EMCM EXPERT MOTOR CONDITION MONITORING. 1 Analog signals
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- Annabelle Kathlyn Montgomery
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2 EMCM EXPERT MOTOR CONDITION MONITORING Based on innovative measurement method (intellectual property of KONCAR - Electrical Engineering Institute Inc.), EMCM enables early detection of the most common faults in induction motors. Electrical machines are involved in all areas of modern life, they come in various sizes, and fulfill their tasks independently or as part of a complex system. Manufacturing processes depend on the reliability and availability of electric motors in power plants, refineries, chemical plants, foundries, mills, paper manufacturing plants, transport, etc. By equipping induction motors with an expert system for condition monitoring and fault detection, the users will get a continuous access to the machine and will be able to detect the most common faults at an early stage. EMCM Features Comprehensive on-line monitoring system for low voltage and high voltage induction motors of all powers and sizes Applicable to the motors with squirrel cage and cast cage rotors. Modular and upgradeable system for new, as well as for existing, induction motors Long-term data storage and important events tracking (trends, waveforms, alarms ) Local and remote system access Operator panel - HMI EMCM Processing/protection unit (real time processing, data base, web server, HMI, inputs/outputs) Analog signals Ethernet 3 6 Web HMI (real time data, trends, spectrums, alarms ) Remote user (computer, smartphone, tablet ) 5 SENSORS: 1 vibration sensor (bearing/housing) 2 relative vibration sensor (bearing/shaft) 3 temperature sensor (bearing/winding) 4 current sensor (terminal box) 5 magnetic field sensor (air gap) 6 key phasor (bearing/shaft) 2 3
3 1. Application industries With EMCM unexpected failures can be eliminated in wide range of industries, which means: Maintenance periods can be planned when they are needed and not for preventive purposes Sudden production stoppages don t occur and crisis intervention costs can be eliminated Large repairs like motor rewind are done just-in-time and not when the faults occur Periods between overhauls can be extended thanks to insight into actual motor condition Data collection is quick, efficient and immediately processed, bringing additional time savings 2. Target users Condition monitoring of electrical motors brings benefits to all users whose business depends on secure and stabile production. In order to achieve long and productive motor lifespan, they need to be properly implemented, managed and maintained. MOTOR PRODUCERS EMCM upgrades any motor to a smart one, which differentiates it from similar systems on the market CEMENT (Squirrel cage water cooled motors for mills) SYSTEM INTEGRATORS By integrating motors in predictive maintenance system long term savings for the users and premium service are assured MINING (Slip ring induction motors for conveyor belts) SITE OPERATORS Severe faults can be timely detected, operation time is optimized and overall asset management improved EMCM OIL & GAS (Squirrel - cage closed air circuit cooled motors for pumps, fans and compressors) CMB 2 CMB n CMB 1 WATER AND WASTEWATER (Water pumps drive with brush lifting device) COMPACT MEASUREMENT BOX (CMB) MARINE (Induction motors for ship maneuvering and technological drives) The robust design of the compact measurement box (CMB) enables its direct use on the machine. Control cabinets and terminal boxes are now no longer required. The CMB is fully sealed and therefore ideally prepared for wet, dirty or dusty conditions. 4 5
4 3. Software Users can get insight into measuring data through local touch display (local HMI) and through web server (web application). Local visualization provides information on real-time data, waveforms, vibration spectrums, trends and setup. All screens can be modified according to the customer s requirements (e.g. interface in his native language). 4. Expert tools Besides classical tools for data analysis, EMCM system enables: Advanced trending crucial for predictive monitoring (smart trending ) Automated reports that provide all important information to the user 5. Documentation Complete documentation required for system installation, maintenance and usage of the EMCM system is available. Usual documentation scope includes: Mechanical documentation Electrical documentation User instructions Initial state records Certificates, test reports.. Local HMI The EMCM system is equipped with a multiuser web server which enables remote access and overview of all system data through standard web browser. This web server provides access to the EMCM system from any desktop or a laptop computer (with Windows or ios operating system), tablet (with ios, Android OS ) or smartphone (with ios, Android OS ). System access doesn t require any additional software since it uses standard web browsers (Google Chrome, Internet Explorer, Mozilla Firefox, Safari ). Web server enables insight into real-time data, vibration spectrums, trends, waveforms and alarms for increase of measurement values as well as for fault detection. 6. Services We provide complete service package required for system installation, commissioning and usage of the EMCM system: Consulting services on how to select an optimal monitoring system for new and existing induction motors Installation and commissioning Staff training Expert interpretation of the acquired monitoring results (locally or through remote system access) Remote web application (HMI) 6 7
5 7. EMCM Versions Customers can choose between different versions of EMCM systems based on their needs and requirements. Two main versions are at disposal, but further customization is possible on request. SENSORS: 1 vibration sensor (bearing/housing) 2 temperature sensor (bearing/winding) 3 current sensor (terminal box) EMCM version - V1 SENSORS: 1 vibration sensor (bearing) 2 relative vibration sensor (bearing/shaft) 3 temperature sensor (bearing) 4 current sensor (terminal box) 5 magnetic field sensor (air gap) 6 key phasor (bearing/shaft) EMCM version V2 Processing unit receives the signals from the measuring sensors, performs signal processing and enables protective function via 2-level digital relays. The system has an illuminated, low-reflection LC display with two lines of 16 characters for data display and can communicate with server computer or other systems via standard-based communication protocols. The system has basic software capabilities for alarming and trending of measurement data. This makes it an ideal solution for smaller machines because of its excellent price/performance ratio. EMCM can be easily installed and integrated with other EMCM systems into one centralized system. Processing unit receives the signals from the measuring sensors, performs analog/digital conversion, signal filtering and processing. It enables a protective function via 2-level digital relays. The system can communicate with server computer or other systems via standard-based communication protocols. The operators panel enables local insight into measurement data through touch sensitive display in various sizes. The software calculates complex features like FFT analysis, orbit and s max calculation, smart trending of measurement data, fault detection and fault locator, automated report generation This version of EMCM system is an ideal solution for larger machines and systems because of its advanced features. The modularity of the EMCM system allows customization of all critical user information for optimized asset management. INTEGRATION (Ethernet) E.g. (feed pump application) by measurement of motor electrical parameters (power, current ) and hydraulic parameters (flow, pressure), the users get insight into efficiency of their application with assistance of EMCM advanced trending tool. Web HMI on computer, tablet or smart phone (real time data, trends, alarms, reports) 8 9
6 8. EMCM specification 9. Sensors Architecture: Data acquisition unit with the real time controller and local HMI Analog inputs/outputs: Vibration inputs (IEPE) or velocity Relative displacement inputs (orbits, s max ) Current input (motor current measurement) Key phasor input (rpm) Air gap magnetic field measurement (rotor winding faults, eccentricity) RTD (pt100) or thermocouple inputs Standard inputs (0/4 20 ma or 0/2 10 V) for : flow, level, pressure, Standard outputs (0/4 20 ma or 0/2 10 V) Digital/relay outputs: Number of outputs: 2 to 8 Continuous current: 6 A Maximum switching power: 1500 VA Maximum switching voltage: 250 VAC/DC Maximum switching frequency: 0,1 Hz Rated isolation voltage: 300 V overload (category III) by EN Surge withstand: 4 kv (1,25/50 µs), by IEC 5017 Communication: Ethernet 10/100 Supported protocols: Modbus TCP slave, FTP server, IEC , HTTP server (other on request) Power supply: DC: 80 V to 370 V, AC: 85 to 264 V, frequency 47 to 63 Hz Maximum allowed power supply interruption: 100 ms for 230 VAC/ 20 ms for 115 VAC Test voltage: 3 kv (2 kv against ground) Temperature range: Operational temperature range: -20 C to +70 C -0 C to +55 C (for version with touch screen) Storage temperature range: -40 to +85 C Dimensions: Cabinet IP 54 (IP 66 on request) WHD: depends on system configuration Data visualization: Web browser for remote access and local client application through touch screen Data logging: Database for long-term data, alarm and events archival Compliance with standards: EMC immunity/emission : EN (IEC :2005), EN A1+A2 (IEC A1+A2), EN (IEC ), EN A1 (IEC A1), EN (IEC ), EN A1 (IEC A1) Vibration/shock resistance (EN /EN /29) Accelerometers and velocity sensors Relative displacement sensor Speed sensor This sensor is used for measurement of absolute bearing and housing vibrations. Temperature sensors Pt100, RTD, thermocouple Magnetic flux/field sensor Current measuring sensor Process value transducers This sensor is used for measurement of shaft relative displacements (orbit, s max ). This sensor is used for measurement of rotating speed and as a reference for a signal processing (key phasor). This sensor is used for measurement of bearing and winding temperature. This sensor is used for measurement of magnetic field or magnetic flux inside a machine air gap (detection of rotor winding faults and eccentricity ). This sensor is used for measurement of motor current and as restrictive class parameter (smart trending ). Different transducers and sensors are used for measurement of important process values of the machine (voltage, flow, pressure ). EMCM system can receive and process any analog and digital signals from sensor or transducer which features standard voltage or current signal (on request) without any influence on measurement circuitry
7 KONČAR Electrical Engineering Institute Inc. Department for Rotating Machines Fallerovo šetalište 22, Zagreb, Croatia Phone: Fax: mcm@koncar-institut.hr CONFIGURE YOUR OWN MONITORING SOLUTION AT:
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