Tor Ole Bang-Steinsvik, Advanced Solutions, …© ABB Group March 16, 2009 | Slide 2 Maintenance...
Transcript of Tor Ole Bang-Steinsvik, Advanced Solutions, …© ABB Group March 16, 2009 | Slide 2 Maintenance...
© ABB Group March 16, 2009 | Slide 1
Tor Ole Bang-Steinsvik, Advanced Solutions, 12.03.2009
Condition Monitoring Electrical System Vibration – New wireless option
© ABB Group March 16, 2009 | Slide 2
Maintenance Workplace
Electrical System Condition Monitoring
Why?
LV Circuit Breaker Monitor
LV Motor Control Centre Monitor
MV Switchgear Monitor
Drive Monitor
TEC – Transformer Monitor
Sea Cable Monitor
Vibration Monitoring
Online Wired
Online Wireless - WiVib
Agenda – Condition Monitoring
© ABB Group March 16, 2009 | Slide 6
Optimized maintenance workflow reduces time to action
Continuous Condition Monitoring
Fault Condition Reporting
Alarming and Paging
Access to detailed diagnostic
Fault Report Submitting into CMMS
Work order information in 800xA
Monitoring
Reporting
Analyzing
Decision
ActionSubmit
Maintenance Workplace
Notify
© ABB Group March 16, 2009 | Slide 7
Maintenance Workplace
Electrical System Condition Monitoring
Why?
LV Circuit Breaker Monitor
LV Motor Control Centre Monitor
MV Switchgear Monitor
Drive Monitor
TEC – Transformer Monitor
Sea Cable Monitor
Vibration Monitoring
Online Wired
Online Wireless - WiVib
Agenda – Condition Monitoring
© ABB Group March 16, 2009 | Slide 8
Conditon Monitoring System
Note:Time Synchronization
View
Signals
OPC/Modbus/etc.
DCS
(Electrical) (Vibration) (Process)
Portal
(Performance Monitoring)
© ABB Group March 16, 2009 | Slide 11
Why Condition Monitoring on electrical systems?
HSEReduce risk of fireReduce CO2/NOx emissionsReduce energy consumption
Improved production outputPredictive maintenance of production facilitiesFaster fault findingAllow operation closer to limits
OPEXMore efficient maintenance work processesExtended equipment lifetimeLess spare parts need in store – improved logistics for parts
Loss of electric power is a known, but little investigated cause of downtime!
© ABB Group March 16, 2009 | Slide 12
Maintenance cost:
Distribution1 Safety equipment 11,7 %2 Electric power distribution 11,3 %3 Instrumentation 10,6 %4 Piping specialities 8,7 %5 Lifting 8,1 %6 Pressure vessels and storage tanks 5,7 %7 Piping, pipeline, risers and umbilical 5,0 %8 AC, equipment for refrigeration 5,0 %9 Turbines 4,4 %10 Manually operated valves 4,2 %11 Pumps 3,8 %12 Power generation/transformation 3,8 %13 Communication equipment 3,1 %14 Other 3,1 %15 Safety relief valves 3,0 %16 Combustion engines 2,6 %17 Actuator operated valves 0,9 %18 Not relevant 5,2 %
100,0 %
Maintenance cost distribution for 10 north-sea fields:
18,9%
© ABB Group March 16, 2009 | Slide 14
trip unit for Tmax T4-T5 and Isomax S6
LV Circuit Breaker Monitor
PR122
PR123
PR332
PR333
PR222DS
trip units for Emax
trip units for Emax X1 and Tmax T7
© ABB Group March 16, 2009 | Slide 15
LV Circuit Breaker Monitor
Local bus unit
Trip coil
Contacts
CB statuscontacts
Temperaturesensor
EP010
Trip unit,electronic
Ratingplug
Keyplug
Currentsensors
Load side, electrical
Supply side,electrical
Supply / Loadside, electrical
© ABB Group March 16, 2009 | Slide 24
DriveMonitorTM
DriveMonitorTM is a diagnostic system which provides:
Easier root cause analysis – reduced Mean Time To Repair
Early detection of potential failure
Remote access allows support from external expert
Continuous monitoring of status and respond when changes occur
Predefined diagnostic actions, prosessing and reporting
Monitoring of drive’s performance, and, if required, other shaft line components (main circuit breaker, transformer, motor)
© ABB Group March 16, 2009 | Slide 27
TEC – Transformer Monitor
The TEC (Transformer Electronic Control) is a diagnostic system which provides:
Statements about the operating condition and load ability prediction
Diagnoses and recommendations for corrective actions if problems with the transformer should occur (oil/winding temperature, tap-changer wear, moisture and hydrogen content in oil)
Prediction of the consumed lifetime based on overload forecasting and winding hot-spot calculations
Optimum cooling performance according to load and controlled wear on cooling pumps and fans
© ABB Group March 16, 2009 | Slide 28
Sea cable monitoring
.
Based on fiber optic distributed temperature sensing (DTS)
Provides continuous and repeatable measurements, in real-time, of the location and the temperature of many thousands of points along the optical fiber sensor.
The environment of a submarine cable, particularly at the ends, can change. Monitoring the temperature will alert the maintenance system should the cable, for example, be stretched or bent, since the stress on the cable will change.
Individual sections of the cable can be identified as different zones (i.e around a buoy) that can be independently programmed to generate an alarm via the maintenance system when the temperature in any zones reaches a pre-set limit, thus helping to both protect the cable and prevent outages.
Graphical user interfaces, temperature profiles and data are integrated into Asset Optimizer.
© ABB Group March 16, 2009 | Slide 29
Maintenance Workplace
Electrical System Condition Monitoring
Why?
LV Circuit Breaker Monitor
LV Motor Control Centre Monitor
MV Switchgear Monitor
Drive Monitor
TEC – Transformer Monitor
Sea Cable Monitor
Vibration Monitoring
Online Wired
Online Wireless - WiVib
Agenda – Condition Monitoring
© ABB Group March 16, 2009 | Slide 30
Vibration analysis – basic principles
Component Part Sub type Potential Failure Frequency
Journal Wear, loose etc. RPMRolling Element Spalling etc. HF (BPFO, BPFI & BSF)
Rotor/shaft Unbalance, misalignment RPM
Mec
hani
cal
Bearings
Gearwheel Wear, cracks RPM x No. Teeth + sidebands
1. Rotational frequency of the fan
2. Rotational frequency of the motor
3. Misalignment of the shaft at the coupling
4. Fan unbalance
5. Tooth meshing frequency
6. A developing fault in the ball-bearing
13
2 4 5
6
Accelerometer
© ABB Group March 16, 2009 | Slide 31
Vibration Monitoring- the objective
Proven technology for predictive maintenance of rotating equipment
Detect incipient failure
planand
prepare Shutdown and
repair
Cost effective means of avoiding production loss and minimising
maintenance cost
Protection system- to prevent catastrophic failure
Primary safety system with safety critical performance standards
Shut machine
down within msec
Manual data gathering today - Ideal opportunity for wireless technology
Wired systems are preferable (for now)
© ABB Group March 16, 2009 | Slide 32
Vibration Monitoring – Online wired protection and monitoring
MCM800
Asset OptimizerTM
Maintenance Workplace
OPC server
Ethernet switch
Acc 1
Acc 3
Acc 2
SAP/MAXIMO CMMS
MPM810
TBU850
AnalystTM
ABB Asset Monitor Integration
RelaySpee d
© ABB Group March 16, 2009 | Slide 33
WiVib – Wireless monitoringVibration monitoring of motors and rotating
equipmentCost effective for motors < 400kWNon-intrusive (very simple installation)Fully autonomous – no WLAN requiredSmall, inexpensive, wirelessRobust communication in industrialenvironmentLong battery life >5 yearsSuitable for EX Zone 1 environment
© ABB Group March 16, 2009 | Slide 34
WiVib development historyConsortium headed by ABB
Sponsor:
PrototypeInitial concept Product
© ABB Group March 16, 2009 | Slide 36
OTC Spotlight on new technology award 2008http://www.otcnet.org/2008/spotlight/