www koncarmonitoring com PREDICTIVE MAINTENANCE IN PRACTICE Case

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www. koncarmonitoring. com PREDICTIVE MAINTENANCE IN PRACTICE Case studies and success stories

www. koncarmonitoring. com PREDICTIVE MAINTENANCE IN PRACTICE Case studies and success stories

MACHINE CONDITION MONITORING Project background Toro 3 hydropower project is operated by Costa Rica's

MACHINE CONDITION MONITORING Project background Toro 3 hydropower project is operated by Costa Rica's state-owned utility Instituto Costarricense de Electricidad (ICE). The US$190 million project is located in the Alajuela province and was co-funded by ICE, Banco de Costa Rica and utility company Jasec. Toro 3 powers over 60, 000 households and is a continuation of the project's Phases 1 and 2. Why this solution KONČAR Group was responsible for design, manufacture, delivery, supervision, setting up and putting into operation two 29. 7 MVA hydro generators, including excitation systems, unit vibration monitoring systems, generator power and neutral point equipment, metal clad busbars and auxiliary consumption transformers. The solution was selected to monitor and protect the complex operations of the hydro plant and preserve the investment by focusing on critical machine parts according to customer requirements. The solution protects the plant by activating shutdown of the plant if critical values are reached. Benefits and results for the client The solutions is a modular and custom specific protection against all harmful parameters (vibrations, temperatures, air gap, magnetic field, partial discharges, cavitation) resulting with increased productivity and protected production. The plant operators can identify most important machine faults and get key information for effective asset management through expert tools. The problems like large inventory of spare parts and unplanned production shutdowns can be eliminated and prevented. TORO 3, COSTA RICA 49 MW of installed capacity $190 mil. project value 190 GWh annual generation 2013 Commission year 02

MACHINE CONDITION MONITORING Project background The Chaparral project will boast an 87. 5 m-high

MACHINE CONDITION MONITORING Project background The Chaparral project will boast an 87. 5 m-high dam and two Francis type turbines, which will use water from the Torola river. The dam's maximum capacity will be 189 Mm 3. It will have average production of 66 MW, equivalent to the consumption of approximately 200, 000 families. Work on the dam was suspended in 2010 after the Agatha storm, and the Italian building company abandoned the project. Why this solution KONČAR Group was rewarded the project together with ČKD Blansko Holding from Czech Republic. The scope of the delivery are two generators with 36 MVA power that should be monitored and assessed continuously by the local operator - Comisión Ejecutiva Hidreléctrica del Río Lempa (CEL). Benefits and results for the client In order to preserve the generator value, the requirements of the tender will be completely fulfilled with machine condition monitoring system. The scope of monitoring includes full range of expert tools for easy access and data analysis on site and remotely. The measuring values include vibration monitoring, air gap and partial discharge that will be integrated in one customer interface in order to obtain key data in a user friendly way. EL CHAPARRAL, EL SALVADOR 66 MW of planned installed capacity 290 mil. € Value of the project 200, 000 Households powered 2018 Planned commission year 03

SHAFT CURRENT AND VOLTAGE PROTECTION Project background The Ituango Dam, also referred to as

SHAFT CURRENT AND VOLTAGE PROTECTION Project background The Ituango Dam, also referred to as the Pescadero-Ituango Dam, is an embankment dam currently under construction on the Cauca River near Ituango in Antioquia Department, Colombia. Development of the project is being proposed by EPM Ituango, a consortium of Empresas Publicas de Medellin (EPM) and the Antioquia government. The dam's power plant will have a nominal hydraulic head of 197 meters (646 ft) and contain eight 307 megawatts (412, 000 hp) Francis turbine-generators. Why this solution Shaft current and voltage protection system monitors and protects the shaft generator against bearing damages. Because bearing insulation deteriorates with usage, the current flow can cause serious damages to the bearing and cause extensive economic damage. The high value of the project was the reason why bearings need to be additionally protected. Benefits and results for the client With the system installed a problem is detected on time and before major damage occurs. Monitoring of shaft currents and a quick response to increasing amplitude of these currents is an easy way to protect the expensive power generation equipment. The plant operators have a full control of the system with online analysis, protection based on harmonic composition and real trending of measured values. The interpretation of results is easy, simple and secure. ITUANGO DAM, COLUMBIA 2, 456 MW of installed capacity $2. 8 billion cost of construction 9, 200 GWh Annual generation 2018 Commission year 04

SHAFT CURRENT AND VOLTAGE PROTECTION Project background The El Quimbo Dam is a concrete

SHAFT CURRENT AND VOLTAGE PROTECTION Project background The El Quimbo Dam is a concrete faced rock-fill dam (CFRD) and hydroelectric power project under development in the Huila Department of southwestern-central Colombia. The powerhouse located at the toe of the dam has two vertical axis Francis turbines each of 200 MW capacity. Each is designed for a discharge of 166. 53 cubic meters per second (5, 881 cu ft/s). The generators are of the synchronous type with a generation capacity of 225 MVA. Why this solution One of the requirements defined by the client, EMGESA ESP S. A. , was that the generator units are protected against bearing damages. Considering the investment value it was necessary to protect the crucial equipment with a monitoring system that can prevent major economic damages, such as generator shutdown that can occur as a result of shaft currents. Benefits and results for the client The plant operators have a full control of the system with online analysis, protection based on harmonic composition and real trending of measured values. The personnel on site was trained to get full benefits of the system and learn how to interpret results, as well as how to recognize faults in the early stage of development. Equipped with this information the operator can optimize its maintenance periods for the time when they are actually needed. EL QUIMBO, COLUMBIA 400 MW of installed capacity $837 mil. project value 2, 216 GWh annual generation 2015 Commission year 05

SMALL HYDRO CONDITION MONITORING Project background Pamilo Hydro Power Plant is located in Palovaara,

SMALL HYDRO CONDITION MONITORING Project background Pamilo Hydro Power Plant is located in Palovaara, Karelia, in the south east of Finland. It is the tenth-largest power plant in Finland. The total installed capacity is 89 MW (2 x Francis turbine of 34 MW and 1 x Francis turbine). It is notable for being Vattenfall's largest hydroelectric power plant in Finland. HPP PAMILO, FINLAND 89 MW Why this solution of installed capacity KONČAR Group has performed revitalization, installation of new stator and reinsulation of the poles on one of the units that has 34 MW capacity. The customer used the occasion to upgrade its plant with state-of-the-art monitoring system and protect its investment against unplanned outages, as well as to prolong the lifetime of the plant. The compact solution allows monitoring of key parts such as upper and lower generator bearing and turbine bearing. 6, 550 km² Benefits and results for the client Condition monitoring of small hydro plants is extremely important due to the fact that the plants are usually located outside of urban area. The solution monitors key functions and common problems that may cause malfunctions. With the possibility of accessing data from any location in the world, the stakeholders can rely on the system and be sure that the plant is secure through advanced functions like alarm setting, real time trends, early fault detection and automatically generated reports. catchment area 256 GWh Annual generation 1955 Commission year 06

EXPERT MOTOR CONDITION MONITORING Project background The 300 MW plant began operating in 1983,

EXPERT MOTOR CONDITION MONITORING Project background The 300 MW plant began operating in 1983, and is owned and operated by Elektroprivreda Republike Srpske. It is a supercritical power station and sources 1. 8 million tones of lignite coal a year from the nearby Gacko coal mine, which is operated by Gacko Mine and Power. In 2015 an agreement was made with China’s Dongfang Electric Corporation (DEC) for the construction of a new 350 MW unit at Gacko plant. Why this solution A public tender was released with the purpose of protecting critical production motors that increase the availability of these machines. The reason behind this is to assure high safety of the overall production process, because operational issues of the motors can impact the work of the main generator, which in the end can make a big damage to the production. Benefits and results for the client By equipping critical motors with condition monitoring system, the operator receives full overview of key parameters like vibrations, relative shaft displacement, speed of rotation, magnetic field and temperature levels. This means that serious motor failures such as rotor broken bars, cage ring damages, rotor eccentricity, bearing damages and others can be detected much before normal production operation is jeopardized, this leaving enough time to optimize the maintenance periods. GACKO THERMAL PLANT, BOSNIA 300 MW of installed capacity 750 mil. € Value of the plant expansion 1, 500 GWh Annual generation 1983 Original commission year 07

ROTOR WIRELESS MEASUREMENT SYSTEM Project background WEINZÖDL, AUSTRIA After more than 30 years in

ROTOR WIRELESS MEASUREMENT SYSTEM Project background WEINZÖDL, AUSTRIA After more than 30 years in operation, the power plant was comprehensively modernized, gaining two new Kaplan bulb turbines as well as generators optimized for performance. Austrian electricity operator, VERBUND, has invested more than 20 million euros in the modernization. The new turbines and generators increased the electricity generated by a formidable 20 percent without undertaking any changes to the outside of the facility or in the reservoir area. 54 MW Why this solution As a part of the modernization, a specific focus was placed on the elimination of rotor failures that have occurred before. The rotor of a new turbine alone weighs 15 tons and has a diameter of just under 4 meters. The decision was made to install a system that could without too much interference measure excitation values. This specific solution can measure the parameters that normally can’t be measured, such as the excitation of the big generators. The solution is also modular, which means it can be expanded to measure temperature, vibrations, magnetic field, air gap, etc. Benefits and results for the client A wireless solution was presented and completely fulfilled its purpose. The installed system measures excitation current and voltage while the power is supplied from the excitation using converter. This enables a stabile flow of measurements that can be accessed from the operator panel. Using devices that are installed on rotor and stator, the system starts automatically when it is connected to a power supply. This makes it ideal for operations with multiple starts and where time needs to be saved. 08 of installed capacity 20 mil. € Value of last modernization 22, 000 Households power 1982 Original commission year

ELECTRICAL MACHINE BLACK BOX HPP ZAKUČAC, CROATIA Project background The Zakučac hydro power plant

ELECTRICAL MACHINE BLACK BOX HPP ZAKUČAC, CROATIA Project background The Zakučac hydro power plant was constructed in the lower flow of the Cetina River, near Omiš. Zakučac is the largest plant in Cetina River basin and the largest hydro power plant in Croatia by its installed capacity and potential power production. After the reconstruction of the plant the installed capacity will amount to 4× 144 MW and is expected to be finished in late 2016. 538 MW Why this solution of installed capacity Electrical machine black box was installed specifically to detect harmful working conditions of the generators. The operator of the plant, HEP Croatia, decided to use the modernization as an opportunity to install a system that will provide more information on the failure types. The suggestion from KONČAR Institute was to monitor non-standard conditions that represent a significant electromagnetic and thermal stress for the machine, which greatly reduces its lifetime. 133 mil. € Benefits and results for the client The client received the system that provides data that standard monitoring systems don’t measure. This includes machine conditions such as: » » » 09 Asynchronous operation Incorrect synchronization Significant asymmetry » » » Two-phase operation Run-out (over-speed) Overloading » » » Excessive heating of stator iron or stator winding Excessive vibration of the generator housing Number of machine stars Value of last plant upgrade 2, 000 GWh annual generation 1962 Original commission year

CUSTOM SOLUTION: MONITORING AND CONTROL Project background One of our customers wanted a solution

CUSTOM SOLUTION: MONITORING AND CONTROL Project background One of our customers wanted a solution that will speed up the production, monitor key processes and enable quality reporting. Because the production often resulted with products that were defected or don’t satisfy quality standards, the goal was to monitor key parameters and use this information to optimize its production with an online production management system. FORGING FACTORY, SLOVENIA 22 forging machines Why this solution Wirelessly monitored Since the production process is very specific, a solution was required that can be fully adapted to eliminate problems and make production more efficient. Together with equipping each forging machine with the appropriate equipment, a custom specific software was developed, so that the plant staff can get quickly insight into key production values and modify production lines according to real time data. Production control Benefits and results for the client With a custom system in place, the plant users can focus on key performance indicators like number of perfect and faulty products. Each of the machine can be monitored analyzed with respect to temperature levels, norm, successful rate, errors including intuitive graphic presentation of historical values. The machine data can be used to give production orders in the same interface or to print out materials that contain bar codes which can be used to start or modify the production on the machine directly. Finally, a custom report is generated that shows production information important for the managers. 10 Machines can be stopped and started in online interface Efficient production Key machine parts and products are controlled

CUSTOM SOLUTION: MONITORING OF MACHINE EFFICIENCY Project background HVAC PRODUCER, SERBIA The requirement of

CUSTOM SOLUTION: MONITORING OF MACHINE EFFICIENCY Project background HVAC PRODUCER, SERBIA The requirement of the customer was to implement an advanced monitoring system that not only measures the values, but also archives the values in the database and uses the same for application control. The goal was to compare values obtained from different configurations of the monitored application and focus on key process indicators. This tailored made solution was required to have an exact number of input channels to measure and integrate data such as electrical values, pressure, temperature, flow, rotational speed and others (overall 50 channels). Custom applications Why this solution Within the system each user can insert specific test parameters (acceleration (ramp), acceleration duration, constant speed duration, load). In this way it is possible to use the same process parameters for different configurations of the monitored system and then later compare the results and choose the one with the highest efficiency. Benefits and results for the client The client was able to integrate all measured data obtained from different configurations and then determine which of possible configurations had the biggest effect on his production. Using the software and the database for advanced measurement archiving, the system can provide crucial information for test object (max. efficiency for various process parameters and configurations of the test object). The customized web application is used to configure key elements in a fast and effective way and at the same time to integrate the data in a single computer interface. 11 Stationary and portable usage 50 channels For measuring of production values Efficiency calculation The advanced software calculates combination of inputs that results with maximized machine output

REFERENCES More than 20 GVA worldwide monitored! 12

REFERENCES More than 20 GVA worldwide monitored! 12

SCHEDULE A LIVE 1 -ON-1 DEMO SCHEDULE NOW Our experts will show you how

SCHEDULE A LIVE 1 -ON-1 DEMO SCHEDULE NOW Our experts will show you how advanced predictive maintenance can transform your business by optimizing production and cut down your costs. The 1 -on-1 discussion will provide you with: most common types of rotating machine failures cost effective alternatives to expensive analysis integrated monitoring of multiple machines methods for early detection of severe faults answers to your questions

Achieve more with less resources! Contact us for more information For the last 50

Achieve more with less resources! Contact us for more information For the last 50 years we have been helping many clients accross the globe to optimize their production and save their costs. Our team of experts has impressive experience in broad range of rotating machines types and different areas of asset management » » Large and small hydro plants Hydro and turbo generators Electrical motors Machine production, usage and maintenance www. koncarmonitoring. com +385 99 392 1974 @ kmsupport@koncar-institut. hr Fallerovo šetalište 22 Zagreb 10002, Croatia KONČAR Electrical Engineering Institute, Inc.