Technical Feature
Enging’s real-time MonItoring System focused on the
Following the growing trend of Industrial Internet of Things (IIoT) and Industry 4.0, Enging’s Motor Condition Monitoring (MCM) solution is an advanced real-time monitoring system focused on the predictive maintenance of industrial electric motors. It is estimated that the average downtime costs due to electric motor failures in an industrial factory is around 90.000€ and 450.000€ per hour for critical application failure. In oil refineries, this value can reach one million euros per hour.
predictive maintenance of industrial electric motors Jorge Estima - PhD R&D Manager
, Enging
Currently, the traditional maintenance techniques applied to these assets are based on real-time measurements of temperature and vibration levels. Although these approaches provide basic fault diagnostic information on possible motor faults, they do not allow or present serious limitations when it is required to clearly detect and localize an incipient or existing fault. Furthermore, these approaches usually require the physical access to the electric motor to take measurements or to install specific sensors. Therefore, in various applications such as submerged pumps, explosive environments or remote/inaccessible locations, the physical access or the possibility to use the traditional monitoring solutions is not possible or very limited.
Considering this, Enging and United Utilities has developed an innovative approach that allows to effectively monitor electric motors, even the ones that do not allow easy access. Enging’s MCM just needs to acquire the electric signals (voltage and currents) that supply the electric motor, which are easily available at the control panel (MCC), making very simple to install.
These analogue signals are acquired by a dedicated data acquisition board and sent to a gateway device that collects data from the different motors. The information is then sent to a Cloud service or to a central server, where it is processed. Afterwards, any user with access permissions can see what is happening in real-time with the different devices. Most importantly, if something abnormal is detected, this intelligent platform sends an email to defined users, warning about the device condition, the fault type, its location and severity level. All this information can also be easily integrated with SCADA systems or any other platform, making it very versatile.
At the core of this system is an advanced algorithm that integrates the most recent technological developments on condition monitoring and fault diagnosis of electric motors, using just electric signals. This algorithm allows to detect failures in all parts that comprise electric drives:
Supply Problems: • Voltage unbalance; • Problems in power converters and soft-starters; • High harmonic distortion;
40 drain TRADER | April 2018 |
Stator Faults: • Winding short-circuits/degradation; • Magnetic core problems;
Rotor Faults: • Rotor broken bars (in squirrel cage motors); • Magnetic core problems; • Startup resistances unbalance (in wounded rotor asynchronous motors); • Slip-ring/contact problems (in wounded rotor asynchronous motors);
Mechanical Problems: • Eccentric rotor/load; • Misalignment; • Bended shafts; • Cocked Bearings;
Load Problems: • High/abnormal oscillations; • Problems in belt/pulley systems.
The algorithm computes several fault indexes associated to the different fault categories, allowing to tracking small deviations due to early faults. Since it is very sensitive, incipient faults can be therefore detected in a very early stage, allowing to schedule maintenance actions and avoid unintentional stoppages and loss production costs.
In conclusion, Enging’s MCM solution is the most advanced real-time electric motor monitoring system, that effectively allows easy and early faulty detection. The main selling points are:
• Can be used in all applications, with or without variable speed drive, including submerged or inaccessible motors, where traditional methods cannot be applied;
• Very sensitive algorithm based on the most recent scientific developments, allowing to detect incipient faults for proper and effective predictive maintenance;
• Computation of energy efficiency parameters, allowing users to track and optimize electricity consumption;
• Future proof solution, integrating the most advance technologies related to Industry 4.0.
www.draintraderltd.com
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