CONDITION MONITORING THE BEST WAY TO SAVE YOUR MONEY

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Condition Monitoring System from Vulkan SeaCom

AGENDA

History of the Vulkan Group

Reasons for condition monitoring

2

Machine diagnostics

3

Benefits and ROI

4

Conclusions

5

1

(3)

VULKAN History

1889

Foundation of

VULKAN, production

of Brewing equipment

1918

Production of

screw-band clutches,

For the first time able

to engage under load

1941

Production of

marine reversing

gear box with

VULKAN introduced

the first highly flexible

coupling world wide

(

VULKAN

EZ-Coupling

)

1951

VULKAN introduced

RATO, the first

coupling with a linear

1982

1993

For the first time

VULKAN

introduced

silicone instead

of rubber

2006

Start of VULKAN’s

own rubber

production in Herne

1999

Integration of

SeaCom

into the

Vulkan Group

(4)

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Condition Monitoring System from Vulkan SeaCom

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 evaluation

of physical

dimensions i

n real

time

-Preventive maintenance

-CMS and MDS

(5)

AGENDA

History of the Vulkan Group

Reasons for condition monitoring

2

Machine diagnostics

3

Benefits and ROI

4

Conclusions

5

1

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Condition Monitoring System from Vulkan SeaCom

maintenance strategies

CORRECTIVE 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

(7)

Inspection of plant at

preset 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 strategies

PREVENTIVE MAINTENANCE

- timetable maintenance

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Condition Monitoring System from Vulkan SeaCom

Condition

monitoring by

MDSWind®

• condition

parameter

• load curve

• wind phase

quantification of

total data to define

the ideal

date/point of time

for maintenance

event-driven time-based condition-based

maintenance strategies

PREVENTIVE MAINTENANCE

- condition based maintenace

(9)

Permanent online monitoring of the

individual

machine

condition by

continuous

measurm

ent

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 date

s

optimized preventive maintenance becomes predictive

maintenance

Condition based maintenance

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Condition Monitoring System from Vulkan SeaCom

service-team

• operating

company and

diagnostic center

• operating

company

• MDSWind®

with

diagnostic

center (dc)

event

registration and

rapports

planning

preventive

maintenance

reparation,

servicing

feedbacks-documentation

archiving,

(object

database)

Condition based maintenance

maintenance

process

optimized for

life cycle costs

(11)

Online condition monitoring system MDSWind

®

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Condition Monitoring System from Vulkan SeaCom

AGENDA

History of the Vulkan Group

Reasons for condition monitoring

2

Machine diagnostics

3

Benefits and ROI

4

Conclusions

5

1

(13)

Online condition monitoring system MDSWind®

MDSWind® System in power plant

data acquisition, analyzing, threshold monitoring, automatically alarm

reporting, archiving

A

u

t

o

A

l

a

r

m

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

S

W

in

d

®

B

row

s

er

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Condition Monitoring System from Vulkan SeaCom

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)

(15)

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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Condition Monitoring System from Vulkan SeaCom

• kinematic

• process data

• measurement

diagnostic center - processes

phase 1 - configuration and validation

• kinematic

• classification

validation

• limits

• standard

value

optimize

(17)

Diagnostic center processes

reference phase

• kinematic

• classification

validation

• Limit‘s

• Standard value

optimize

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Condition Monitoring System from Vulkan SeaCom

Protection phase

event

• alarm

• failure

analysis

• diagnosis

• expertise

reports

• Condition report

• recommodation

(19)

AGENDA

History of the Vulkan Group

Reasons for condition monitoring

2

Machine diagnostics

3

Benefits and ROI

4

Conclusions

5

1

(20)

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Condition Monitoring System from Vulkan SeaCom

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

(21)

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 line

Ensuring highest reliability of non redundant components

Save inspection intervals of monitored system

Improved 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

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Condition Monitoring System from Vulkan SeaCom

with MDSWind®

without MDSWind®

defect in bearing

total devastation of

gearbox

per type of WTC

per 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 h

approx. 15 - 60 h

Without consideration of the

additional cost to hire a crane

and the associated labor cost

(23)

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

Inbetriebnahme WEA "XYZ" 01.01.2002 Versicherung über Revisionsklausel der Allianz

Einbau CMS in 2005

keine Revision durchgeführt in 2007 Getriebeschaden (Ausbruch auf einer Zahnflanke) in 2009

mit CMS ohne CMS

Maschinenschaden: 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 €

Lower damage costs

because condition monitoring

with MDSWind

Settlement of

claim

Settlement of

breakdown

Cost of damage

Difference :

€87,901.13 = $123,061.40

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Condition Monitoring System from Vulkan SeaCom

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

(25)

AGENDA

History of the Vulkan Group

Reasons for condition monitoring

2

Machine diagnostics

3

Benefits and ROI

4

Conclusions

5

1

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Condition Monitoring System from Vulkan SeaCom

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 THANKS

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Condition Monitoring System from Vulkan SeaCom

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.

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