, inactive, confirmed, unconfirmed ...)

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Customized monitoring systems

» Based on the clients’ demand KONČAR can integrate

» monitoring with control system» This means that customers can use

real time data to adjust their production processes and integrate monitoring with automation systems

» Our experience includes monitoring systems for forging applications, HVAC production and others

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A look into some demo accounts

Shaft current and voltage protection Small hydro condition monitoring

Expert motor condition monitoring Roundness measurement instrument

CONTROL + mouse CLICK – to launch the web app behind these images.

http://mcm.koncar-institut.hr/shcm/#/Overview/SHCM

http://mcm.koncar-institut.hr/shcm/#/Overview/SHCM

http://mcm.koncar-institut.hr/EMCM/#/Overview/EMCM

http://mcm.koncar-institut.hr/EMCM/#/Overview/EMCM

http://mcm.koncar-institut.hr/rmi/#/test/rotor

http://mcm.koncar-institut.hr/rmi/#/test/rotor

http://mcm.koncar-institut.hr/scvp/#/Alarm/SCVP

http://mcm.koncar-institut.hr/scvp/#/Alarm/SCVP

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Rotating machines site tests

» The testing provides comprehensive information on general condition, operation, load, power supply and drive of the motor

» This type of test is normally done every 1 – 2 years with properly working motors

ON-LINE TESTING OF ELECTRICAL MOTORS

TYPICAL TESTS INCLUDE

Voltage Level (Over) [%]

Voltage Level (Under) [%]

Voltage Unbalance [%]

THD [% of fund.]

Total Distortion [% of fund.]

Current Level [%]

Current Unbalance [%]

Load [%]

Ef. Service Factor [p.u.]

Rotor Bar [db]

Op. Point [%]

Loss Difference [%]

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» The goal of this test is to check and determine the condition and quality of the motor insulation system

» The information obtained is used to increase the quality and reliability of the motor during its future operation.

» The test program includes various type of tests:

» Insulation resistance and polarization index measurement

» Winding resistance measurement

» Insulation current measurement during the linear voltage increase (Ramp Test) up to 50 kV

» DC Hipot testing

» Insulation to ground testing with stepped DC voltage (DC Step-Stress Hipot Test)

» Surge test (up to 30 kV)

» Dissipation factor (tg ) and tip-up test up to Un

» Partial discharge measurement

OFF-LINE TESTING OF ELECTRICAL MOTORS

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» The goal of this test is to check and determine the condition and quality of generator stator and rotor winding

» The test program of a stator includes:

» Measurement of insulation resistance to ground and between phases

» Insulation current measurement during the linear voltage increase

» Measurement of the dissipation factor (tg) of the winding insulation

» Partial discharge measurememt of the stator winding

» The test program of a rotor includes:

» Measurement of winding insulation resistance

» Measurement of resistance of the winding

» Measurement of impedance of the winding

» Interpole connections testing and pole drop test

GENERATOR WINDING TESTING

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» Hydro plants

» Thermal plants

» Oil refineries

» Cement plants

» Sugar production

» Off-shore platforms

» Paper industry

» Steel factories

REFERENCES

» Fertilizer production

» Glass industry

» Shipyards

» Water management

» Water distribution

» Pharmaceuticals

» Food and beverage

» Nuclear plants

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The following slides are all computer modelled examples of measurements we can take from live Rotating Machines – and then the operating parameters and behaviours we can model from sensor data.

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R&D – Computer Modelling

Finite Element Models (FEM)

Electromagnetic calculations

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Analytical ventilation and heat transfer

calculations

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Computational Fluid Dynamics calculations

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Mechanical FEM calculations

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Mechanical Finite Element Method calculations

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Mechanical FEM calculations

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The Business Case for RATS

• GOLD service clients get a GOLD service product.

• Save on Engineer Time / Costs –use Predictive Maintenance to plan Interventions

• Modern, and developing solutions.

• In house CM / PM experts to use and draw on.

• Improve offer during tenders / competitions.

• Industry 4.0 / IoT credentials.

• Your branding not Koncar.

Richard Brooks – Business Development

Condition Monitoring [email protected]

UK Desk +44 33 022 30 604UK Cell + 44 7971 513 184

mailto:[email protected]

Rotating machinery condition monitoring presentation for Linked In RATS group - Rotating And...

Engineering

Transcript of Rotating machinery condition monitoring presentation for Linked In RATS group - Rotating And...