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EC Systems – GS-Hydro cooperation

EC Systems – GS-Hydro cooperation. Agenda. About EC Systems & EC Group Dedicated systems for industry Condition monitoring systems EC Systems – GS-Hydro R&D project. History. Started in 1992 500 employees in the holding (EC Grupa) ISO 9001 standard since 1999

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EC Systems – GS-Hydro cooperation

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  1. EC Systems – GS-Hydro cooperation

  2. Agenda • About EC Systems & EC Group • Dedicated systems for industry • Condition monitoring systems • EC Systems – GS-Hydro R&D project

  3. History • Started in 1992 • 500 employees in the holding (EC Grupa) • ISO 9001 standard since 1999 • Implementation of engineering and software development projects worldwide • R&D cooperation with best technical universities from around the world

  4. Key facts about EC Systems • 45 people: HW, SW, automation engineers • Strong R&D capabilities (connection to the AGH University) • Specializations: • Dedicated systems for industry: industrial software and hardware development • Condition monitoring systems

  5. R&D cooperation

  6. Selectedcustomers

  7. Dedicated systems for industry

  8. We develop: • Data acquisition & monitoring • Test automation • Analysis & diagnostics • Visualization & control • Data management • High level software • Low level software • Electronics

  9. Technologies (electronics) • Hardware platforms • Microcontrollers 8/16/32 bit • ARM, AVR, MSP • FPGA (Xilinx, Altera), DSP • Standards • ATEX • RoHS • IEC 61508 • ISO 14000 • Production • Pick & Place system (BGA, 0402 technology) • Climatic chamber • EMC testing • Environments & tools • IAR, KEIL embedded • Active VHDL • Protel/ EDA • P Spice • ANSI C, ASM

  10. Technologies (software) • Hardware platforms • Industrial PCs • PC in-the-box • Embedded • Operating systems • Windows (XP, Vista, 7) • Windows Embedded • Windows CE • Linux/Unix • VxWorks, QNX, RTX • Databases • MS SQL • My SQL • Oracle • Environments • Rational Rose • .NET/ Visual C# • Visual C++ • Eclipse (QNX, Java) • MATLAB/SIMULINK • LabView • CUDA • Web-based • ASP .Net • Silverlight • Java

  11. Project examples

  12. Power Plant Monitoring & Diagnostics • monitoring & diagnostics for power generation units • data aggregation and replication • real-time database • software integration • dedicated modules • communication backbone • interfaces to other systems • DCS • PLC

  13. Wireless Bus Diagnostics • Single diagnostic system for all bus subsystems • Fleet management • Unified software integrating functions from various systems coming from third party vendors • Collecting data in common diagnostic platform • Integration with maintenance database

  14. Railway Maintenance & Diagnostic Center • Integration of info from 8 system types • Large geographical area • Compliance with railway regulations • Flexible architecture • Reporting module

  15. Condition monitoring

  16. Simple solutions • VIBTransmitter – single-channel vibration monitoring and protection • VIBDAQ – from 2 up to 16 channel data acquisition • Signal conditioners – from 1 to 16 channels

  17. VIBTransmitter - single-channel monitoring and protection • RMS or PEAK measurement • Detection of elevated vibration due to damaged bearings, gears, unbalance, misalignment, loose foundation, fractured pistons, shafts. Etc. • Protection through relay outputs • 4-20 mA output to SCADA/DCS Special designs for: • Reciprocating compressors (measurement in angular intervals) • Proximity probes

  18. VIBex CMS • Online condition monitoring system for rotating machinery • Use of cutting-edge science: advanced signal processing, intelligent algorithms • Advanced analysis • Order spectrum • Envelope spectrum • Harmonic line identification • Automated limit setting • Notification (e-mail, SMS) • Early fault detection on gears, shafts & bearings

  19. EC Systems Diagnostic Center

  20. Key benefits of condition monitoring • Warning against failures • Better reliability • Optimized maintenance plan • Lower maintenance costs • Less planned and unplanned downtime

  21. CMS Industrial implementations

  22. Wind turbines • 160 wind turbines in 27 wind farms in Germany • GL & Allianz certification

  23. Reciprocating compressors • Much vibration & noise from normal, failure-free operation • Additionalmeasurements • Harsh operational environment (salt, water, temperatures, explosive zone) • Ourexperiences: • Offshoregas platform • Compressorstations • Chemicalplants

  24. Printing machine • Very complicated kinematics • 40 bearings on 10m2 • 30 gears • 3 vibration sensors

  25. EC Systems – GS-Hydro R&D project

  26. EC Systems – GS-Hydro R&D project Experimental model high-pressure non-welded hydraulic piping mains with function of self-diagnostics of threaded fittings • Main advantages: • Elimination of welding (time savings, less explosion hazard) • Simple mounting • Mounting on-site • Online wireless monitoring system of the connections

  27. EC Systems – GS-Hydro R&D project Research for optimal monitoring method, experimental measurements of: • Operational pressure, • Pressure rise time, • Amplitude of high frequency vibration (accelerometers & vibroscanner), • Strain in connection vicinity (strain gauges), • Excitation value in the system (volumetric flow rate & pressure of the medium), • Temperature of the connection area.

  28. EC Systems – GS-Hydro R&D project Final online monitoring system: • Battery powered, • Optional energy harvesting, • Measurements selected based on prior research, • Ability for embedded advanced analysis (validation, spectrum, enveloping), • Wireless data transfer, • ATEX certificate.

  29. EC Systems – GS-Hydro R&D project Main potential customers: • Mining • Oil extraction & transport • Marine industry Other potential applications: • construction of hydraulic supply systems, • silt conveying installations, • cement conveying installations, • high pressure water pumping.

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