condition monitoring the best way to save your money

1 - 17VULKAN COUPLINGS21. Juli 2010

CONDITION MONITORING THE BEST WAY TO SAVE YOUR MONEY

2 - 29Condition Monitoring System from Vulkan SeaCom28h of June 2011 l WEDOW RÜDIGER

AGENDA

History of the Vulkan Group

Reasons for condition monitoring2

Machine diagnostics 3

Benefits and ROI4

Conclusions5

1

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28h of June 2011 l WEDOW RÜDIGERCondition Monitoring System from Vulkan SeaCom

VULKAN History

1889

Foundation of VULKAN, production of Brewing equipment (compressors)

1918

Production of screw-band clutches,For the first time able to engage under load

1941

Production of marine reversing gear box with high maneuverability

VULKAN introduced the first highly flexible coupling world wide (VULKAN EZ-Coupling)

1951

VULKAN introducedRATO, the firstcoupling with a linear characteristic

1982

1993

For the first time VULKAN introduced silicone instead of rubber

2006

Start of VULKAN’sown rubber production in Herne

1999

Integration of SeaCom into the Vulkan Group

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Coupling Lokring Drive Tech SeaCom

Flexible Couplings

- ship s main propulsion- ship s auxiliary drive- PTO s- boat propulsion

Pipe Connections

- Freezers- Refrigerators- Air condition units

Brakes, dumpings in Ships and wind industry

- boat propulsion- industrial drive- mobile drive- railway- crank shaft dampers

Measurement system for industrial applications

-Programming of micro-controllers

- Development of programs of visualization and evaluationof physical dimensions in real time

-Preventive maintenance-CMS and MDS

VULKAN Group


AGENDA




Benefits and ROI4

Conclusions5

1

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maintenance strategiesCORRECTIVE MAINTENANCE- damage orientated maintenance

• No attempt at maintenance and inspection until damage occurs

• Procedure of durability is used until breakdown of the last component in the chain

event- oriented

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• Inspection of plant atpreset intervals–revision presetting

• Dismounting and inspection of component parts

• Replacement of component parts with disregard to wear (too early)

• Cost-intensive method

event-driven time-based

maintenance strategiesPREVENTIVE MAINTENANCE- timetable maintenance

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Condition monitoring by MDSWind®• condition parameter• load curve• wind phase…quantification of total data to define the ideal date/point of timefor maintenance

event-driven time-based condition-based

maintenance strategiesPREVENTIVE MAINTENANCE- condition based maintenace

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• Permanent online monitoring of the individual machine condition by continuous measurment

• Replacement of component parts with special regard to their actual condition

• Rimely shutdown of plant in prudent consideration of the measured /predicted condition

• Rest possible individual estimation for maintenance dates• optimized preventive maintenance becomes predictive

maintenance

Condition based maintenance

Advantages of predictive condition-based maintenance:

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• service-team

• operating company and diagnostic center

• operating company

• MDSWind®with diagnosticcenter (dc)

event registration and rapports

planning preventive maintenance

reparation,

servicing

feedbacks-documentation

archiving, (object

database)

Condition based maintenance

maintenanceprocess

optimized forlife cycle costs

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Online condition monitoring system MDSWind®

Functional principle of condition monitoring system MDSWind®


AGENDA




Benefits and ROI4

Conclusions5

1

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MDSWind® System in power plantdata acquisition, analyzing, threshold monitoring, automatically alarm

reporting, archiving

customer, operator, service team

Auto

Alarm

evaluation, analyzing, interpretation

reports with recommendations

data archiving, creating and building a object database of the monitored

power plant

support and supply of

the interface (via internet) to the object

database

operating company (with diagnostic center)

MD

SWin

d®Br

owse

r

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Tasks for SeaCom diagnostic center with MDSWind®:

• continuously monitoring of condition data

• data analysis and evaluation

• archiving condition data and evaluation results referring to individual turbines within the plants

• damage detection at an early stage

• monitoring of trends

• Information data supply for maintenance structure

Plant database (object database)


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Tickets with reports and

recommendations• SeaCom

DC

Schedule, maintenance and reparation• operator

Repairs and maintenance• service team

Tickets with

feedback• operator

position of diagnostic center in the process of maintenance-information flow

event management system- EMS

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• kinematic• process data• measurement

diagnostic center - processesphase 1 - configuration and validation

• kinematic• classification

validation • limits• standard

value

optimize

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Diagnostic center processesreference phase

• kinematic• classification

validation

• Limit‘s• Standard value

optimize

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Protection phase

event

• alarm• failure

analysis

• diagnosis• expertise

reports

• Condition report• recommodation

Diagnostic center processes


AGENDA




Benefits and ROI4

Conclusions5

1

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support for condition-based maintenance planning

increase / stabilization of technical availability

reduction of maintenance costs

avoidance/ prevention of plant stoppages

induction of specific repair tasks

Benefit of condition monitoring system MDSWind®

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Current and early information of normal or abnormal operation as well as load profiles of the propulsion system

Avoid overload and unnecessary wear on the drive lineEnsuring highest reliability of non redundant componentsSave inspection intervals of monitored systemImproved availability of the complete drive line by avoiding failures due

to preventive maintenance as well as purposeful planning of spare parts

Fast support due to remote diagnostics of measurement data that is independent of the location

Support inspection of the classified personal

Benefit of service concepts with MDSWind®

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with MDSWind® without MDSWind®defect in bearing total devastation of

gearbox

per type of WTCper position in drive train

€ 2,500 – 32,000$3,500 – 44,800

€ 75,000 – 240,000$ 105,000 – 336,000

down time

cost

approx. 600 happrox. 15 - 60 h

Without consideration of the additional cost to hire a crane and the associated labor cost

Return on Investment

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example of our customer (O&M company), with our MDSWind®

Inbetriebnahme WEA "XYZ" 01.01.2002Versicherung über Revisionsklausel der AllianzEinbau CMS in 2005keine Revision durchgeführt in 2007Getriebeschaden (Ausbruch auf einer Zahnflanke) in 2009

mit CMS ohne CMSMaschinenschaden: 120.000,00 € 140.000,00 €Unterbrechungsschaden: 11.219,00 € 37.397,00 €Schaden gesamt: 131.219,00 € 177.397,00 €

Abzug wg. nicht durchgeführter Revision: 115.000,00 €Abzug wg. Verschleiß: 25.000,00 €60 % vom Rest-Maschinenschaden: 57.000,00 €Regulierung Maschinenschaden durch Versicherung: 57.000,00 € 25.000,00 €

Regulierung BU: 9.723,13 € 0,00 €

Schaden gesamt: 131.219,00 € 177.397,00 €Regulierung Maschinenschaden durch Versicherung: 57.000,00 € 25.000,00 €Regulierung BU: 9.723,13 € 0,00 €Kosten Schaden 64.495,87 € 152.397,00 €

Differenz: 87.901,13 €

Kosten Installation CMS: 10.000,00 €lfd. Kosten CMS seit 2005 (ca. 1.000 € pro Jahr) 5.000,00 €Kosten gesamt: 15.000,00 €

Lower damage costsbecause condition monitoringwith MDSWind

Settlement of claim

Settlement of breakdown

Cost of damage

Difference : €87,901.13 = $123,061.40

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Cost of damage in comparison with replacement vs. repair real example from our client (O&M company), with our MDSWind®

Replacement generator, gear, main bearing

Repair of generator, gear, main bearing

Replacement of shaft

Repair of shaft


AGENDA




Benefits and ROI4

Conclusions5

1

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Highest reliability of WTC by the application of a condition monitoring system

Avoidance of overload and needless abrasive wear

Revised Availability of WTC

Faster support because remote service and independent from location and type measured data

Saving of money with regard to costs of spare parts, technical support and in finding the precise reason and or nature of damage.

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MANY THANKSFOR YOUR KIND ATTENTION

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DISCLAIMER

Any liability for information given within this presentation will be herewith disclaimed.

1. The basic target of this presentation is the provision of information, no responsibility is given for the correctness, completeness and admissibility of these information or any illustration within this presentation.

2. All rights of the author to illustrations and/or any other information given within this presentation remain with him.

3. Rights to given added values, inventions and third party labelings remain with the rights owner.

4. The presentation should only be used for the purpose of describing VULKAN or VULKAN products and may only be used or duplicated unrestrictedly and without modifications.

condition monitoring the best way to save your money

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