Condition monitoring |
Advancing hydropower monitoring
In the dynamic field of hydropower, condition monitoring has become essential for ensuring efficient and reliable operations across both new and existing infrastructure. MC-monitoring has developed innovative solutions tailored to meet the evolving needs of hydropower plants worldwide.
IWP&DC spoke with Salvatore Adamo, Managing Director, about the company’s cutting-edge technologies, the challenges they address, and the future of hydrogenerator monitoring
Above: MC-monitoring AirGap Sensor AGS-212 M4. The air gap transducers from MC- monitoring are state-of-the- art sensors, engineered with cutting-edge technology to meet the demanding needs of various industrial applications
Below: Technician installing an air gap sensor on the stator core laminations, ensuring precise positioning for accurate measurements
MC-MONITORING’S EXTENSIVE PORTFOLIO includes advanced sensor technology, data acquisition units, and condition monitoring software, which collectively provide hydropower operators with early detection capabilities to preemptively identify and address potential issues. Salvatore Adamo, Managing Director of MC- monitoring, emphasizes the importance of this integrated approach: “Our goal is to deliver comprehensive systems that preemptively catch problems, preventing costly downtime and maximizing efficiency.” By leveraging these advanced tools, hydropower plants can ensure reliability and optimize their operational output.”
Enhancing reliability and efficiency A standout aspect of MC-monitoring’s technology is its
air gap monitoring system. This system continuously measures the rotor-stator distance, a critical factor in ensuring optimal performance. Adamo explains that accurate air gap data is essential for detecting rotor misalignments, mechanical deformations, or eccentricities. “This level of insight allows for proactive maintenance, transforming traditional maintenance strategies from reactive to predictive,” he notes. By addressing potential issues early, the system not only enhances reliability but also contributes to improved overall efficiency by minimizing unplanned downtime. MC-monitoring has also introduced groundbreaking innovations in air gap measurement. Utilizing non-contact sensors and high-frequency sampling, the company has achieved a level of accuracy that was previously unattainable. These advancements reduce susceptibility to environmental disturbances, ensuring reliable data. “By making air gap monitoring more precise and less prone to interference, we provide consistent and trustworthy information for operators,” Adamo points out.
Integrated sensors, data acquisition
units and software Integrated sensors, data acquisition units, and software solutions lie at the heart of MC-monitoring’s comprehensive approach. High-precision sensors, designed for durability and accuracy, capture high- resolution data on critical parameters. These data are processed and transmitted by robust acquisition units such as the PMS-300P, enabling a comprehensive, real-time view of equipment health. This seamless integration extends to MC-monitoring’s CMS-500P condition monitoring software, which provides operators with powerful analytics and actionable insights. Adamo emphasizes that the technology is “designed to deliver
20 | November 2024 |
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reliable and resilient performance, even under the harshest conditions, ensuring that operators can make informed decisions with confidence.”
The challenges of aging infrastructure One of the biggest hurdles for hydropower operators
is managing aging hydrogenerators. These older machines often suffer from insulation degradation, mechanical wear, and rotor eccentricity. MC-monitoring has developed solutions that are both robust and adaptable to address these issues. From durable sensors that maintain accuracy despite extreme conditions to predictive analytics that identify trends in equipment wear, MC-monitoring’s technology enables operators to plan maintenance activities more effectively. “We give plant operators the tools to prioritize maintenance and extend the life of their assets,” Adamo states.
Adapting to the demand for flexible
hydropower As the energy landscape evolves, hydropower plants are increasingly expected to operate flexibly, handling frequent load changes and start-stop cycles. To meet this demand, MC-monitoring has refined its technology to process data rapidly and adapt to operational variability. The systems now employ adaptive algorithms that maintain precise monitoring under shifting conditions.
Compact solutions The confined spaces within hydrogenerators pose
another significant challenge. In response, MC- monitoring has developed compact, high-performance sensors that require minimal space. These sensors, such as the AGT (Air Gap Transducers), are engineered to deliver advanced monitoring capabilities without necessitating extensive structural modifications. Adamo says: “Our designs focus on miniaturization and modularity, ensuring that even the most space- constrained environments can benefit from our technology.”
Emerging trends The future of hydropower monitoring is shaped by trends
like the rise of digital twins, increased IoT integration, and AI-driven analytics. MC-monitoring is at the cutting edge of these innovations, incorporating advanced data analysis tools that enable predictive maintenance. Adamo is optimistic about these advancements: “Digital twins and AI will fundamentally change how we approach condition monitoring, making it more
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