Embed Size (px)
Citation preview
Condition Monitoring and Machine Diagnostics
CONDITION MONITORING SYSTEMS ROTOR DYNAMICS SOUND AND VIBRATION ANALYSIS
4 9 7 4 8l
3 90
1 23
4 5 6 7 29 91287
Fig. 1: Shock tests for the
determination of solid borne sound in
a nuclear power plant
Fig. 2: Self-contained breathing
apparatus training at the fire station
Fig. 3: Stain Gauges application on an
vibrating pipeline
MONITORING SYSTEMS CONDITION MONITORING ROTOR DYNAMICS
The engineering firm Kerntech is a flexible service provider. Working in close collaboration with industry as well as with applied
research. Our aim is to provide the customized monitoring solutions you need to run your plant safely and efficiently
- correlation of physically different signals (neutron
flux, pressure, temperature, etc.)
Systems and programming
We offer custumized program and system devel-
opment services for a wide range of measure-
ment and monitoring requirements. For example,
this could involve the automatic signalling and
supervision of operational parameters.
Measurement and monitoring systems / Auto-
matic monitoring systems
Application-oriented development of vibration and
loose parts monitoring systems.
We offer:
- Development and design
- Installation of additional instrumentation
- Realization of special measurements
- Display and visualization of status signals, test
results and trend charts
- Integration in existing data networks, maintenance,
and remote maintenance systems
Benefits:
- Improved production rate by running the
machines at low-wearing conditions
- Avoidance of progressive damage through an
early warning system
- Improved informational basis for concerted
maintenance tasks
Condition Monitoring and Machine Diagnostics for Industrial Plants
Our excellence is
- Vibration and loose part monitoring
- Special measurement and test engineering
- Design, development, and implementation of
automatic machinery monitoring, programs for
early failure detection, and trend analysis
- Measurement, control, and display systems
- Nuclear-thermohydraulic stability measurements
Loose parts monitoring
Loose parts monitoring
Impact sound measurements on externally accessible
components and installations of temporary accessory
instrumentation including signal processing:
- Detection of impacts at compo nents of primary
and/or secondary circuits (e.g. conduits, steam
genera tors, reheaters, and pumps)
Loose parts monitoring within the pressure vessel of
boiling water reactors during power operation for the:
- detection of impacts between fuel elements,
instrumentation lances, and the single tubes of
the lances
Special measurements
Short-term and flexible measurements with
additional or already existing instrumentation.
With on-line evaluation and on-site result
reporting on the:
- determination of control circuit parameters
- field measurements and documentation of the start
up of new or replaced components
- determination of diagnosis parameters to prevent
future damage
- determination of fluid resonances in piping systems
- long and short term trend tracking of operating
parameters (such as temperature, pressure, flow
rate, etc.)
1
2
3
7 908 8
2 28 87 9099
6625
22,22201
62, 2 08
8289
79 92 2 3
SOUND AND VIBRATION ANALYSIS
Individual data acquisition and control
programs
Measurement and data analysis software tailored to
your specific area of application.
We offer:
- Measurement and control programs customized to
your specific needs (e.g. pumps, rotating machinery)
- Support and advice on the selection of hardware
- Program development in LabView™ (National
Instruments) or C++
- Applications for stationary measuring systems as
well as compact mobile solutions on laptop or
embedded-PC basis
Benefits:
- Test benches require customized data acquisition
systems - we develop efficient solutions according
to your needs
- Fast program development based on the program-
ming language LabView™, particularly designed for
measurement problems
- High performance applications through machine-
oriented programming in C++
Industrial display equipments
We develop customized display and monitoring
units for the process and operating surveillance.
We offer:
- Small series and individual manufacturing
- Supervision and control of test stations, assembly
lines, and adjustment settings of the machinery etc.
- Development of different computing and control
platforms: industrial PCs, flat/panel PCs with touch
screen, compact and robust box computers, PLC
and micro controller solutions
- Also as field bus system for remote supervision or as
measuring instrument/for data acquisition in areas
difficult of access
Vibration diagnosis
We provide vibration monitoring solutions
tailored to the specific needs of nuclear power
plants as well as to conventional facilities.
Measurements including on site assessment
according to international standards such as ISO
10816, ISO 7919 and ASME ANSI OM-3.
Fig. 1: Shows a display unit for the
continuous supervision of parameters
in a steam turbine (turbine stress
evaluator) and how it is deployed in
power plants
Fig. 2: Run-up test to determine the
structure resonance
Fig. 3: Nuclear-thermohydraulic
stability measurements by means of a
decay-ratio trend
Power plant measurements
Analysis of the standard reactor instrumenta-
tion signals following the German Nuclear
Safety Standards Commission specification (KTA
3204) for the documentation of components of
primary and secondary circuits of the pressurized
water and boiling water reactors.
Instrumentation in use:
- In- and out-core neutron flux
- Thermocouples
- Pressure sensors
- Flow rate test points
- Travel sensor and accelerometer
Analyzed components:
- Pressure vessel
- Core barrel and core shroud
- Fuel assemblies
- Instrumentation lances
- Circulating pumps
- Shaft adjustments and sealings
Oscillation and alternating pressure
measurements
In addition to the rotor dynamical observations of
vibrations of turbo-machinery, we also examine their
fluid dynamical causes. This
means the investigation of
components such as pumps,
turbo charger, axial and
centrifugal compressors,
turbo-engines and steam tur-
bines. Typical fluid dynamical
phenomena, which may
generate vibrations on those
components, are e.g. rota-
ting stalls, surge, acoustic
resonances and cavitation.
Pipe vibrations
Excessive pipe vibrations in-
duce unwanted load and may cause severe problems.
With regard to this, vibration analyses are a useful
tool to increase efficiency by detecting and avoiding
unfavourable excitation mechanisms. Whether or not
the pipe vibrations are within the permitted limits can
be verified by measurements of vibrational accelera-
tion, speed and displacement.
An effective vibration reduction is only possible if the
excitation mechanisms are known. Hence, a multi-
1
3
2
03:45 04:00 04:15 04:30 04:45 05:00 05:15 05:30 05:45 06:00 06:15 06:30
0,500,550,600,650,70
Stab 1
4-19
aus
Stab 3
8-35
aus
Stab 3
4-15
aus
Stab 1
8-39
aus
YU-1
0 au
s
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1,0
Abb. 01c
Ebene A (YQ31X077)
Ebene D (YQ31X080)
Mittl. Decay Ratio über alle Messpos.
+ /- Sigma
Decay R
atio
50
75
100
th. Leistung Summensignal (YQ00X011)
th. Leistung (YQ31X080)
Nuklear-Thermohydraulische
Stabilitätsmessung,
Lanze 20 Position 44-25
Pth [%
]
Mittl. Frequenz über alle Messpos.
+ /- Sigma
Uhrzeit
Fre
q. [H
z]
0 5 10 15 20 25 30 35 40 45 50 55 60 65
0
30
60
90
120
150
180
210
240
166 Hz
Fig.06
88 Hz
APSD Accelaration
[(m/s²)²/Hz)]
time [s]
frequency [H
z]
1,000E-51,778E-53,162E-55,623E-51,000E-41,778E-43,162E-45,623E-41,000E-30,0017780,0031620,0056230,010000,017780,031620,056230,10000,17780,31620,56231,000
Floating Spectra vertical vibration
at the bearing motor side driving shaft of the pump (A10)
29,6 Hz
50-53 Hz
34
4 588738
0.0901 1 0,987²²
1234 1,89279832355
Validation and measurement of the
natural mode of a CSM-56B engine on
MTU test bench
channel vibration analysis is advisable also when
excessive pipe vibration is already ascertained. Unlike
simple hand held vibrometers, these multi-channel
measurements allow for the modal and frequency-
selective analyses required to do a technical assess-
ment.
Pipe vibration can be traced back to inhomogeneous
flows which cause vibrations at the natural frequency
of the pipe. Those vibrations at the natural frequency
may lead to high oscillations already by minor excita-
tions. Pipe vibrations may also be caused by pumps,
compressors and fluid resonance.
Bearing diagnostics
Defect bearings are one of the foremost reasons for
outages of machinery. Supervision of roller bearings
can predict oncoming disruptions opening up for
preventive maintenance and loss avoidance.
We offer:
- Customized solutions: Regular bearing diagnostic
services and supervision through alarm systems
- Development of measuring and analysis systems for
continuous supervision; applicable on-site or to the
remote maintenance
- Preparation of status reports and expert opinions
- Root cause analysis in case of repeatedly fast-
wearing bearings
Benefits:
- Cost reduction: Bearings diagnostics enable the
prevention of unexpected and expensive machinery
failures. Furthermore, they offer a possibility to
reduce premature replacements of bearings.
- Reliability: Undetected bearing defects may cause
significant damage. Bearing monitoring, eventually
in combination with vibration control, is a way to
minimize or obviate risk
Monitoring and diagnosis of pumps
Pumps are critical elements in the operating process
of many industrial systems. Our range of services
includes what you need to operate pumps safely and
efficiently.
We offer:
- Noise-based detection of cavitation
- Bearing diagnostics
- Trend and long-run monitoring
- Vibration monitoring: Sourcing and measures in
case of excessive vibrations
- Mobile stand-by duty: As trouble shooting or
continuously to prevent problems
- Multi phase spiral pumps in oil-production industry:
we offer on-site vibration measurements on the
oilfield
- Chemical industry: Condition monitoring on pumps
with magnetic clutches by magnetic field analysis
Strain gauges
Strain gauges offer a possibility to analyse the dy-
namic load on a structure which could lead to dete-
rioration of the component. Thus, the relevant force
time history can be determined. Modal and vibration
analyses help to determine the natural mode of the
components. Based on those measures treatments
for vibration level reduction can be established.
Fig. 1: The bearing diagnosis enables
early failure detection of bearings
Fig. 2: Measurement of blade
vibrations of turbo chargers
Fig. 3: Vibration analysis of a
multiphase pump
1 2
3
Orbits of a feed-water pump with limits
according to DIN ISO 7919
-100 -75 -50 -25 0 25 50 75 100
-100
-75
-50
-25
0
25
50
75
100
-100 -75 -50 -25 0 25 50 75 100
-100
-75
-50
-25
0
25
50
75
100
30.05.2002
19.05.2006
13.06.2006
limit A/B
limit B/C
limit C/D
S(p-p)Max
= 90 µm
Shaft vibration
0RL13V051
0R
L13V
052
S(p-p)Max
= 180 µm
30.05.2002
19.05.2006
13.06.2006
limit A/B
0RL12V053
0R
L12V
054
7 908 8
2 28 87 9099
6625
22,22201
62, 2
8289
79 92
CONTACT
How to find us...
Kerntech GmbH
Tel. +49.511. 67 66 88 73
Fax +49.511. 67 66 88 88
Vanity: 0700-KERNTECH
E-mail:
Executive director:
Dr. Jürgen Fiedler
www.kerntech.de
Barsinghausen and follow the B65. Leave the B65 and drive
this road for approximately 70 meters before turning left in
the street Neue Rehre. Leave the Neue Rehre and turn to
your left in the Steinradweg. You find your destination on
the right side at the Forsthaus.
References:
In particular we have many years of
work experience with:
Eon-Kernkraft
Eon Kraftwerke
Vattenfall
MTU
VW
Sincor
Richter Chemietechnik
Layo
ut:
Bern
d.S
chu
ster@
xxsd
esi
gn
.de
