flyer - ENDIPREV

Condition Based Maintenance Solutions
High technology solution portfolio for
efficient induction machinery
testing and assessment
INCREASED RELIABILITY
Importance: Induction machinery, such
Endiprev’s monitoring and
as motors, generators or transformers,
diagnostic inspection programmes
are the most vital pieces in industrial and
increase operational
power generation plants. The availability
and reliability of these equipment largely
reliability and availability.
depend on the condition and behaviour of
Monitoring methodologies can be
several key components.
used as early warning
system for potential damages.
Regular Service: For a reliable
operation of the machine it is
recommended to perform regular
EXTENDED MAINTENANCE
inspections of the rotor and stator.
INTERVALS
Inclusion of advanced monitoring tools and
Maintenance intervals can be
services in this diagnostic concept
extended due to the early warning
provides the best prerequisite to reliably
detect defects at an early stage, which
indicators gathered via offline
might endanger operation in the future.
inspections and online monitoring.
Endiprev’s customized monitoring
Services available
and diagnostic packages consider
optimization between time-based
and condition based maintenance
Extended Park’s Vector Approach
Motor
concepts.
Thermography Analysis
Page 3
COST EFFICIENT
Endiprev’s tools are easy to apply
and install due to the modularized
Insulation Resistance Test
Endiprev’s tools are easy to apply
and install due to the modularized
concept.
Relevance
Supply
Misalignment
and
Unbalance
High
Energy
Quality
MCSA,
Vibration
Analysis
Partial
discharge
EPVA
EPVA
EPVA
MCSA
Energy
Quality
Medium
EPVA
(Tension)
Insulation
Statoric
electrical
asymmetry
Page 4
Low
concept.
PLANNING AHEAD
Load
Supply
Page 2
Broken
Bars
EPVA,
MCSA,
IPSA
Bearings
faults
Load
Mechanical
Problems
Vibration
Analysis
Vibration
Analysis
Wavelet
EPVA,
MCSA,
IPSA
EPVA,
MCSA,
IPSA
Four levels of monitoring available
Level 4 (under development): data connection to central server (e.g. utility headquarter), extended
remote support with Service Centre expertise and continuous data assessment
Level 3: permanent equipment, local server, and data assessment on request
Level 2: portable equipment, local data collection and periodic
data assessment
Level 1: Sensor, cabling and connection box
Condition Based Maintenance Solutions
Extended Park’s Vector Approach
Electrical Signature Analysis (ESA) is the name a general set of techniques for monitoring condition of electrical machines
by analysing their electric signals.
Extended Park’s Vector Approach (EPVA) is the technique of spectral analysis of the magnitude of the vector the Park.
The current signals are collected and pass through Park transformation, following the module is calculated Park vector and
finally the spectrum. This technique is quite useful in calculating the imbalance electric motors without torque control. The
result is a demodulated spectrum that takes into account variations in the three phases current.
Case Studies
«Very good job!»
Secil — Outão cement plant
Challenge
Diagnosis of failure of engine CEM, 3 MW,
6kV (vertical mill drive)
Faults detected
Static and dynamic eccentricity asymmetry in
the stator circuit
Maintenance works
Check the alignment of the motor with the
load
Tighten engine mounts
Benefits
Avoid unnecessary degradation of the engine
«Thanks, we’re glad we’ve
called you!»
Jomar — wooden chipboard plant
Challenge
Fault detection in ABB motor, 355 kW, 400V
Faults detected
Severe asymmetry in stator circuit
Maintenance works
Replacing the engine during planned
maintenance work
Benefits
Avoided the cessation of production, since
this engine is crucial in the production
process
Repair the engine replaced before the
equipment loss
«This problem
couldn’t be solved
for more than a year!»
Safra wind farm
Challenge
Detect anomalies that led the generator
Winergy 1.675MW, 690V to stop when it
reached the 800kWh
Faults detected
Finding of a significant asymmetry in the
circuit of the generator stator
Parameter setting in the control of power
converter
Tighten engine mounts
Benefits
Increasing the availability of the turbine
Avoid random stoppage of the wind turbine
References
“[…] experimental results show that bearing faults can be effectively detected by using this new approach. Even for an
early stage of damage development […] Although vibration monitoring of mechanical bearing frequencies has been
traditionally used for detecting machine bearing failures, the obtained results concerning the used of the Extend Park’s Vector
Approach clearly demonstrate that this technique can be a strong alternative to the vibrations analysis, without
requiring access to the motors, situation that in some common industrial applications prevents the used of the vibration
analysis at all. Moreover, the EPVA proved to be more sensitive to the damages occurring in the bearings inner race
than the vibration analysis itself. When compared to the motor current spectral analysis the EPVA is undoubtedly
much more advantageous.”
Silva, J.L.H.; Cardoso, A.J.M.; , "Bearing failures diagnosis in three-phase induction motors by extended Park's vector approach," Industrial Electronics Society, 2005.
IECON 2005. 31st Annual Conference of IEEE , vol., no., pp. 6 pp., 6-10 Nov. 2005
doi: 10.1109/IECON.2005.1569315
URL: http://ieeexplore.ieee.org/stamp/stamp.jsp?tp=&arnumber=1569315&isnumber=33243
“Park transform approach has better diagnosis capabilities than the Concordia transform”
Onel, I.Y.; Benbouzid, M.E.H.; , "Induction Motors Bearing Failures Detection and Diagnosis: Park and Concordia
Transform Approaches Comparative Study," Electric Machines & Drives Conference, 2007. IEMDC '07. IEEE
International , vol.2, no., pp.1073-1078, 3-5 May 2007
doi: 10.1109/IEMDC.2007.382825
URL: http://ieeexplore.ieee.org/stamp/stamp.jsp?tp=&arnumber=4270799&isnumber=4270762
“[…] results obtained by the extended Park’s vector approach are more
discriminating than those obtained by the traditional FFT technique.”
Benbouzid, M. E. H.; Kliman, G. B.; , "What Stator Current Processing Based Technique to Use for Induction
Motor Rotor Faults Diagnosis?" Power Engineering Review, IEEE , vol.22, no.8, pp.62, Aug. 2002
doi: 10.1109/MPER.2002.4312474
URL: http://ieeexplore.ieee.org/stamp/stamp.jsp?tp=&arnumber=4312474&isnumber=21976
Rua da Gandarada 39
3450-133 Mortágua,
Portugal
Phone (+351)231927035
Fax(+351) 231927049
[email protected]
Condition Based Maintenance Solutions
Thermography Analysis
Thermography is a non-intrusive diagnostic technique, which can be
performed while the machine is energized and operating. The inspector can
make simultaneous temperature measurements on the surface of the
machine or driven load. The analysis can be in real time or digitally stored
for later analysis and documentation. Most electrical equipment will exhibit
some type of a thermal pattern before failure. Even though the imminent
failure is internal and thus out of view, the atypical heat generated by the
anomaly will show up on the surface of the equipment. Thermographic
analysis can be a comparison of temperature
rise above another surface of the piece of
equipment, a rise above a comparative piece of equipment, a rise from a baseline
thermograph, or simply user determined upper temperature limit.
Modern thermography equipment is sophisticated enough to give both qualitative
information in the form of color changes relative to temperature changes and quantitative
information of actual measured temperature at a specific point on the equipment surface.
Thermography can identify several problems with machines including the following:
— Filter or other air flow restriction problems that cause a temperature increase
— Mechanical, lubrication, or cooling problems at the machine bearings
— Machine winding problems such as overload or dirt buildup
— Overloading due to design, operation, or electrical problems
— Evaluation of conduit box, cable terminations, CTs, arresters, etc.
When used with other analytical techniques such as vibration, oil analysis
and machine current testing, thermographic equipment is a valuable tool for
any machine maintenance program.
Highlights
 Shows a visual picture so temperatures over a large area can be compared
 Capable of catching moving targets in real time
 Able to find deteriorating, i.e., higher temperature components prior to their
failure
 Can be used to measure or observe in areas inaccessible or hazardous for other
methods
 Non-destructive test method
 Can be used to find defects in shafts, pipes, and
other metal or plastic parts
 Can be used to detect objects in dark areas
Rua da Gandarada 39
3450-133 Mortágua,
Portugal
Phone (+351)231927035
Fax(+351) 231927049
[email protected]
Condition Based Maintenance Solutions
Insulation Resistance Test
This test determines the resistance of insulation between conductor
and ground. Low values may indicate moisture, dirt, or damaged
insulation. This short-time test involves connecting an insulation
resistance tester across the insulation for a period of time until the
insulation is evenly charged, which may take up to 60 seconds.
The “insulation resistance tester” (megohmmeter) is a high-range
resistance meter with a built-in direct current generator. It measures
and calculates the insulation resistance based upon milliampere or
microampere leakage between conductors and ground. Insulation
resistance tester reads through and also across the surface of the
insulation. A non-manual insulation tester is typically used when a
polarization index or dielectric absorption ratio is to be computed. If the
phases of the machine can be disconnected, each phase of the
winding should be tested separately, which allows measurement of the
phase-to-phase insulation.
By taking and recording readings periodically, a basis for judging the insulation condition can be made. Any
persistent downward trend is a warning of needed maintenance, even though the readings may be higher than
the suggested minimum safe values. Equally true, as long as periodic readings are consistent, the results may be
satisfactory, even though close to the minimum values. However caution should be exercised for machines
approaching minimum insulation resistance value.
Highlights
 Quality control measure at the time a piece of electrical equipment is produced
 Installation requirement to help ensure specifications are met and to verify
proper hookup
 Periodic preventive maintenance task
 Troubleshooting tool
Rua da Gandarada 39
3450-133 Mortágua,
Portugal
Phone (+351)231927035
Fax(+351) 231927049
[email protected]