Condition monitoring for rotating equipment Condition monitoring for rotating equipment in the process industry
✔ Increase in system availability with optional vibration analysis
✔ Minimization of maintenance and repair work, as predictive maintenance makes smart use of electrical variables
✔ Minimal installation effort and easy retrofitting of active power measurement for condition monitoring for rotating equipment
Rotating equipment must operate without errors around the clock every single day.
Condition monitoring
In process automation, the term “rotating equipment” is used to describe equipment that rotates – and is typically driven by an electric motor. This includes pumps, compressors, agitators, fans, and extruders.
Do you know what the availability and the precise condition of your production-relevant system components are? With condition monitoring for this equipment, you will benefit from optimized maintenance intervals. Moreover, you will also reduce energy costs, because the systems run at the optimum operating point. System availability will be increased, because damage due to cavitation, blockages, bearing damage, etc., is recognized early and can therefore be avoided.
Rotating equipment is the primary cause of unplanned system downtimes.
Empowering predictive maintenance
A large proportion of unplanned failures are caused by rotating equipment. Until now, these elements were either maintained in fixed time frames or not at all. Consequently, maintenance is carried out too early, or in some cases too late, leading to production downtimes.
With permanent motor and pump monitoring, you focus on the relevant signs of wear and satisfy the prerequisites for predictive maintenance. Armed with this information, a pending failure can be predicted and maintenance performed at exactly the right time. Moreover, you have access to information on the state of health of your system parts at all times.
Reliable rotating equipment monitoring
With permanent monitoring of critical pumps and motors, we enable you to perform maintenance at precisely the right time. Depending on the size and type of machine, hydraulic, mechanical, or electrical monitoring may be useful.
Starting points for status assessment using a pump as an example
Early detection of defects and malfunctions
The electrical power provides information regarding the run, state, and operating point of the system parts. The monitoring system can be retrofitted quickly and cost-effectively and is therefore also suitable for smaller or medium-sized pumps and motors.
The active power characteristic can be used to identify numerous error patterns, allowing maintenance to be performed at the right time.
Typical active power characteristics
The graphics illustrate the monitoring and diagnostics of electric motors for blockages, pollution, and wear, for example. These allow you to recognize critical load states and to protect pumps, actuating drives, fans, and compressors.
Active power characteristic: Normal operation and air bubbles
Active power characteristic: Pollution and blockages
Active power characteristic: Dry running
Effective motor and pump monitoring
Motor operating values are recorded using the electrical active power via current and voltage measurement. For three-phase machinery, this is possible in combination with a direct circuit, contactor, or frequency converter.
If additional sensors are used for monitoring, the monitoring model will be fine-tuned even further. The data is transferred to a higher-level system, e.g., to a cloud, MES, database, or asset management system. This ensures that the production process is not impacted.
