Advanced condition monitoring system for rotating machines
- 1. ADVANCED CONDITION MONITORING SYSTEMS FOR ROTATING MACHINES www.koncarmonitoring.com tradition. knowledge. responsibility.
- 2. | Advanced condition monitoring systems for rotating machines tradition. knowledge. responsibility. 2 3 Preserving investment value, reducing costs and increasing production revenue are the goals of every plant operator. With constant pressure on the machines to produce more, failures occur more often and continuous production process is jeopardized. Introducing a proper machine monitoring system is the first step towards operational improvements on a daily basis. Timely detection of problems prevents serious machine damage and in financial terms brings substantial savings. When predictive maintenance is accepted and used across the entire organization, the results impact many areas including profit and loss figures. The research shows that maintenance represents fully 15% - 40% of the operating cost of a plant and up to 35% of these costs is unnecessary. Whether it is installed on new equipment or during a refurbishment phase, the costs of predictive maintenance program are minor compared to the benefits that such program brings. Helping our clients to solve their problems and increase their productivity has been motivating us since the first day. Located in Zagreb, Croatia, as a part of KONCAR Group, we develop products for applica- tions in hydro, wind, process industries and other areas. Our passion for new and innovative products is motivating us to grow and create value for our clients. With our educated and experienced team, we extend the lifetime of most complex equipment and solve problems that others can’t. Because of our expertise and flexibility we are a preferred supplier of many international companies in power generation and energy sector. Condition monitoring brings value in many areas of business Over 50 years of know-how in rotating machines & energy field More than 20 GVA monitored with our solutions! Importance of predictive maintenance Who we are Worldwide recognized and implemented SHUTDOWN PLANNING Maintenance shutdown can be scheduled when it is convenient for the organization. OPTIMIZED WORKLOAD Maintenance activities are optimized thanks to the data availabil- ity and resource utilization. DAMAGE AVOIDED Extensive damage resulting from sudden failure can be avoided. LOWER REPAIR TIME Repair time can be minimized, which results with reduced ma- chinery downtime and higher equipment availability. CLEAR PROBLEM SOLUTION The system identifies the nature of the problem while expensive approaches are eliminated. JUST-IN-TIME MAINTENANCE Maintenance periods can be planned when they are needed and not only for preventive purposes. INVENTORY AVAILABILITY Lower inventory levels required for spare parts that may not be always available, or are simply too expensive. DATA COLLECTION Quick, efficient and immediately processed data brings time sav- ings and better of flow of information in the organization. SHORT PAYBACK PERIOD With capital failures prevented, payback period is achieved in a very short period of time. ENVIRONMENTAL AND PERSONNEL SAFETY Having a system that alarms users when big faults occur means protecting the area from accidents and injuries.
- 3. | Advanced condition monitoring systems for rotating machines tradition. knowledge. responsibility. 4 5 MAINTENANCE AND LIFETIME EXTENSION INSTALLATION AND COMMISSIONING PLANT AND MACHINE MANAGEMENT Recognizing different needs of your machine during its lifetime is the first step towards fault-free ma- chine operations. From the early stages of production to commissioning, regular usage, and mainte- nance, our solutions help to identify and prevent most common rotating machine problems. The tech- nology behind them makes sure that all market players perform their tasks efficiently and achieve their goals. The machine lifetime has a well-known scenario – after the initial critical phase before the machine is commissioned, the probability of failure increases with its age, until faults suddenly start to appear more and more. Identifying problems on time will assure that the machine value is preserved and its lifetime extended. Solutions that save money and time Right products for right customers at the right time PROBABILITYOFFAILURE Verification of stator winding connection Hydro Water & Wastewater Synchronous and induction machines Producers,OEMs Vibrations Air gap Stator and rotor roundness Process Energy Hydro and turbo generators System integrators & turn-key companies Relative shaft displacement Speed of rotation Operational asymmetries Wind General industry Medium & high voltage motors Site operators Temperature levels Torsion of mechanical parts Machine centering Process values (current,voltage) Partial discharges Winding damages Maintenance experts Magnetic field Any other value (e.g. hydraulic values,load angle) Stator winding connection 1 1 1 Measurement of stator and rotor roundness 2 2 2 2 Fixation of rotor wedges 3 3 3 Machine centering 4 4 44 Recording of harmful operations 5 5 Wireless rotor fault detection 6 6 Shaft current and voltage protection 7 7 Fault detection of electrical motors 8 8 Small hydro monitoring 9 9 Monitoring of large hydro systems 10 10 Excitation winding fault detection 11 11 Air gap measurement 12 12 Shaft torque, load angle and power measurement 13 13 Detailed vibration analysis 14 1414 0,1 1 10 100MACHINE AGE MACHINE PRODUCTION INTERVENTIONOVERHAULOPERATION TARGET USERSINDUSTRIES COVERED APPLICATION MONITORING AND INSTRUMENT SCOPE
- 4. | Advanced condition monitoring systems for rotating machines tradition. knowledge. responsibility. 6 7 Machine condition monitoring (MCM) Small hydro condition monitoring (SHCM) Expert motor condition monitoring (EMCM) Shaft torque and power monitoring (ST&P) Shaft current and voltage protection (SCVP) Electrical machine black box (EMBB) Stationary monitoring solutions MCM is a modular solution applicable to power plants and machines of all sizes. It allows integra- tion of key values and equipment according to customers’ requirements enabling full insight into machine operations. SHCM is a compact solution designed for small hydro plants of all types and age. It targets the most important elements of the operation and allows efficient and cost-effective monitoring of plants located in rural areas. EMCM provides users with crucial information for integrated and smart motor management. The solution uses advanced methods for early fault de- tection of key motor parts, minimizes maintenance costs and saves a lot of resources especially in pro- cess-intensive industries. STP gives the complete picture to users by mon- itoring torsional vibrations which lead to major machine damage and thus cause financial losses. The system can also be expanded with advanced measurements of machine efficiency and load an- gle, which is especially important in hydropower and ship industry. SCVP detects shaft currents and voltages that may damage the generator bearings and thus prevent greater economic damages. The know-how built in the system protects expensive machines from one of the major generator damages. EMBB records machine issues that allow manufactur- ers to get insight into conditions caused by user mis- handling (asynchronous operations, number of ma- chine starts and stops, run-out, extensive vibrations, etc.). This important information helps producers to protect themselves from penalty fees which are not caused by their product. INDUSTRIES INDUSTRIES INDUSTRIES APPLICATION APPLICATION APPLICATION TARGET USERS TARGET USERS TARGET USERS MONITORING SCOPE MONITORING SCOPE MONITORING SCOPE Installed for the permanent period, these solutions allow users to have continuous access to key elements of their equipment and optimize their maintenance periods. *The meaning of the symbol is stated on pages 4-5 INDUSTRIES INDUSTRIESAPPLICATION APPLICATIONTARGET USERS TARGET USERSMONITORING SCOPE MONITORING SCOPE INDUSTRIES APPLICATIONTARGET USERS MONITORING SCOPE
- 5. | Advanced condition monitoring systems for rotating machines tradition. knowledge. responsibility. 8 9 Vibration measurement instrument (VMI) Roundness measurement instrument (RMI) Instrument for winding fault detection (WFD) Custom specific instruments Slow-roll runout instrument (SRI) Field measurement instrument (FMI) Portable monitoring and diagnostic instruments VMI is a user-friendly instrument made for rugged field applications with the focus on radial and ax- ial bearing vibration measurements according to norms and standards. Equipped with a fast and reliable processing unit, the system integrates various advanced options for quick and effective data management. RMI instrument significantly saves time during the machine production. The system measures impor- tant stator and rotor values regulated by norms, using methods that eliminate time-consuming pro- cess. WFD provides real-time information on excitation winding failure, which is one of the biggest prob- lems of hydro generators. Using advanced technol- ogy for fault detection of the severe problem, the instrument is a crucial equipment for all profes- sionals trying to avoid production shutdowns. Custom specific instruments are designed to focus on values most relevant to the users. The solution platform integrates most important functions for the field usage and can be adapted to almost any kind of application. Up to 50 output channels can be con- figured to monitor special machine elements such as rotor faults, partial discharges, air gap, shrink fit, machine efficiency, etc. SRI instrument measures mechanical imperfections such as out-of-roundness and non-concentricity of the shaft. It gives insights into runout imperfections values that have to be regulated according to standards in or- der to assure stable generator operations. FMI helps during the machine production by detect- ing issues related to the incorrect connection of stator windings and by making easier on-site modifications and repair. With simple installation and clear and ac- tionable readings, machine production is quicker and testing time shorter. Portable instruments can be used with multiple machines when needed during the produc- tion, commissioning, and maintenance – perfect when time and money are limited factors. *The meaning of the symbol is stated on pages 4-5 INDUSTRIES INDUSTRIESAPPLICATION APPLICATIONTARGET USERS TARGET USERSMONITORING SCOPE MONITORING SCOPE INDUSTRIES INDUSTRIESAPPLICATION APPLICATIONTARGET USERS TARGET USERSMONITORING SCOPE MONITORING SCOPE INDUSTRIES INDUSTRIESAPPLICATION APPLICATIONTARGET USERS TARGET USERSMONITORING SCOPE MONITORING SCOPE
- 6. | Advanced condition monitoring systems for rotating machines tradition. knowledge. responsibility. 10 11 With our set of tools we make sure that results obtained from the machines are used to effectively plan maintenance periods, increase revenue and reduce maximally the number of machine faults. Our premium services cover all of your needs. From training to diagnostic of all types of rotating ma- chines, our experts are dedicated to help you fulfill your objectives and save resources. Actionable monitoring with smart tools Full range services for your machine CLOUD INTERFACE SOFTWARE Access to web application from any computer in the world. No special installation software, free of charge for additional users, no expensive investment. TRAINING We organize on-site and remote training on rotating machines and on how to save resources with condition monitoring. INTEGRATION OF MULTIPLE MACHINES AND KEY VALUES Our modular platform allows multiple machine integration to a single interface. All critical applications and their values can be monitored from one place. EXPERT SUPPORT Our team is available to support you in all phases of machine life cycle – from solution design to implementation and interpretation of results. SMART TRENDING The unique feature uses advanced algorithms that pre- dict point when a failure will occur, which makes it ideal for optimized maintenance planning. DIAGNOSTIC SERVICES The scope of our work covers visual inspection, tests and diagnostics and condition prediction. This includes on- and offline tests, as well as testing before, during and after the overhaul. ADVANCED FAULT DETECTION Using our in-house method we detect failures at early stage and focus on critical machine part with no special diagnostic equipment required. EQUIPMENT LIFETIME ESTIMATION Thanks to our knowledge and experience we use ad- vanced methods to estimate machine lifetime with respect to its design, operations and condition. CALCULATION OF MACHINE EFFICIENCY WITH CONTROL FUNCTION State-of-the-art knowledge built in our system allows calculation of machine efficiency and usage of real time information to set machine inputs resulting in maximized production output. R&D During the past 20 years we have been involved in more than 700 generator and 7000 motor projects. FEM and CFD calculations, dynamic effects, motion and real material properties are some of the skills we implement in rotating machines. AUTOMATICALLY GENERATED REPORTS With automated reports key stakeholders get tailor-made insight into machine status, which significantly saves their time. PROCESS OPTIMIZATION No matter what your goal is – equipment protection, cost reduction or process improvement, we help you to achieve more and increase your productivity.
- 7. LET’S CONNECT: tradition. knowledge. responsibility. www.koncarmonitoring.com +385 99 392 1974 kmsupport@koncar-institut.hr Fallerovo šetalište 22 Zagreb 10002, Croatia KONČAR Electrical Engineering Institute, Inc.