Company Overview
Agenda •
Introduction
•
CAM Platform Overview – SAW Temperature Sensors – Partial Discharge Monitoring – Humidity Sensor – Monitoring Units
•
System Configurations
•
Installation
•
Marketing & Business
•
Case Studies
Introduction
Maintenance Strategies (Run to Failure): Results in lengthy, unexpected outages.
• Reactive
(Periodic): inconsistent, and failure could occur between inspections
• Preventative
(Continuous) monitoring): sensors constantly monitor asset during all operating conditions, providing true asset health for predictive maintenance.
• Condition Based
Asset Failure Rates
Data on failure patterns compiled by NASA and the US Navy show only 18% of asset failures are ar e age related, and 82% ar due to random fai fai lures Failure Patterns of Simple and Complex Items
http://www.arcweb.com/Blog/Post/260/Proactive-Asset-Manageme og/Post/260/Proactive-Asset-Management-with-IIoT-and nt-with-IIoT-and-Analytics -Analytics
Condition Based Monitoring (CbM) Using continuous monitoring instruments to gather asset parameters para meters and analyzin analyzing g data to trend and diagnose diagnose the asset health condition over time. Classic P-F Curve
Benefits to Electrical Power Critical Assets Optimize Performance Increase Reliability Lower total maintenance cost • Extend asset life • Minimize downtime with proactive planning • Improve employee safety • Avoid catastrophic catastrophic failure • • •
Primary Causes Of Critical Asset Failure • Compromised Connections
Poor contact, connections, corrosion, wear, or loosening • Results in Elevated Heating •
• Insulation Degradation • Aged,
worn, or or damaged insulation insulation creates dielectric dielectric breakdown • Results in Corona and Partial Discharge • Air Dielectric Breakdown
Excess environmental moisture and condensing atmosphere • Results in tracking and flashover from High Humidity •
Critical Asset Monitoring (CAM) Platform Comprehensive System for continuous, real-time monitoring of electrical asset primary failure modes. CAM-4 Temperature Sensors
Partial Discharge
• • • • •
Touch panel HMI Monitoring (temp, PD, humidity) Concentrator: display and log data for up to 7 external Readers Onboard data storage Multiple communication protocols
Reader •
Humidity Sensor
•
Remote Monitoring (temp, PD, humidity) Modbus RTU (RS485) coms.
CAM Platform Applications •
Low, Medium and High Voltage Switchgear – Incomers, Feeders, Bus Ties
•
Bus ducts / ISO Phase bus ducts
•
Ring main units
•
Transformers
•
Generators
•
Generator Circuit breakers
•
Load Tap Changers
•
Rectifier Stacks
•
Capacitor reactance matching banks
IntelliSAW On the Grid Generation Transmission Distribution Customers
Power Generation Plants Transmission Substations (step-up) Transmission Substations (step-down) Commercial Customers
Heavy Industrial Customers Distribution Substations
Steel Plant
Aluminium Plant
Data Center
Hospital
Petrochem
CAM Platform Overview
System Architecture CAM-4 • Local HMI • Local alarming (contact closure) • Inte Interface rfaces s to SCADA / Historian Historian • Monitoring (temp / PD / humidity) • Data concentrator Reader • Monitoring (temp / PD / humidity) • Communicatio Communications ns back to CAM-4 Sensors • Each monitoring unit can have a unique configuration
Monitoring Capabilities •
12 Temperature sensors
•
4 PD air interfaces
•
8 humidity sensors
Installation Example (MV Switchgear) •
SAW Temperature Sensors – Bus connections – Breaker Input – Breaker Output
Monitoring Unit
CAM
Temp Air Interface
– Cable Connections • Air
Interfaces
– Temperature only (mast) – PD
and Temperature
•
Humidity Sensor
•
Monitoring unit
Humidity Sensor
x3
x3
PD & Temp Interface
SAW Sensors
x3
Surface Acoustic Wave (SAW) Temperature Sensors
SAW Temperature Sensors •
PASSIVE sensor modules – NO power wiring required – Powered by Radio Frequency signals (425 to 442 MHz) – Range: -25˚C to +125˚ C (Accuracy: ±2˚C, Resolution: ±0.2˚C)
•
20+ year sensor life expectancy – Crystal Resonator Technology – Proven technology since 1918
•
Designed for electrical power asset applications – Robust sensor baseplate (tin plated brass) – No internal sharp points, prevents corona – Bolt Mount: 13mm or ANSI ½ in. (54Nm Torque) – Type Tested • IEC
62271-1 Withstand voltage: 95kV/1m and 185kV impulse • IEC 62271-200 Short circuit withstand: 63kA/3s, 171kA peak
SAW Operations
Damped harmonic waveform
Cold Temperature: - Contracts - Fr Fre eque uenc ncy y is is hig igh her IDTs IDTs deposited on crystal substrate
Hot Temperature: - Expands - Fr Fre equ quen ency cy is lo low wer
SAW Operations
434.6
434.421 MHz
434.4 ) Z H M ( Y C N E U Q E R F
Resonator-1 Frequency Range
434.2
Difference = 85°C
434 433.8
Resonator-2 Frequency Range
433.6
433.734 MHz
433.4 -2 5
0
25
50
75
1 00
1 25
150
Sensor Installation Example (Bolt Mount)
Sensor Installation Examples (Alternatives)
Heat Shrink
Tie Wraps 3M Tape
Large Scale System Installation
A total of 34 340 0 ca cabi binet nets s (35kV) were each instrumented with a 6-sensor configuration
Partial Discharge (PD)
What IS PD? •
Localized breakdown of insulation
• Arcs •
within or along surface of insulator
The breakdown causes emissions: – Current
spikes between conductors
• Milliamp • Pico to
to Ampere currents
Nano-coulomb discharges
– Electromagnetic – Acoustic – Ozone
(radio or light)
Why measure PD? • A •
leading indicator of cable damage and insulation failure.
PD Magnitude is linked to the rate of deterioration since each event causes further damage.
• Trending is most important: – A
low level of PD increasing quickly signifies a major defect
– a
high level of PD that is stable indicates there is a major defect, but it is not getting worse
IntelliSAW PD Detection System •
Ultra-High Frequency (UHF) PD Detection
•
Distinguishes PD events from noise with realtime algorithms & band-pass hardware filters
• Concise data •
reporting ideal for trending
Completely non-contact to provide highest safety rating
Applicable to monitoring monitoring all critical assets due to low cost and ease of installation
Signal Filtering to Reject Noise •
Filters are used to select signals from one of three bands (300, 600, and 1200MHz)
•
UHF energy in the selected frequency band is AM detected & processed
•
Typical PD Broadband Frequencies in Assets: – Motors, Transformers, Long Cables are – Switchgear cabinets have – Bus
Low Frequencies
medium frequencies centered on cavity resonance
ducts act as waveguides and transmit high frequencies
Signal classification
Noise:
Surface Discharge (Corona):
Internal Discharge (PD):
• Signals not correlated to line
• Occurs at the negative half cycle
• Occurs within the bulk of the
frequency
• May have other modulation for data transmission
• Might be transient or persistent
where electrons emitted from the metal ionize the air
• Significant odd and even harmonics of the power line frequency
material and causes progressive damage to insulation
• Occurs approximately equally for positive and negative cycles
• Presents as even harmonics of the power line frequency
Quantifying Quantifyin g PD Data for Trending • Analyze
defects for for one power cycle
•
Calculate cumulative charge for all defects
•
Provide one data point as a weighted average
PD = 1,050 1,050 pC cum/cycle cum/cycle
defects
PD Monitor Installation Example
PD & Temperature Monitoring Installation Example
CAM Air Interfaces are used for PD monitoring and temperature sensor measurements.
Humidity Sensor
Why measure Humidity? •
Humidity contamination and moisture on the insulation insul ation surface surface resul results ts in long term insulation insulation damage and metallic corrosion: – Leads
to elevated heating
– Partial
discharge / Surface tracking
– Potential
for shorts and flashover
Industrial Humidity Sensor •
Humidity & Ambient Temperature
•
Ideal for bus ducts and switchgear cable compartments
•
Rugged construction: – Sintered
cap
– Threaded
•
stainless steel body
– M12
water resistant connectors
– 4kV
surge protection
Multi-drop for up to 8 sensors
Monitoring Units and HMI
Reader (Remote Monitoring Unit) •
Up to 4 air interfaces – Temperature and/or PD
•
Up to 12 Temperature sensors – Read range: ~1.75m – Redundant antenna configuration
•
Up to 8 Humidity sensors
•
Modbus RTU communications c ommunications – Serial
RS485
•
24V to 60V DC
•
Type tested for electrical power asset environments
CAM-4 • 4.3” touch panel HMI •
Monitoring Capabilities – Up to 4 air interfaces • Temperature
and/or PD
– Up
to 12 Temperature sensors
– Up
to 8 Humidity sensors
•
Universal Input Power (100 – 250V ac/dc)
•
4 configurable dry contact alarm outputs
•
Extended data storage (USB interface)
Multiple unit interface (up to 7 readers) • Industry standard communications •
– Modbus
RTU, Modbus TCP, DNP3, IEC-61850
CAM-4 HMI Examples
Summary Screen
Temperature Detail Screen
PD Detail Screen
Summary Screen with Warning and Alarms
Temperature Graphical Screen
PD Graphical Screen
System Configuration
Example Distribution Substation Configuration High Voltage
Step Down Transformer
Bus Duct
Incomer
Feeder
Feeder
CAM-4
Reader
Reader
Feeder
Bus Tie
Reader Reader
Reader
Reader B u s D u c t
Local or Remote SCADA Reader
Step Down Transformer
CAM-4
Reader
Reader
Reader
Incomer
Feeder
Feeder
Feeder
Reader
Reader
Bus Duct
Bus Tie
R e a d e r
Example Industrial Customer Substation Layout
Sensorr and Air Senso Air Interface Interface Place Placement ment
•
MV Cubicle Measurements – 12
SAW temperature sensors
– PD
in cable compartment – Humidity in cable compartment
Sensor and Air Interface Placement
Measurement Configuration Software •
SAW temperature sensor and air interface port combinations
•
Temperature sensor calibration
•
PD monitoring ports and measurement characteristics
•
Humidity sensor
•
Communication (RS485) interface
Case Studies
GCB Failure Prevention: US Utility •
US utility peak power plant used semi-annual inspection.
During transition to continuous monitoring observed completely corroded GCB contact. • If this generator had been brought into service, $250K & loss of life. •
MV Switchgear Panel: China Power Plant •
12KV SWGR R phase temp. is 20 C higher than S & T phases.
•
Replaced insulator, problem resolved
•
(Note – PD monitoring might have caught this much earlier)
Capacitor Bank: UAE Utility •
Gulf Region Utility
•
Temperature rise of 33kV Series Capacitor Reactance Matching Banks during peak operation
•
Confirmed iSAW alar Confirmed alarm m reporting reporting using FLIR system
•
Cap banks taken down for f or repair
PD Detection: US Utility •
North East USA Utility
•
Humidity condensing in bus duct causing partial discharge
•
Recommended install of more heaters
Bus Duct Monitoring: US Utility •
This peak power plant experienced a bus duct flashover f lashover due to condensation. – Even
when heaters are used to control humidity, heater failure can go undetected. • The new bus duct has added continuous humidity monitoring.
LVDB Panel: UAE Utility •
Gulf Region Utility
Temperature rise of fuse contact during peak operation, becoming worse over several days • Confirmed iSAW alarm reporting using FLIR system •
•
Reseated fuse and returned normal operation
Critical Asset Monitoring
Continuous Monitoring - Prim Primary ary Fail Failure ure Dete Detecti ction: on: »
Temp, Humidity, PD
- Integra Integrates tes int into o exist existing ing SCADA infrastructure
Early Warning - Data Data ca capt ptur ured ed - Tre rend nds s ana analy lyzed zed - Ala Alarm rm thres threshol holds ds set set for automatic alerts
Vigilance
Resolution Assets
protected Avoid Costly downtime Avoid Injury Increase Reliability
Open Discussion…
