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O liOnline -
Condition MonitoringCondition Monitoring
in Power Plants
P i U l d Sh dPreventing Unplanned Shutdowns
| Power Plants IS-M | Seite 1 www.dmt.de
Power Plant online Condition Monitoring – Why ?
Trouble-free operation and the avoidance of unforeseen failures are prerequisites for smooth power plant operation.
Through condition monitoring, damage can be detected at a very early stage before an actual failure would occur.
The operator is thus in the position to carry out the necessary exchanges or repairs in line with shutdown periods that are planned.
| Power Plants IS-M | Seite 2 www.dmt.de
DMT online Condition Monitoring System
The DMT system analyzes the mechanical condition of machinery components including bearings, shafts, motors and other drive train components.
Machine operators and maintenance staff are alerted to mechanical problems in their early phases of development.
Unplanned machinery downtime and runnability problems are avoided.
| Power Plants IS-M | Seite 3 www.dmt.de
Benefits of the DMT Machine Monitoring System Increase of plant availability Increase of plant reliability Improvement of the operating safety Improvement of the operating safety Improvement of machine safety Reduction of maintenance costs Increase in the service life of machines and systems Increase in the service life of machines and systems Avoidance of capital machine damages Prevention of unplanned down times
| Power Plants IS-M | Seite 4 www.dmt.de
Profitability of maintenance strategies
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m a i n t e n a n c e s t r a t e g i e s
| Power Plants IS-M | Seite 5 www.dmt.de
source:
Electrical Power Research Institute
m a i n t e n a n c e s t r a t e g i e s
Monitoring a wide variety of power plant installationsinstallations
Cooling water pumps Condensate pumps Induced draughts Induced draughts Fresh air ventilators Turbines Coal pulverisers Coal pulverisers And other installations
| Power Plants IS-M | Seite 6 www.dmt.de
DMT online Condition Monitoring System detects
Wear Bearing damage Out-of-balance condition Toothing damage Coupling damage Damage at blades Impending mixed friction Cavitation Assembly alignment errors Corrosion Off-spec operating states
by combining and correlating structure-borne noise signals with process
| Power Plants IS-M | Seite 7 www.dmt.de
y g g g pparameters (power, speed, pressure, etc.)
Overview of pumps in plant
7
8
9
1 Cooling water pumps
5
61 Cooling water pumps
2 Condensate pumps
3 SPAT units
12
4 4 Heating pumps
5 Coal pulverizers
3
6 Fresh air ventilator
7 Induced draughts
8 Quencher pumps
| Power Plants IS-M | Seite 8 www.dmt.de
3 p p
9 Vacuum pumps / band filter
Control panel shows the critical machines
Industrial power plant
Structure-borne noise spectra with monitoring
thresholds and developemnt of bearing damage
| Power Plants IS-M | Seite 9 www.dmt.de
An unscheduled outage was avoided
Detected failures – some examples
Pitting on the gear Destroyed slot wedges Tooth flank corrosion
Bearing wear damage B k lli l tC it ti d
| Power Plants IS-M | Seite 10 www.dmt.de
Bearing wear damage Broken rolling-elementCavitation damage
DMT online Condition Monitoring means
Shorter inspection times
Extended inspection intervalls
References
Recirculating pumps for district heating system
KSB
Lower maintenance costs
Continuous status monitoring
system
Pressure booster pumps for district heating system
KSB
Primary coolant pumps Halberg Continuous status monitoring
Trend analyses and forecasting
L hi i lif
y p p g
Condensate pumps Weller
Secondary condensate pumps KSB Longer machine service life
Reduced personnel costs
Secondary condensate pumps KSB
Quencher pumps Sulzer
Turbo feed pumps Sulzer Early recognition of wear
Process and system optimization
Turbo feed pumps Sulzer
Vacuum pumps (belt filters) Siemens
S
| Power Plants IS-M | Seite 11 www.dmt.de
Higher availabilityIntermediate coolant pumps KSB
Examples
PlantSafe®: Monitoring of Power PlantsPlantSafe®: Monitoring of Pipeline StationsPlantSafe®: Monitoring of RefineriesPlantSafe®: Monitoring of Pipeline Stations
MineSafe®: Monitoring of underground coal mines
WindSafe®: Monitoring of wind energy converterWindSafe : Monitoring of wind energy converter
| Power Plants IS-M | Seite 12 www.dmt.de
Machinery diagnosticsPlease contact us:
DMT GmbH & Co KGDMT GmbH & Co. KGIndustry SystemsAm Technologiepark 145307 Essen Germany45307 Essen, [email protected]
+49 201 172 1666 +49 201 172-1666
| Power Plants IS-M | Seite 13 www.dmt.de
