CONDITION MONITORING THE BEST WAY TO SAVE YOUR MONEY

Transcription

1 CONDITION MONITORING THE BEST WAY TO SAVE YOUR MONEY VULKAN COUPLINGS 21. Juli

2 AGENDA History of the Vulkan Group Reasons for condition monitoring Machine diagnostics Benefits and ROI Conclusions 2-29

3 VULKAN History Production of screw-band clutches, For the first time able to engage under load 1918 VULKAN introduced the first highly flexible coupling world wide (VULKAN EZ-Coupling) 1951 For the first time VULKAN introduced silicone instead of rubber 1993 Integration of SeaCom into the Vulkan Group Foundation of VULKAN, production of Brewing equipment (compressors) Production of marine reversing gear box with high maneuverability VULKAN introduced RATO, the first coupling with a linear characteristic Start of VULKAN s own rubber production in Herne 3-29

4 VULKAN Group Coupling Lokring Drive Tech SeaCom Flexible Couplings Pipe Connections Brakes, dumpings in Ships and wind industry Measurement system for industrial applications - ship s main propulsion - ship s auxiliary drive - PTO s - boat propulsion - Freezers - Refrigerators - Air condition units - boat propulsion - industrial drive - mobile drive - railway - crank shaft dampers -Programming of microcontrollers - Development of programs of visualization and evaluation of physical dimensions in real time -Preventive maintenance -CMS and MDS 4-29

5 AGENDA History of the Vulkan Group Reasons for condition monitoring Machine diagnostics Benefits and ROI Conclusions 5-29

6 maintenance strategies CORRECTIVE MAINTENANCE - damage orientated maintenance event- oriented No attempt at maintenance and inspection until damage occurs Procedure of durability is used until breakdown of the last component in the chain 6-29

7 maintenance strategies PREVENTIVE MAINTENANCE - timetable maintenance event-driven time-based Inspection of plant at preset intervals revision presetting Dismounting and inspection of component parts Replacement of component parts with disregard to wear (too early) Cost-intensive method 7-29

8 maintenance strategies PREVENTIVE MAINTENANCE - condition based maintenace event-driven time-based condition-based Condition monitoring by MDSWind condition parameter load curve wind phase quantification of total data to define the ideal date/point of time for maintenance 8-29

9 Condition based maintenance Advantages of predictive condition-based maintenance: Permanent online monitoring of the individual machine condition by continuous measurment Replacement of component parts with special regard to their actual condition Rimely shutdown of plant in prudent consideration of the measured /predicted condition Rest possible individual estimation for maintenance dates optimized preventive maintenance becomes predictive maintenance 9-29

10 Condition based maintenance MDSWind with diagnostic center (dc) operating company and diagnostic center event registration and rapports serviceteam feedbacksdocumentation archiving, (object database) planning preventive maintenance maintenance process optimized for life cycle costs reparation, servicing operating company 10-29

11 Online condition monitoring system MDSWind Functional principle of condition monitoring system MDSWind 11-29

12 AGENDA History of the Vulkan Group Reasons for condition monitoring Machine diagnostics Benefits and ROI Conclusions 12-29

13 Online condition monitoring system MDSWind MDSWind System in power plant data acquisition, analyzing, threshold monitoring, automatically alarm reporting, archiving MDSWind Browser support and supply of the interface (via internet) to the object database evaluation, analyzing, interpretation reports with recommendations data archiving, creating and building a object database of the monitored power plant operating company (with diagnostic center) A u t o A l a r m customer, operator, service team 13-29

14 Online condition monitoring system MDSWind Tasks for SeaCom diagnostic center with MDSWind : continuously monitoring of condition data data analysis and evaluation archiving condition data and evaluation results referring to individual turbines within the plants damage detection at an early stage monitoring of trends Information data supply for maintenance structure Plant database (object database) 14-29

15 position of diagnostic center in the process of maintenanceinformation flow Tickets with feedback operator event management system- EMS Tickets with reports and recommendations SeaCom DC Repairs and maintenance service team Schedule, maintenance and reparation operator 15-29

16 diagnostic center - processes phase 1 - configuration and validation kinematic process data measurement validation kinematic classification limits standard value optimize 16-29

17 Diagnostic center processes reference phase validation kinematic classification optimize Limit s Standard value 17-29

18 Diagnostic center processes Protection phase Condition report recommodation reports analysis diagnosis expertise event alarm failure 18-29

19 AGENDA History of the Vulkan Group Reasons for condition monitoring Machine diagnostics Benefits and ROI Conclusions 19-29

20 Benefit of condition monitoring system MDSWind support for condition-based maintenance planning increase / stabilization of technical availability reduction of maintenance costs avoidance/ prevention of plant stoppages induction of specific repair tasks 20-29

21 Benefit of service concepts with MDSWind Current and early information of normal or abnormal operation as well as load profiles of the propulsion system Avoid overload and unnecessary wear on the drive line Ensuring highest reliability of non redundant components Save inspection intervals of monitored system Improved availability of the complete drive line by avoiding failures due to preventive maintenance as well as purposeful planning of spare parts Fast support due to remote diagnostics of measurement data that is independent of the location Support inspection of the classified personal 21-29

22 Return on Investment with MDSWind defect in bearing per position in drive train without MDSWind total devastation of gearbox per type of WTC cost 2,500 32,000 $3,500 44,800 approx h Without consideration of the additional cost to hire a crane and the associated labor cost down time 75, ,000 $ 105, ,000 approx. 600 h 22-29

23 Cost of damage example of our customer (O&M company), with our MDSWind Lower damage costs because condition monitoring with MDSWind Settlement of claim Inbetriebnahme WEA "XYZ" Versicherung über Revisionsklausel der Allianz Einbau CMS in 2005 keine Revision durchgeführt in 2007 Getriebeschaden (Ausbruch auf einer Zahnflanke) in 2009 mit CMS ohne CMS Maschinenschaden: , ,00 Unterbrechungsschaden: , ,00 Schaden gesamt: , ,00 Abzug wg. nicht durchgeführter Revision: ,00 Abzug wg. Verschleiß: ,00 60 % vom Rest-Maschinenschaden: ,00 Regulierung Maschinenschaden durch Versicherung: , ,00 Settlement of breakdown Regulierung BU: 9.723,13 0,00 Schaden gesamt: , ,00 Regulierung Maschinenschaden durch Versicherung: , ,00 Regulierung BU: 9.723,13 0,00 Kosten Schaden , ,00 Differenz: ,13 Difference : 87, = $123, Kosten Installation CMS: ,00 lfd. Kosten CMS seit 2005 (ca pro Jahr) 5.000,00 Kosten gesamt: ,

24 Cost of damage in comparison with replacement vs. repair real example from our client (O&M company), with our MDSWind Replacement generator, gear, main bearing Repair of generator, gear, main bearing Replacement of shaft Repair of shaft 24-29

25 AGENDA History of the Vulkan Group Reasons for condition monitoring Machine diagnostics Benefits and ROI Conclusions 25-29

26 Highest reliability of WTC by the application of a condition monitoring system Avoidance of overload and needless abrasive wear Revised Availability of WTC Faster support because remote service and independent from location and type measured data Saving of money with regard to costs of spare parts, technical support and in finding the precise reason and or nature of damage

27 MANY THANKS FOR YOUR KIND ATTENTION 27-29

28 DISCLAIMER Any liability for information given within this presentation will be herewith disclaimed. 1. The basic target of this presentation is the provision of information, no responsibility is given for the correctness, completeness and admissibility of these information or any illustration within this presentation. 2. All rights of the author to illustrations and/or any other information given within this presentation remain with him. 3. Rights to given added values, inventions and third party labelings remain with the rights owner. 4. The presentation should only be used for the purpose of describing VULKAN or VULKAN products and may only be used or duplicated unrestrictedly and without modifications