Condition monitoring of large systems in power plants can come in various forms and functions, whereas different stakeholders want to have access to different information. They all, however, share the same goal - to protect their investment.
According to a study from IRD Balancing LLC, in the United States alone is spent more than $200 billion annually on maintenance. The research also shows that between 15% - 40% of the operating costs of a plant represent maintenance costs, out of which 28% - 35% is unnecessary spending.
According to a study from IRD Balancing LLC, in the United States alone is spent more than $200 billion annually on maintenance. The research also shows that between 15% - 40% of the operating costs of a plant represent maintenance costs, out of which 28% - 35% is unnecessary spending.
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In this real life example gross profit with an implemented predictive maintenance program rises from 20 € to 25.5 € million, which increases gross margin from 20% to almost 26%.
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3 KEY QUESTIONS TO CONSIDER WHEN SPECIFYINg a monitoring system
When defining and choosing a proper machine monitoring system decision makers and experts should consider these questions:
1. What is the purpose of the monitoring system?
The first step should always be to set realistic goals. A technical team should in this phase closely examine the critical areas that should stay intact and define key functions that a monitoring system should perform.
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2. What factors influence the scope of monitoring?
Not all machines need a fully equipped monitoring. To determine the scope consider these key questions:
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If your answers show that the equipment is important, working conditions are harsh and faults occur regularly, then there is a big need to invest in a monitoring system.
3. What type of monitoring system to install?
Once the decision has been made to invest in predictive maintenance programme, some additional questions need to be considered in order to ensure its easy implementation and uninterrupted production process.
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Answering all these questions will prepare you for the process of searching for the right supplier and save a lot of time in the later phases.
what is MCM system?
Machine condition monitoring (MCM) is a modular solution that integrates key monitoring functions into a single platform defined by the customers' needs. Thanks to its modularity customers can use the solution for almost any kind of application, values and in all areas where asset management is a priority. It can be equally effective when implemented in large power plants with couple of hundreds MW installed and when installed on small and medium sized hydro plants.
Its state-of-the-art tools allow monitoring of all key elements and report crucial information to key stakeholders that can react promptly and protect their equipment. Together with our team the customers can define their own scope of monitoring and decide which features to integrate in order to focus on areas that bring the most significant process improvements.
The system has been successfully installed on more than 6 GVA across the world and is helping customers to make better decisions when operating large energy systems. For more information on installation possibilities visit the solution configurator part or case studies and references to see some of the projects we participated in over the last couple of years.
Its state-of-the-art tools allow monitoring of all key elements and report crucial information to key stakeholders that can react promptly and protect their equipment. Together with our team the customers can define their own scope of monitoring and decide which features to integrate in order to focus on areas that bring the most significant process improvements.
The system has been successfully installed on more than 6 GVA across the world and is helping customers to make better decisions when operating large energy systems. For more information on installation possibilities visit the solution configurator part or case studies and references to see some of the projects we participated in over the last couple of years.
technical description
MCM meets the requirements of ISO 7919-5 and ISO 10816-5 and is applicable to all machine types. The main parts of the MCM monitoring system are: the front edge (measuring sensors and signal conditioners), and processing/protection unit.
The front edge (measuring sensors and signal conditioners)
Measuring sensors are installed in such a way that they do not affect the existing measurements or machine construction, and their replacement and adjustment are provided in a simple way.
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Typical installation of the sensors for measuring relative shaft displacement (position 1) and rotation speed sensor (position 2) |
Sensor cables are properly fixed and protected by steel flexible protective tubes which prevent mechanical damage to the cable. They lead directly to the processing unit. Junction boxes (protection IP 66 with anti-condensation heaters in them) are connected with processing unit cabinet by a special signal cable.
Processing/protection unit receives the signals from the measuring sensors, performs analog signal filtering, performs analog/digital conversion (digitalizes them), performs signal processing, enables a protective function via digital outputs (relays) and communicates with the master and slave systems by a standard-based communication protocols.
Processing/protection unit with associated measurement modules
Processing unit cabinet is fully examined and tested according to the standard procedures and relevant standards. Monitoring system comes fully configured in accordance with the system requirements. In addition to the standard tests, functionality of the cabinet can be demonstrated to the customer (on request) during FAT (Factory Acceptance Test).
All measurement data are available from the database with a complex structure and data compression for a lifetime of the machine. Tools for system and user administration, setup and administration of the alarm support easy navigation through the program. Local visualization enables insight into real-time data, waveforms, spectrums, trends and setup. All screens can be modified according to the customers' requests such as interface in a native language.
All measurement data are available from the database with a complex structure and data compression for a lifetime of the machine. Tools for system and user administration, setup and administration of the alarm support easy navigation through the program. Local visualization enables insight into real-time data, waveforms, spectrums, trends and setup. All screens can be modified according to the customers' requests such as interface in a native language.
The system is equipped with a multiuser web server that enables connection and overview of all system data by using a standard web browser. This web server provides an access to the monitoring system from any desktop, laptop computer or smartphone and tablet. Web server can simultaneously serve multiple users (at least 50 simultaneous connections).
Measured values
MCM system measures the values according to the customers’ requirements and with the sampling frequency 10 to 30 kHz. Below is the list of the selected critical values that the system measures.
Vibration monitoring and balancing system unit
The unit measures:
- Relative shaft vibrations (relative to the bearing housing) – relative vibrations measurement is performed by two relative displacement. Sensors are installed in the same plane perpendicularly to each other so it is possible to measure the maximum relative displacement vector and orbit
- Rotating speed measurement – measurement of one pulse per machine revolution
Client software supports the following user screens (HMI):
- 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
Generator Air Gap Monitoring System
Air gap monitoring is of key importance because the shape and location of the rotor and stator on a large hydro generator are affected by several factors like: centrifugal force, thermal and magnetic forces, mechanical expansion with load due to temperature increase, concrete growth, etc.
Understanding the rotor and stator shapes, positions and minimum air gap dimensions provides
the operator with the information needed to remove a machine from service before serious
damage from magnetically induced overheating or rotor-to-stator rub occurs.
Understanding the rotor and stator shapes, positions and minimum air gap dimensions provides
the operator with the information needed to remove a machine from service before serious
damage from magnetically induced overheating or rotor-to-stator rub occurs.
Client software supports following calculations:
- distribution of air gap for each pole
- rotor and stator roundness
- concentricity
- run out
- deformation of the stator
- magnetic unbalance
- rotor-stator contact
Process values measurement
Process values are imported to monitoring system via standard communication protocols such as MODBUS, IEC104 and others. Most common values to import are active and reactive power, generator currents and voltages, temperatures and others.
Partial Discharge Monitoring System
Partial discharge system consists of 3 couplers per generator installed on generator end winding and processing unit that analyses data collected from couplers installed outside the generator enclosure. Analyzed data is sent to other systems via standard communication protocol as well as through analog outputs (4-20mA).
Diagnostic system
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:
- Mean values calculations (RMS)
- Events calculation
- Alarm calculation (alarm and warning for each measured/processed value)
- Calculation of Smax
- Orbit calculation
- Signal filtering
- Spectral analysis
- Rotating speed calculation
The signal calculations are afterwards presented in the following charts and graphs:
- 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 ...)
- 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 ...)
To determine machine condition, process data from power plant control (measurement points or calculated values) can be integrated in the system through standard communication.
CONNECTIVITY
Web integration of power equipment into a single access point which supervises critical equipment in multiple power plants.
MODULARITY
Measurement of key parameters according to customer’s specific needs that can be upgraded for large plants with complex measurements.
INTEGRATION
Web integration of power equipment into a single access point which supervises critical equipment in multiple power plants.
Web integration of power equipment into a single access point which supervises critical equipment in multiple power plants.
MODULARITY
Measurement of key parameters according to customer’s specific needs that can be upgraded for large plants with complex measurements.
INTEGRATION
Web integration of power equipment into a single access point which supervises critical equipment in multiple power plants.
CUSTOM DEFINED PARAMETERS
Customers define their own set of monitoring parameters whose behavior is in-depth analyzed and reported.
FOCUS ON CRITICAL MACHINE PARTS
Monitoring scope can focus on critical areas of each machine - stator, rotor, shaft, bearings, etc.
FAST PROCESSING OF KEY VALUES
The selected values are monitored in real time and even the most demanding parameters are fast processed thanks to the powerful processing units.
Customers define their own set of monitoring parameters whose behavior is in-depth analyzed and reported.
FOCUS ON CRITICAL MACHINE PARTS
Monitoring scope can focus on critical areas of each machine - stator, rotor, shaft, bearings, etc.
FAST PROCESSING OF KEY VALUES
The selected values are monitored in real time and even the most demanding parameters are fast processed thanks to the powerful processing units.
DATA ACCESS
Data can be accessed via local HMI (Human Machine Interface) and online. It can also be accessed simultaneously from various users from any place in the world using standard internet connection.
REMOTE ANALYSIS
Our team of experts can on request access the database of the system and create detailed reports for different types of stakeholders that need crucial information on their investment.
CUSTOMIZATION
The system interface can be modified to customers' needs including translation of the interface language into a desired one.
Data can be accessed via local HMI (Human Machine Interface) and online. It can also be accessed simultaneously from various users from any place in the world using standard internet connection.
REMOTE ANALYSIS
Our team of experts can on request access the database of the system and create detailed reports for different types of stakeholders that need crucial information on their investment.
CUSTOMIZATION
The system interface can be modified to customers' needs including translation of the interface language into a desired one.
FAULT DETECTION WITH DMFM
MCM uses our own developed and patented DMFM method for fault detection. This method gives approx. 200 times higher resolution in fault detection than other commonly used methods, which makes it ideal for detection of faults in early development (for detailed description of the method visit Expert motor condition monitoring part).
SMART TRENDING
With this tool we can estimate the point in the future at which the critical values will be reached and danger alarm triggered. This not only helps staff to find the optimal level of machine load, but it also helps in planning the maintenance periods when they are actually needed. For further explanation visit our Expert motor condition monitoring part.
AUTOMATED REPORTS
Customers have the option of receiving periodically automated reports presenting information on machine status. This is especially important if there is no dedicated personnel responsible for condition monitoring and no time is devoted to this area. Together with our clients we define the scope of the report that can afterwards be sent automatically to multiple email accounts. Take a look at our sample report.
MCM uses our own developed and patented DMFM method for fault detection. This method gives approx. 200 times higher resolution in fault detection than other commonly used methods, which makes it ideal for detection of faults in early development (for detailed description of the method visit Expert motor condition monitoring part).
SMART TRENDING
With this tool we can estimate the point in the future at which the critical values will be reached and danger alarm triggered. This not only helps staff to find the optimal level of machine load, but it also helps in planning the maintenance periods when they are actually needed. For further explanation visit our Expert motor condition monitoring part.
AUTOMATED REPORTS
Customers have the option of receiving periodically automated reports presenting information on machine status. This is especially important if there is no dedicated personnel responsible for condition monitoring and no time is devoted to this area. Together with our clients we define the scope of the report that can afterwards be sent automatically to multiple email accounts. Take a look at our sample report.
You want us to help you design and implement the optimal monitoring solution? Choose on of the options below or contact us for more information.