MCM Motor Condition Monitor Winner 1998 TBTAKTTGVTSAD WINNER

MCM Motor Condition Monitor Winner 1998 TÜBİTAK-TTGV-TÜSİAD WINNER OF THE TECHNOLOGY AWARD 2007 Institute of Eng. & Tech. Patent No : US 6014598 TR 1998/02541 B

ﺗکﻨﻮﻟﻮژی پﺎﻳﺶ ﺑﺪﻭﻥ ﺳﻨﺴﻮﺭ ،MCM M. Sadeghlou Stock Engineering Services info@stock-eng. com Professor Dr. A. Duyar ARTESIS A. S. www. artesis. com Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Technology THE TECHNOLOGY AND Winner 2007 Institute of Eng. & Tech. HOW IT WORKS Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM ﻧﺼﺐ Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

پﺎﺭﺍﻣﺘﺮﻫﺎ ﻣﺤﺎﺳﺒﻪ ﻭ ﻗﺮﺍﺋﺖ پﺮﻳﻮﺩ ONE ITERATION (1. 5 minutes) Modelling, Parameter Calculations Winner 2007 Institute of Eng. & Tech. V-I DAQ (6 sec) Tel. : 021 44665701 Front Panel Update Fax: 021 44665739 info@stock-eng. com

MCM ﺷﺮﻭﻉ کﺎﺭ MCM Parameters 1) Device Address 2) Nominal Voltage (L-N) • ﺗﻨﻬﺎ ﺍﻃﻼﻋﺎﺗی کﻪ ﺩﺭ ﺯﻣﺎﻥ ﻧﺼﺐ ﺑﺎﻳﺪ ﺑﻪ ﻣﻨﺘﻘﻞ ﺷﻮﺩ MCM 3) Nominal Current 4) Frequency 5) Motor Speed 6) Connection Type Winner 2007 Institute of Eng. & Tech. 7) Voltage and Current Calibration Values MCM Default Password is ‘m’ Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

ﺭﻭﺗﻴﻦ پﺎﻳﺶ Alarm Level 3 -Phase Motor Measured Output NORMAL WATCH LİNE ? Input WATCH LOAD ? Comparison EXAMINE -1 Winner 2007 Institute of Eng. & Tech. Mathematical Model EXAMINE -2 Estimated Output Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM’s Front Panel Warning LED’s OK WATCH LINE (Abnormal changes in supply voltage) : ﺩﺭ ﺻﻮﺭﺕ ﺗﺪﺍﻭﻡ آﻼﺭﻡ ﺑﺎﻳﺪ ﻣﻮﺍﺭﺩ ﺯﻳﺮ چک ﺷﻮﺩ. E 2 پﺎﺭﺍﻣﺘﺮﻫﺎی ﻣﺪﻝ گﺮﻭﻩ ، ﺗﻐﻴﻴﺮﺩﺭ ﻭﻟﺘﺎژ ﻭﺭﻭﺩی harmonic levels – capacitor - isolation of cables- motor connector or terminal slackness - contacts of the contactor WATCH LOAD Changes in process is observed ﺍگﺮ ﺗﻐﻴﻴﺮ ﺑﺎﺭ ﺑﺪﻭﻥ آگﺎﻫی ﺍپﺮﺍﺗﻮﺭ ﺑﺎﺷﺪ check; leakages – valve & vane misadjustments – filters getting dirty (fans, compressors) . ﺩﺳﺘگﺎﻩ ﺷﺮﺍﺋﻂ ﺑﺎﺭ ﺷﺪﻳﺪ ﺭﺍ ﺩﺭ ﻣﺪﻝ ﻣﺤﻠﻮﻅ ﻣﻴکﻨﺪ Update ﺍگﺮ ﺗﻐﻴﻴﺮ ﺑﺎﺭ ﺑﺎ ﺧﻮﺍﺳﺖ ﺍپﺮﺍﺗﻮﺭ ﺑﺎﺷﺪ ﺑﺎ ﻓﺮﻣﺎﻥ PERFORM MAINTENANCE (Examine 1) Fist level alarm ﻋﻴﺒی ﺩﺭ ﻣﺎﺷﻴﻦ ﺭﺥ ﺩﺍﺩﻩ. Check imbalance – misalignment – bearing/ bearing hausing – motor shaft - broken rotor bar - isolation of stator windings- over lubrication and lubrication leakages through oil belt Winner 2007 Institute of Eng. & Tech. Driven equipment mechanical problems (gear box, compressor, fan, pump, press, conveyor. . etc) - friction and breakdown of fan blades - breakdown of pump sealing – incorrect conveyor chain tension problem -. . . etc STOP (Examine 2) Second level alarm آﻨﺎﻟﻴﺰ ﺗﻔﺼﻴﻠی ﻭ ﺧﺎﻣﻮﺵ کﺮﺩﻥ ﻣﺎﺷﻴﻦ ﺗﻮﺻﻴﻪ ﻣﻴﺸﻮﺩ. ﺗﻐﻴﻴﺮ ﻭﺿﻌﻴﺖ ﻣﺎﺷﻴﻦ ﻧﺴﺒﺖ ﺑﻪ ﻣﺪﻝ ﺑﺴﻴﺎﺭ ﺷﺪﻳﺪ ﺍﺳﺖ Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Clustering Algorithm Power Factor C 2 C 1 C 3 Frequency Gain (A/V) Winner 2007 Institute of Eng. & Tech. During the learning period MCM treats each operating point of the motor as a cluster in the three dimensional space (powerfactor, gain, supply frequency. Therefore, each cluster has a seperate statistical model. During the monitoring mode each data is compared with the closest cluster. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Learning Period Developed fault rn a ele R Fault After Maintenance ng rni d a Le erio P Winner 2007 Institute of Eng. & Tech. Learning Period Suggested Learning point Tel. : 021 44665701 Actual Learning point Fax: 021 44665739 Fault Detection point info@stock-eng. com

ﺟﺮﻳﺎﻥ ﺷﺪﺕ ﻃﻴﻒ ﻧﻤﻮﻧﻪ ﻳک Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

SOME OF MCM REFERENCES US NAVY آﻤﺮﻳکﺎ ﺩﺭﻳﺎﺋی ﻧﻴﺮﻭی : ﺑﺮﺧی ﺍﺯ ﻣﺸﺘﺮﻳﺎﻥ ﻧﺎﻣﺪﺍﺭ ﺟﺪﻳﺪ Cherry Inc. ،Sinopec ﻧﻔﺖ ﻭ پﺘﺮﻭﺷﻴﻤی چﻴﻦ Automotive Petrochemical Energy Iron&Steel Water Food&Beverage Unimar Winner 2007 Institute of Eng. & Tech. National Power Metal Procesing Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Petrochemical Iron&Steel Energy Water Airways Winner 2007 Institute of Eng. & Tech. Universities Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCMScada+Diagnostics ﻧﺮﻡ ﺍﻓﺰﺍﺭ On OK 15. 612 308. 356 0. 89 5. 8909 4. 5687 10. 1843 0. 5679 1. 4893 ﺩﺳﺘﺮﺳی ﺑﻪ ﺍﻣکﺎﻧﺎﺕ ﺗﺸﺨﻴﺺ ﻋﻴﺐ ﻭ ﺭﻭﻧﺪ گﻴﺮی کﻠﻴﺔ پﺎﺭﺍﻣﺘﺮﻫﺎ Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCMScada with Diagnostics ﺍﻓﺰﺍﺭ ﻧﺮﻡ پﺎﺭﺍﻣﺘﺮﻫﺎی ﻣکﺎﻧﻴکی پﺎﺭﺍﻣﺘﺮﻫﺎی ﺍﻟکﺘﺮﻳکی Winner 2007 Institute of Eng. & Tech. ﻭﺿﻌﻴﺖ آﻼﺭﻣﻬﺎ Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Case Histories case history • چﻨﺪ ﻧﻤﻮﻧﻪ Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Steam Turbine Generator (95 MW) Unbalance and Misalignment Problem Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Belt Problem – ANAM Semiconductor co. , Korea Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

ﺷﻨﺎﺳﺎﺋی ﻭ ﺭﻓﻊ ﺍﺷکﺎﻝ گﻴﺮﺑکﺲ ﺭﺍﺩﺍﺭ Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Iron and Steel: Coupling Problem Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

FAN Unbalance Problem Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

FAN Unbalance Problem Tighten loose bolt Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Stator Insulation Problem Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Internal Electrical Problem Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

PUMP: Bearing and Bent Shaft Phosphate Pump Increase in 10 th and 12 th mechanical parameters Second bearing change and replacement of bent shaft Bearings changed Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Bearing Housing Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Gear Box Radar Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Pump: Misalignment Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Monitors Energy Quality Voltage Balance THD Current Balance Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Monitors Energy Consumption 26 th April 1 st May Current Voltagex 0, 05 Power factor x 10 Active Power Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Connection Diagram Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Communication Terminating Resistors Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Communication Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Communication MCM Motor Condition Monitor VIA LAN Winner 2007 Institute of Eng. & Tech. MOXA NPort DE-311 TCP/IP-RS 232/RS 422/RS 485 Converter Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Communication ETHERNET SWITCH TCP/IP RS 422/RS 485 TO TCP/IP CONVERTER RS 422/RS 485 CABLING ETHERNET SWITCH VIRTUAL COM PORT Winner 2007 Institute of Eng. & Tech. COMPUTER Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Remote Monitoring Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Installation MCM Parameters 1) Device Address 2) Nominal Voltage (L-N) 3) Nominal Current 4) Frequency 5) Motor Speed 6) Connection Type Winner 2007 Institute of Eng. & Tech. 7) Voltage and Current Calibration Values MCM Default Password is ‘m’ Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Installation ONE ITERATION (1. 5 minutes) Modelling, Parameter Calculations Winner 2007 Institute of Eng. & Tech. VI DAQ (6 sec) Tel. : 021 44665701 Front Panel Update Fax: 021 44665739 info@stock-eng. com

MCM Modes MCM has six working modes IDLE CHECK 1. LEARN (4000 Iterations) 2. IMPROVE (8000 Iterations) 3. MONITOR Winner 2007 Institute of Eng. & Tech. UPDATE Tel. : 021 44665701 (1500 Iterations) Fax: 021 44665739 info@stock-eng. com

MCM Modes IDLE : This is MCM’s programming mode. In this mode MCM is completely passive and it can be programmed for a particular motor. For instance, motor plate values such as nominal current, nominal voltage can be entered into MCM using the key pad in the front panel. Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Modes CHECK: In this mode, MCM takes data once and processes this data to calculate physical parameters (rms values of voltages and currents, powerfactor, active power etc. ), modelling errrors, phase ordering between voltages and currents. Then, it compares these values with the motor plate values entered in the programming mode and gives an alarm if there any inconsistancies between the motor plate values and the measured values or if the phase ordering is incorrect. Before sending MCM to learn mode the check mode should be used to detect if there any problems in the connections to MCM or in MCM itself. Winner 2007 Institute of Eng. & Tech. a. Motor Values b. Alarm [Hexadecimal Number] For instance Alarm e 0 Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Phase Ordering Vr Ir -It -Is Is Vt Vs Winner 2007 Institute of Eng. & Tech. It -Ir Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Modes Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Modes LEARN : This mode continues for a preset number of iterations (default value 4000) during which MCM creates a mathematical model and classifies the signals. IMPROVE : This mode starts immediately after the learn mode and continues for again a preset number of iterations (default value 8000) during which MCM updates the mathematical model at each iteration. Winner 2007 Institute of Eng. & Tech. MONITOR : After the learning period is over, MCM starts the monitoring or test phase. During this phase MCM forms a new model with every new set of data and compares the parameters of this model with the parameters of the model obtained in the learning mode. Since the model obtained in the learning period is a statistical model, the comparison is done statistically. It also compares the motor currents with the currents produced by the model obtained during the learning period. Depending on these comparisons MCM issues warning signals for the user. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Modes Px Load A New Load B Py Winner 2007 Institute of Eng. & Tech. UPDATE : It is possible that MCM may not learn all the operating points of the motor. İf we wish MCM to learn certain operating points while it is in the monitor mode, we can simply give the command Update, then MCM will start updating the mathematical model for a preset number of iterations (default value 1500). When updating is finished it will automatically go to monitoring mode. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCM Commands GO IDLE : MCM is sent to IDLE mode and MCM waits for user interraction. CHECK MOTOR : MCM is sent to CHECK Mode. RUN : With this command, MCM first starts the learn mode, then it continues with the improve mode and finally it automatically starts monitoring. This is the automatic working mode of MCM. RESUME : During any working mode MCM can be send to Idle mode. If we give the Resume command in the Idle mode MCM will continue from the point that it left any mode. Winner 2007 Institute of Eng. & Tech. UPDATE : MCM is sent to UPDATE mode to learn a new operating condition. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

SECTION 5 ADVANCED LEVEL USE Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Advanced Level Use It is possible to customize the behavior of MCM by adjusting various settings. As usual a valid password must be supplied before the Edit Settings menu can be entered. The following table summarizes the settings that can be changed together with their significance. It is recommended that the original values of each setting be recorded prior to changing them. Winner 2007 Institute of Eng. & Tech. ﺍﻧﺠﺎﻡ ﻣﻴﺸﻮﺩ کﻪ ﺷﺎﻣﻞ Edit Settings ﺗﻐییﺮ ﺩﺭ پﺎﺭﺍﻣﺘﺮﻫﺎ ﺍﺯ ﻃﺮﻳﻖ ﻣﻨﻮی . ﺍﻗﻼﻡ ﺯﻳﺮ ﺍﺳﺖ Harmonic Values 2 - Motor Values 1 - Motor Settings 4 - Comm. Settings 3 - Alarm Thresholds 6 - CT/VT Calibration Values 5 - Run Settings 8 - Versions 7 - Change 10 Phase Ordering 9 - Password Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Edit Settings Menu Items Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

Advanced Level Use Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com

MCMSo. C İnter Electronic Detective Multimeter Federal Elektrik Smart Electronic Motor Protection Relay & Contactor Iskra Motor Condition Monitor Autoguard Digital Condition Monitor Kron Predictive Multifunction Analyzer Winner 2007 Institute of Eng. & Tech. Tel. : 021 44665701 Fax: 021 44665739 info@stock-eng. com