| Condition monitoring
about forecasting and optimization than reaction.” The company is actively developing solutions to harness these trends, enhancing the predictive and analytical capabilities of their systems.
Exploring new applications MC-monitoring’s adaptable technology is expanding
beyond traditional hydro plants. New markets, including pumped storage facilities, offshore tidal energy systems, and small-scale hydropower projects, are increasingly adopting MC-monitoring’s solutions. This expansion demonstrates the versatility of the technology in supporting a diverse range of renewable energy systems. “We see tremendous potential in applying our monitoring expertise to these emerging markets,” says Adamo.
Incorporating digital twins and AI Digital twin technology represents one of MC-
Monitoring’s most significant advancements. By creating virtual models of hydrogenerators, plant operators can simulate real-time conditions and test various operational strategies. These simulations provide valuable insights into equipment behavior, helping to optimize maintenance planning. Adamo believes that “digital twins offer a proactive approach to machine health management, improving decision-making and efficiency.” Artificial intelligence and machine learning are
revolutionizing hydrogenerator monitoring by enhancing predictive capabilities and fault detection. MC-monitoring leverages these technologies to analyze complex data sets, recognize patterns, and provide actionable insights.
“Our AI-driven analytics continuously improve monitoring strategies and ensure that our solutions are always a step ahead,” says Adamo.
Upgrading condition monitoring For hydropower operators considering system upgrades,
MC-monitoring recommends a strategic approach. Begin with a comprehensive assessment of current monitoring infrastructure and prioritize upgrades for the most critical components. Opt for modular, scalable solutions that can adapt to future technological advances. Adamo advises: “Investing wisely in modular and adaptable systems is key to future-proofing your operations.” MC-monitoring’s systems are designed to integrate seamlessly with existing plant control frameworks, such as SCADA and distributed control systems (DCS). This compatibility ensures a centralized view of machine health and simplifies data management, making it easier for operators to implement condition-based maintenance. “Our solutions are built for seamless integration, complementing rather than complicating existing systems,” explains Adamo.
Conclusion MC-monitoring’s commitment to driving innovation in
hydropower condition monitoring is clear. By combining advanced sensor technology, real-time data acquisition, and AI-based analytics, the company is setting new standards for reliability, efficiency, and foresight in the industry. As hydropower continues to evolve, MC- Mmonitoring is well-positioned to meet the challenges of today and seize the opportunities of tomorrow.
Real-world impact: case studies in action
Detection of rotor pole loosening in vertical hydrogenerators In a vertical hydrogenerator, loosening of the rotor poles is a critical issue that can result in imbalance, excessive vibrations, and even potential mechanical failure, particularly under heavy operational loads. To address this, MC-monitoring implemented a sophisticated solution comprising a combination of vibration sensors and air gap monitoring around the rotor poles. The system continuously tracked vibration patterns and was able to detect early signs of loosening in specific rotor poles. This proactive approach allowed plant operators to schedule a maintenance shutdown in a controlled manner, during which they tightened and reinforced the affected poles. By catching the issue early, the plant avoided significant damage and sidestepped the high costs associated with emergency repairs and extended downtime.
Real-time monitoring of shaft alignment in large generators Large hydrogenerators are prone to misalignment issues between the rotor shaft and stator, which can lead to increased vibration, wear, and potential damage to critical components such as bearings and the rotor itself. To mitigate this risk, MC-monitoring deployed advanced real-time shaft alignment sensors coupled with vibration analysis to monitor alignment deviations. These sensors provided continuous, high-precision data on the axial and radial positions of the shaft. The monitoring system alerted operators as soon as alignment moved beyond acceptable thresholds, enabling quick, minor adjustments. This preemptive action helped extend the lifespan of the bearings, minimize mechanical wear, and optimize the generator’s overall efficiency, avoiding more substantial repairs and operational disruptions.
Detection of vibrational anomalies in Kaplan turbine blades
Kaplan turbines, with their complex adjustable blades, are susceptible to vibrational issues that can compromise blade integrity and lead to inefficient operations or catastrophic failures if not detected in
time. MC-monitoring tackled this challenge by installing vibration sensors directly on the turbine blades. The sensors, in conjunction with advanced data analytics, identified unusual vibrational patterns indicative of wear or structural anomalies. On one occasion, the sensors detected abnormal vibrations on a specific blade, prompting an inspection that revealed early-stage cracks. Thanks to the early warning, plant operators were able to repair the blade before the damage worsened, preventing a costly blade replacement and avoiding significant downtime. Additionally, the monitoring system was instrumental in identifying temperature hotspots during high-load periods, allowing for timely cooling system adjustments and improved ventilation. This intervention minimized the risk of insulation damage and reduced the likelihood of thermal-related failures.
Remote monitoring of generator pole temperatures using RTM-200 contactless sensors Monitoring the temperature of rotor poles in a hydrogenerator presents unique challenges due to restricted access and the high demands of continuous operation. High temperatures in these areas can lead to insulation breakdown, demagnetization, or severe electrical faults, making precise monitoring essential. MC-monitoring addressed this by deploying the RTM-200 contactless temperature sensor, specifically optimized for rotor monitoring in hydrogenerators and motors. The RTM-200 features a 4mm probe that fits into ventilation holes, delivering accurate, linear temperature readings with advanced filtering and signal processing. The sensor connects seamlessly with the MCm Sensor Manager software, enabling real-time temperature and diagnostic monitoring. Its adjustable depth accommodates a wide range of stator cores, allowing for both temporary and permanent installations, with easy removal for maintenance. The implementation of the RTM-200 system allowed operators to continuously monitor rotor pole temperatures, detecting early-stage heating problems that signaled insulation wear or cooling imbalances. By facilitating timely adjustments to the cooling system, this solution helped prevent overheating and contributed to extending the life of the generator.
Above: The PMS-300 PLUS Protection & Monitoring System is a modular 19’’ rack-based solution designed to safeguard and monitor rotating machinery. With its versatile design, it adapts seamlessly to various industrial applications, making it an ideal choice for monitoring and protecting large turbines, generators, or a multitude of smaller machinery
www.waterpowermagazine.com | November 2024 | 21
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45
