MCM MACHINE CONDITION MONITORING.

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2 MCM MACHINE CONDITION MONITORING Rotating machines are one of the key and most valuable components in a power system. Equipping rotating machines with systems for condition monitoring enables predictive maintenance and risk assessment. It ensures: Processing unit (real time processing, modular design, analog inputs/outputs, digital inputs/outputs, ICP, RTD, Pt100, thermocouple ) Higher machine availability Improved safety of service and no unplanned outages or dead times Longer service life Early fault detection Better resource management (time, human, capital) Process values analog and digital (voltage, currents, pressure, flow, ) Operator panel - HMI (real time data, events, orbits, alarms ) Accelerometers, velocity sensors (vibration, velocity) Electrical cabinet Air gap sensor, magnetic flux sensor (eccentricity, pole profile, magnetic induction, inter-coil short circuits) Junction box Ethernet Pt100, RTD, thermocouple (temperature) Partial discharge Analog/digital signals Relative displacement sensors, inductive sensors (radial shaft vibration, radial shaft position, axial shaft position, eccentricity, shaft torque, rotating speed) Remote web user (smartphone, tablet ) Ethernet Ethernet Cavitation Server computer local/remote (data base, web server, HMI, system setup ) 3

local visualization Inputs: Vibration inputs (IEPE) Analog inputs (0-10 V / (0)4-0mA)

on request Digital/relay outputs: Number of outputs: -8 Continuous current: 6 A Maximum

0,1 Hz Rated isolation voltage: 300 V overload (category III) by EN 50178 Surge withstand:

TCP slave, FTP server, IEC 60870-104, HTTP server (other on request) Power supply: DC: 80

interruption: 100 ms for 30 VAC/ 0 ms for 115 VAC Test voltage: 3 kv ( kv against ground)

variant with touch screen) Storage temperature range: -40 to +85 C Dimensions: Cabinet IP

for remote access and local client application through touch screen Data logging: Database

3 1. MCM specification Architecture: Data acquisition unit with the real time controller and local visualization Inputs: Vibration inputs (IEPE) Analog inputs (0-10 V / (0)4-0mA) Speed sensor input(0-10 V) Temprature inputs (RTD, Pt100) Digital inputs Additional inputs on request Digital/relay outputs: Number of outputs: -8 Continuous current: 6 A Maximum switching power: 1500 VA Maximum switching voltage: 50 VAC/DC Maximum switching frequency: 0,1 Hz Rated isolation voltage: 300 V overload (category III) by EN Surge withstand: 4 kv (1,5/50 µs), by IEC 5017 Communication: Ethernet 10/100 Supported protocols: Modbus TCP slave, FTP server, IEC , HTTP server (other on request) Power supply: DC: 80 V to 370 V AC: 85 to 64 V, frequency 47 to 63 Hz Maximum allowed power supply interruption: 100 ms for 30 VAC/ 0 ms for 115 VAC Test voltage: 3 kv ( kv against ground) Temperature range: Operational temperature range: -0 C to +70 C -0 C to +55 C (for MCM variant with touch screen) Storage temperature range: -40 to +85 C Dimensions: Cabinet IP 54 (IP 66 on request) typical dimensions WHD: 800x800x000 Data visualization: Web browser for remote access and local client application through touch screen Data logging: Database for long-term data, alarm and events archival Standards compliance: EMC immunity/emission (EN /EN ) Vibration/shock resistance (EN /EN /9) 4 5

standard communication protocols with server computer

In addition to the measurement data display, the central

system: analysis of the measured results, diagnostic

visualization through operator touch panel.

requests which includes native language.

server that enables a remote access and overview of all

This web server provides an access to the monitoring system

operating system), tablet (with the ios, Android OS ) or

4 Software The processing units are connected through the standard communication protocols with server computer (central diagnostic computer). In addition to the measurement data display, the central diagnostic system enables through expert tools of the MCM system: analysis of the measured results, diagnostic monitoring, recording/storing measurement data and important events (e.g. alarms). Remote web application (HMI) MCM system enables local data visualization through operator touch panel. Local visualization enables insight into real-time data, alarms, trends and orbit plots. All screens can be modified according to the Customer s requests which includes native language. Local HMI The MCM system is equipped with a multiuser web server that enables a remote access and overview of all system data through standard web browser. This web server provides an access to the monitoring system from any desktop or a laptop computer (with Windows or ios operating system), tablet (with the ios, Android OS ) or smartphone (with ios, Android operating system). System access is provided without the need to install additional software using a standard web browser (Google Chrome, Internet Explorer, Mozilla Firefox, Safari ). Web server can simultaneously serve multiple users (up to 100 simultaneous connections). 6 7

www.koncarmonitoring.com 3. Sensors Relative displacement sensor Cavitation sensor This sensor is used for measurement of machine shaft relative displacement and rotor axial displacement.

5 3. Sensors Relative displacement sensor Cavitation sensor This sensor is used for measurement of machine shaft relative displacement and rotor axial displacement. This sensor is used for measurement of cavitation on hydro turbines. Accelerometers and velocity sensors Current measuring sensor This sensor is used for measurement of absolute bearing vibrations, machine housing vibrations and structural machine parts vibrations. This sensor is used for measurement of AC and DC current without interrupting measuring circuit. Tacho sensor (key phasor) This sensor is used for measurement of rotating speed and as a reference for signal processing. Partial discharge sensor This sensor is used for measurement of partial discharge important for assessment of winding isolation condition. Temperature sensors Pt100, RTD, thermocouple Strain gauge sensor This sensor is used for measurement of bearing temperature, core temperature, winding temperature and temperature of any machine part. This sensor is used for measurement of strain in structural parts of machine or its parts. Air gap sensor This sensor is used for measurement of machine air gap (pole/rotor profile). Process value transducer Different transducers are used for measurement of important process values of the machine (current, voltage, flow, pressure ). Magnetic flux/field sensor This sensor is used for measurement of magnetic field or magnetic flux inside a machine air gap and in end winding region of the machine. MCM system can receive and process any analog and digital signals from sensor or transducer that features standard voltage or current signal. 8 9

6 4. Electrical cabinet 5. Documentation electrical cabinet touch panel (local HMI) 3 processing unit 4 additional equipment 3 MCM system is flexible and modular. Based on number of measuring channels, scope of the measuring equipment and Customer requests, we offer appropriate electrical cabinets. Usually cabinets are equipped with: Protective/processing unit with measuring modules, Power sources for measurement equipment Terminals for connecting the sensor signal cables. Heater Lighting Humidity sensor Thermostat Fans for cooling Touch display (operator s panel) Local HMI Server computer IP protection On request Temperature range On request We offer the Customer complete documentation required for system installation, maintenance and usage of the MCM system. The usual scope of the documentation: Mechanical documentation (book I) Electrical documentation (book II) User instructions (book III) Initial state records (book IV) Certificates, test reports (book V) 6. Services We offer the Customer complete services for machine diagnostics. This is enabled through automated reports (3) which is one of MCM expert functions. Also, through web application we can remotely connect to the MCM system and provide the Customer expert analysis of measured (recorded) data (1, ). Server computer (central diagnostic computer) can be part of the electrical cabinet but usually it is installed in main control room with other systems for control and monitoring

7 KONČAR Electrical Engineering Institute Inc. Department for rotating machines Fallerovo šetalište, Zagreb, Croatia Phone: Fax: Web: mcm@koncar-institut.hr

SHCM SMALL HYDRO CONDITION MONITORING. Web HMI (real time data, trends, spectrums, alarms )

SHCM SMALL HYDRO CONDITION MONITORING. Web HMI (real time data, trends, spectrums, alarms ) SHCM Electric power system is a backbone of today s economy which relies on stable, uninterruptable supply of electric energy that is needed both in industry and in most areas of our private lives. According