PGE/REWE 2015

Monitoring of Pumps, Fans and Mechanical Components Using Highly Integrated Wireless Sensors (Room G105, Auditorium Centre, First Floor)

09 Jun 15
2:00 PM - 3:30 PM

Tracks: Theme: Grid Support with Data & Generators

Speaker(s): Jody Townsend, Marketing Communications Manager, Quartzelec Ltd; Bernhard Fruth, Managing Director, Quartzteq GMBH; Herbert Looser, Professor of Physics, University of Applied Sciences, Switzerland; Detlef Hummes, Assistant Professor, American University of Kuwait; Rajendra Nuthakki, Testing, Diagnostics and Monitoring Specialist , Quartzelec Ltd; Eid Mousa Al-Mutari, IMD Superintendent, Al-Zour South Power Station

The frequency analysis of vibrations caused by rotating machines (e.g pumps/fans) can provide useful indicators of future failures. Long-term analysis can avoid expensive outages & reduce associated maintenance & service costs. Whilst working with our client in Kuwait on vibration issues specific to their rotating m/c asset base, we looked to develop a long-term analysis solution to ultimately integrate within the clients’ life extension plan. We present a highly integrated “vibration sensor” which incorporates all critical functions in a miniature module which can be installed virtually in all potential locations. The fully resin encapsulated module incorporates a 3-axes vibration sensor, temp. transducer, microprocessor & “Zigbee” wireless transmitter & antenna. The wireless network is a mesh type, self-configuring network with error correction algorithms, designed for industrial applications, in safe & hazardous atmospheres. Vibration wave shapes are acquired using a sampling frequency of up to 3.6 kHz. This allows numerical calculation of integral parameters such as; velocity, displacement & acceleration & to plot FFT vs. time. The large bandwidth & frequency resolution provides information about various failure mechanisms. The sensor modules have a very low current consumption; in operation as well as in sleep mode, allowing battery or energy harvesting power supply, and consequently a fast & convenient installation procedure (self-configuring). The sensors communicate with a computer, performing data storage & visualization, with primary warning functions for the machine operator. Using a permanent Internet connection, data can be sent to office based engineers/experts and/or a ‘rule based’ expert system that is currently under development. We will present details of the technology involved & results with sea water pump & fan monitoring. This 1st project is part of a life extension plan & an approach to reduce maintenance cost by condition based maintenance.