Test Motors play a key role in Industry 4.0 (fourth industrial revolution), since it manages millions of data from monitored motors and that allows us to generate maintenance and production strategies that can maximize the company’s results.
Test Motors, through its online predictive maintenance tool, TestIM, allows to detect the faults of electric motors or generators and their components, in this case the increase of vibrations of a compressor. It is a compressor with a power of 520 kW.
The TestIM tool can detect power failures, power system, stator, rotor, eccentricities, bearings, shafts, transmission systems or motor load.
TestIM_SmartSoft, the software installed on your server will allow you to keep under control all the motors / generators in your company, from anywhere in the world, you just have to access the Internet and you can view it in real time, with easy configuration reports, as needed.
In June 2018, the TestIM system detects a fault in the compressor part, indicating the color code in the application and Test Motors informs the customer about this important change in the compressor.
The system starts to detect, at the level of vibrations, an important discordance between the real values and the estimated values that the machine should have according to the correct operation of the compressor.
During the month of August 2018, the compressor remained stopped and the manufacturer made some revisions. At the end of August, it was decided to restart the compressor. During the month of September, the group had the following characteristics of vibration level.
Among the RMS values of the vibrations in the compressor, high values were maintained (the orange line marks the new starts after the August stop):
At the beginning of October 2018, the TestIM system began to detect increases in important vibrations also in the motor part. Changes in behavior are shown in the following graphs (Blue value: Actual value, Green value: Estimated value)
On October 8, Test Motors notified the customer about these significant vibration increases in the motor. On October 12, the compressor maintenance company dismantled this group to check its status.
During the repair, the manufacturer made repairs to the part of the motor, specifically, replacement of the bearings and review of the pockets, on October 29, the group went back to work until now. According to the data captured thanks to the TestIM, the vibration analysis of the motor has improved considerably after the repair:
At the vibration RMS level: the vibration acceleration of the motor side Vy-de, after the repair, the measured values (blue curve) return to coincide with the estimated values (green curve) by Machine Learning.
The maximum RMS values of Vy-de are kept close to 50m / s ^ 2; before the repair these values reached up to 80m / s ^ 2.
In the vibration speed, Vyv-de, the same thing happened, the measured values already coincide with the values estimated by Machine Learning. Now the RY of Vyv-de maintains a maximum close to 6mm / s, while before the repair, its maximums already exceeded 10mm / s.
The motor, after the repair, has had an important improvement in its vibrations: the RMS values have recovered the initial levels, in addition, they return to coincide with the values estimated by Machine Learning that correspond to the correct condition of the motor operation.
According to the FFT of the vibration signals, an improvement in the balance and alignment of the motor after the repair has also been detected.
According to the data after the repair of the compressor the improvements are important, the motor manufacturer found several components of the compressor very deteriorated.
Thanks to the predictive technique and artificial intelligence, the detected fault could be treated in time, and by performing the pertinent corrective action, the fault is finally resolved.