© ABB Group March 16, 2009 | Slide 1

Tor Ole Bang-Steinsvik, Advanced Solutions, 12.03.2009

Condition Monitoring Electrical System Vibration – New wireless option

© ABB Group March 16, 2009 | Slide 2

Maintenance Workplace

Electrical System Condition Monitoring

Why?

LV Circuit Breaker Monitor

LV Motor Control Centre Monitor

MV Switchgear Monitor

Drive Monitor

TEC – Transformer Monitor

Sea Cable Monitor

Vibration Monitoring

Online Wired

Online Wireless - WiVib

Agenda – Condition Monitoring

© ABB Group March 16, 2009 | Slide 3

cpmPlus Topology

© ABB Group March 16, 2009 | Slide 6

Optimized maintenance workflow reduces time to action

Continuous Condition Monitoring

Fault Condition Reporting

Alarming and Paging

Access to detailed diagnostic

Fault Report Submitting into CMMS

Work order information in 800xA

Monitoring

Reporting

Analyzing

Decision

ActionSubmit

Maintenance Workplace

Notify

© ABB Group March 16, 2009 | Slide 7

Maintenance Workplace

Electrical System Condition Monitoring

Why?

LV Circuit Breaker Monitor

LV Motor Control Centre Monitor

MV Switchgear Monitor

Drive Monitor

TEC – Transformer Monitor

Sea Cable Monitor

Vibration Monitoring

Online Wired

Online Wireless - WiVib

Agenda – Condition Monitoring

© ABB Group March 16, 2009 | Slide 8

Conditon Monitoring System

Note:Time Synchronization

View

Signals

OPC/Modbus/etc.

DCS

(Electrical) (Vibration) (Process)

Portal

(Performance Monitoring)

© ABB Group March 16, 2009 | Slide 10

Equipment goups x-check with ”electrical equipment”

© ABB Group March 16, 2009 | Slide 11

Why Condition Monitoring on electrical systems?

HSEReduce risk of fireReduce CO2/NOx emissionsReduce energy consumption

Improved production outputPredictive maintenance of production facilitiesFaster fault findingAllow operation closer to limits

OPEXMore efficient maintenance work processesExtended equipment lifetimeLess spare parts need in store – improved logistics for parts

Loss of electric power is a known, but little investigated cause of downtime!

© ABB Group March 16, 2009 | Slide 12

Maintenance cost:

Distribution1 Safety equipment 11,7 %2 Electric power distribution 11,3 %3 Instrumentation 10,6 %4 Piping specialities 8,7 %5 Lifting 8,1 %6 Pressure vessels and storage tanks 5,7 %7 Piping, pipeline, risers and umbilical 5,0 %8 AC, equipment for refrigeration 5,0 %9 Turbines 4,4 %10 Manually operated valves 4,2 %11 Pumps 3,8 %12 Power generation/transformation 3,8 %13 Communication equipment 3,1 %14 Other 3,1 %15 Safety relief valves 3,0 %16 Combustion engines 2,6 %17 Actuator operated valves 0,9 %18 Not relevant 5,2 %

100,0 %

Maintenance cost distribution for 10 north-sea fields:

18,9%

© ABB Group March 16, 2009 | Slide 14

trip unit for Tmax T4-T5 and Isomax S6

LV Circuit Breaker Monitor

PR122

PR123

PR332

PR333

PR222DS

trip units for Emax

trip units for Emax X1 and Tmax T7

© ABB Group March 16, 2009 | Slide 15

LV Circuit Breaker Monitor

Local bus unit

Trip coil

Contacts

CB statuscontacts

Temperaturesensor

EP010

Trip unit,electronic

Ratingplug

Keyplug

Currentsensors

Load side, electrical

Supply side,electrical

Supply / Loadside, electrical

© ABB Group March 16, 2009 | Slide 20

LV Motor Control Centre Monitor - MNS iS

© ABB Group March 16, 2009 | Slide 21

MNS iS

© ABB Group March 16, 2009 | Slide 22

MNS iS

© ABB Group March 16, 2009 | Slide 23

MV Switchgear Monitor – REF542plus

© ABB Group March 16, 2009 | Slide 24

DriveMonitorTM

DriveMonitorTM is a diagnostic system which provides:

Easier root cause analysis – reduced Mean Time To Repair

Early detection of potential failure

Remote access allows support from external expert

Continuous monitoring of status and respond when changes occur

Predefined diagnostic actions, prosessing and reporting

Monitoring of drive’s performance, and, if required, other shaft line components (main circuit breaker, transformer, motor)

© ABB Group March 16, 2009 | Slide 25

DriveMonitorTM

© ABB Group March 16, 2009 | Slide 26

DriveMonitorTM

© ABB Group March 16, 2009 | Slide 27

TEC – Transformer Monitor

The TEC (Transformer Electronic Control) is a diagnostic system which provides:

Statements about the operating condition and load ability prediction

Diagnoses and recommendations for corrective actions if problems with the transformer should occur (oil/winding temperature, tap-changer wear, moisture and hydrogen content in oil)

Prediction of the consumed lifetime based on overload forecasting and winding hot-spot calculations

Optimum cooling performance according to load and controlled wear on cooling pumps and fans

© ABB Group March 16, 2009 | Slide 28

Sea cable monitoring

.

Based on fiber optic distributed temperature sensing (DTS)

Provides continuous and repeatable measurements, in real-time, of the location and the temperature of many thousands of points along the optical fiber sensor.

The environment of a submarine cable, particularly at the ends, can change. Monitoring the temperature will alert the maintenance system should the cable, for example, be stretched or bent, since the stress on the cable will change.

Individual sections of the cable can be identified as different zones (i.e around a buoy) that can be independently programmed to generate an alarm via the maintenance system when the temperature in any zones reaches a pre-set limit, thus helping to both protect the cable and prevent outages.

Graphical user interfaces, temperature profiles and data are integrated into Asset Optimizer.

© ABB Group March 16, 2009 | Slide 29

Maintenance Workplace

Electrical System Condition Monitoring

Why?

LV Circuit Breaker Monitor

LV Motor Control Centre Monitor

MV Switchgear Monitor

Drive Monitor

TEC – Transformer Monitor

Sea Cable Monitor

Vibration Monitoring

Online Wired

Online Wireless - WiVib

Agenda – Condition Monitoring

© ABB Group March 16, 2009 | Slide 30

Vibration analysis – basic principles

Component Part Sub type Potential Failure Frequency

Journal Wear, loose etc. RPMRolling Element Spalling etc. HF (BPFO, BPFI & BSF)

Rotor/shaft Unbalance, misalignment RPM

Mec

hani

cal

Bearings

Gearwheel Wear, cracks RPM x No. Teeth + sidebands

1. Rotational frequency of the fan

2. Rotational frequency of the motor

3. Misalignment of the shaft at the coupling

4. Fan unbalance

5. Tooth meshing frequency

6. A developing fault in the ball-bearing

13

2 4 5

6

Accelerometer

© ABB Group March 16, 2009 | Slide 31

Vibration Monitoring- the objective

Proven technology for predictive maintenance of rotating equipment

Detect incipient failure

planand

prepare Shutdown and

repair

Cost effective means of avoiding production loss and minimising

maintenance cost

Protection system- to prevent catastrophic failure

Primary safety system with safety critical performance standards

Shut machine

down within msec

Manual data gathering today - Ideal opportunity for wireless technology

Wired systems are preferable (for now)

© ABB Group March 16, 2009 | Slide 32

Vibration Monitoring – Online wired protection and monitoring

MCM800

Asset OptimizerTM

Maintenance Workplace

OPC server

Ethernet switch

Acc 1

Acc 3

Acc 2

SAP/MAXIMO CMMS

MPM810

TBU850

AnalystTM

ABB Asset Monitor Integration

RelaySpee d

© ABB Group March 16, 2009 | Slide 33

WiVib – Wireless monitoringVibration monitoring of motors and rotating

equipmentCost effective for motors < 400kWNon-intrusive (very simple installation)Fully autonomous – no WLAN requiredSmall, inexpensive, wirelessRobust communication in industrialenvironmentLong battery life >5 yearsSuitable for EX Zone 1 environment

© ABB Group March 16, 2009 | Slide 34

WiVib development historyConsortium headed by ABB

Sponsor:

PrototypeInitial concept Product

© ABB Group March 16, 2009 | Slide 36

OTC Spotlight on new technology award 2008http://www.otcnet.org/2008/spotlight/