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ABB MACHsense-P Tran Anh Xuan – Account Manager Machine & Motors – DMMG

Motor & Generator Service SONG NHAT

© ABB Group November 24, 2011 | Slide 2

Project: Sixth Sense Overview

Data collectors

(machine running)

Sensors

Detachable sensors

Manual

RAP GPRS ….

Automatic (L1, L2, L3, L4) Spares Replacements Retrofit Upgrade Extended warranty Reliability centered Contracts Availability guarantees

Fixed sensors Embedded / Integrated Retrofit

Fixed type

Premium Standard blackbox

Vibration

Current/Voltage

Flux

Partial Discharge

Sparking

Temp/Speed

: :

Service Products ABB MACHsense ABB LEAP ABB PEP ABB Start-up Fingerprinting

TECHNOLOGY DEVELOPMENT

Algorithms

Syn. motor

Ind. motor

DC motor

Portable type

MachineMonitor

TECHNOLOGY DEVELOPMENT

Internet SONG NHAT

http://www.abb.com/product/seitp322/19e6c63b9837b35dc1256dc1004430be.aspx?productLanguage=us&country=IN�

http://www.abb.com/product/us/9AAC100519.aspx?country=IN�

http://www.abb.com/product/us/9AAC100516.aspx?country=IN�


Project: ABB MACHsense-P

• A walk around condition monitoring service • Periodic measurements • Machine in operating condition

• Detection of defects and evolution over the time by periodic measurements • Preventive maintenance plan based on projected time of defect criticality (over a period of 6 months)

Overview

INSTALLATION Alignment, soft foot, air gap

CAGE ROTOR

POWER SUPPLY

ANTI-FRICTION BEARING

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ABB MACHsense-P

ABB MACHsense-P Development has been done by ABB

Machines Service based on intensive R&D carried out in our corporate research centers

Measurement is done on the operating machine

Measurements & Analysis of Data & Report Measurements are performed by ABB Local Service Centers A summary report is delivered automatically on-site Detailed report is later delivered by Regional Technical Center (RTC)

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ABB MACHsense-P

Equipment A single analyzer for the mechanical and electrical

measurements Measurements 4 Vibration Sensors 3 Voltage clamps 3 Current clamps Temperature sensors (optional) Speed sensor (optional)

Measurements

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Measurement Either 4 vibrations channels

or 7 electrical channels simultaneously

High resolution data collector for quick & high speed data acquisition

Critical comparisons to be made immediately during measurements (e.g. alignment check)

ABB MACHsense-P Measurements

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ABB MACHsense-P

Cage Rotor Rotor winding defects Air gap eccentricity Unbalance Looseness Static and dynamic shaft

bends Internal misalignment Anti-Friction Bearing Bearing defects Bearing assembly defects Lubrication interval estimates

Standard Inspection Analysis

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ABB MACHsense-P

Installation Soft foot Misalignment Foundation resonance

Power Supply Quality Harmonics and distortion Unbalance Over/under voltage,

frequency

Standard Inspection Analysis

-15000

-10000

-5000

0

5000

10000

15000

0 0.02 0.04 0.06 0.08 0.1 0.12

Time [s]

Vo

ltag

e [V

] SONG NHAT


ABB MACHsense-P Standard Inspections

Solution levels Inspection Deliverables Measurements

Requirement When

• Standard • Vibration, voltage, current, temperature (winding, cooler, ambient) and speed • Operation history and maintenance and failures records

• Cage rotor package • rotor winding defects • air gap eccentricity • unbalance • looseness • static and dynamic shaft bends • internal misalignment

• Anti-friction bearing package • bearing defects • bearing assembly defect, • lubrication interval estimates

• Installation • soft foot • misalignment • foundation resonance

•Power supply • harmonics and distortion • unbalance • over/under voltage • frequency

• Maintenance and inspections recommendation

• Measurements of the machine at operating load

• Every six months

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ABB MACHsense-P Advanced Inspections

Solution levels Inspection Deliverables Measurements

Requirement When

• Advanced • Vibration, voltage, current, temperature (winding, cooler, ambient) and speed

• Operation history and maintenance and failures records

• Same as Standard • Cooler

• Fouling • Root Cause Analysis

• Measurements of the machine at operating load and multiple loads or/and start-up

• When defect is suspected either from standard measurement or from observed problems and there is a need for further investigation

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Bearings Vibration Analysis : BeAM®

Common analysis methods use for the envelope method for bearing fault detection

The envelop method uses the envelope of high frequency signals generated by defects and compares it to bearing defect frequencies.

The ABB BeaCon automatic analysis

uses: the auto-correlation time-domain

method to filter out the noisy signals more effectively that traditional method

Technical explanation

0.56 0.565 0.57 0.575 0.58 0.585 0.59-0.4

-0.3

-0.2

-0.1

0

0.1

0.2

0.3

0.4

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Bearings Vibration Analysis : BeAM®

The ABB BeAM® in addition to the ABB BeaCon automatic autocorrelation time-domain analysis:

Perform early shock pulse detector analysis which only extract the shock pulses related to bearing defects using special signal processing methods such as adaptive filtering and likelihood ratios to improve the signal sensitivity.

Estimates the following parameters to evaluate the condition of the bearing:

Kurtosis , high frequency RMS, maximum energy per shock pulse & integrated energy calculations

Technical explanation

0 10 20 30 40 50 60 70 80-3

-2

-1

0

1

2

3

Time [ms]

0 10 20 30 40 50 60 70 80-3

-2

-1

0

1

2

3

Time [ms]

Data sequences that contain shock pulse + noise

Data sequences that contain only noise

Unfiltered vibration signal.

Above signal after proper filtering.

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Sensitivity of different methods to detect bearing faults

Time

Severity of the fault

A spall has been developed

ABB BeAM®

Off-line envelope method and an experienced analyser*

Off-line envelope method and an inexperienced analyser*

ABB BeaCon automatic autocorrelation time-domain

Significant change in crest factor**

Significant change in high frequency RMS value**

Change in bearing temperature**

•Commonly used methods for bearing faults analysis ** Non-specific methods

Lubricant debris monitoring*

Smoke**

Early detection Failure

Significant change in vibration values

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Analysis of other vibration causes

Analysis Automatic analysis for the identification of misalignment,

unbalanced, looseness and soft foot using Principal component Analysis (PCA)

-1 -0.5 0 0.5 1

-0.8

-0.6

-0.4

-0.2

0

0.2

0.4

0.6

45

46

51 30 48

49

3233

50

34

43

4742

29 35

44

28 23241825

31

27202619

57

1415138910

36

61

37

38

Normalised 1st and 2nd Principal Component - 8 harmonics

Misalignment

Soft Foot

Other

Unbalance

Looseness

Typical Mesurement Result Patterns

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Electrical measurements

Analysis • Rotor winding defects • Air gap eccentricity problems • ABB Motor Current Signature Analysis (MCSA) and voltage measurements

Vibration

Slip estimation

Detection of rotor bar faults

Detection of eccentricity

Stator Voltage

Stator Current

S peed

Fault level , Rotor speed Index value

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Advantage of ABB MACHsense-P Technology

Index and fault criticality are specific to each machine. Machine design and construction aspects are accounted for in the calculation

ABB Index Critical level for current with standard method

Life time

Machine “A” Index Critical level with ABB method

Index

Critical level for vibration With standard method

Early fault detection at machine „A“

Early fault detection at machine „B“

Machine “B” Index Critical level with ABB Method SONG NHAT


ABB MACHsense-P

Rotor analysis Simultaneous presence of different

defects can be isolated and analyzed separately

Even if machine is loaded below 50%,

rotor bar defect detection is possible Double cage or deep bar defects at the

slot top can be easily identified Early detection of defects

Advantages

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ABB MACHsense-P

ABB Motor Current Signature Analysis (MCSA) Our diagnostic method reduces the

effect of torque oscillations, variations and

dips caused by power supply and loads

Winding connections Rotor construction

Our diagnostic method is suitable for large machines and takes into account Low slip Larger air gaps

Advantages

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Advantages of ABB MACHsense-P vs. other methods

Model Based Analysis Increases reliability of defect

identification Quantifies defect severity Combined Analysis of current, vibrations, and torque Improves diagnosis accuracy Takes into account machine design &

construction aspects to estimate defect indices & defect criticality

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Advantages of ABB MACHsense-P vs. other methods

Unique motor specific analysis tool Comprehensive analysis Current, voltage and vibration in a single

automated analysis Summary status report issued on site Application specific preventive

maintenance plan with final detailed report

Reduction in unplanned downtime Early warning provides adequate time

for maintenance plan ABB service network available Improves accuracy of diagnosis

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ABB Condition Monitoring

Vibration measurement were taken for two identical Boiler Feed Pump motors. Both measurements were taken for 50 % of machine load.

Nameplate details:

Overall vibration readings in Motor BFP 3C, serial number: 3991201-1 Velocity: 1.02 mm/s Acceleration: 0.46 g

Overall vibration readings in motor BFP 3B, Serial Number: 3991201-2 Velocity: 1.3 mm/s Acceleration: 1.36 g

Power Voltage Current Speed Frequency Poles

2000 kW 6.6 kV 204 A 1487 rpm 50 Hz 4

Case study - Bearings

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ABB condition monitoring

Machine BFP 3C • Bearing OK • Suggested action:

• action category: preferred • next measurement: in six months

Machine BFP 3B • Bearing faulty • Suggested action:

• action category: mandatory • change bearing as soon as possible but not later than 3 months

Case studies – Bearings: Early Warning

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ABB condition monitoring Case study : Recommendations Explanation of Terminology

Probability of Fault Occurrence - Time Scale Service Schedule Measurement Frequency

No actionMeasurements should be repeated between 6 months to a year

PREFERRED Action within months to years.

Schedule service based on changing fault severity over time.

Measurements should be repeated every 6 months

CRITICAL Action within weeks to months.

Scheduled service at next available outage.

The machine should be secured or monitored very closely*

MANDATORY Action likely failure within days to weeks. Perform service as soon as possible.

The machine should be secured or monitored very closely** special short term monitoring schedule

Action Category

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Target machines with ABB MACHsense-P

• for machines above 2000 kW sleeve bearings are often used which are less likely to fail.

• main failure reason is stator winding.

-> ABB LEAP for stator

• Failure Statistics: MV Motors Petrochemical Industry 1999 • Source: IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS . VOL. 35. NO. 4. JULY/AUGUST 1999

57,40

18,40%

5,66%

2,80% 14,60% 0.95%

Distribution of failures for motors less than 2000 kW

Bearing

Stator

Rotor

Shaft

External devices

• for machines less than 2000 kW anti-friction bearings are main failure reason

-> ABB MACHsense-P

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