compro 2000 in action
TRANSCRIPT
Roy Douglas
Carbone of America
WMEA 2009
ComPro 2000 in Action
Profile Measuring Instruments
• Contact Probes
– Dial Indicator
– Pundicator
– Feinpruf – Analogue
(1986)
– MMS6000 – Digital
(1996)
– CL Profiler (2008)
• Non-Contact Probes
– Compro 2000 (2006)
– ComPro 2000MP
(2009)
How the ComPro 2000 Works
• Eddy-Current Transducer
– Sampling Frequency 1MHz
– Measuring Range
• 20 mils
– 200 points per Bar
– Proximity of Copper
– Not suited to Steel
– Each Probe Calibrated
Individually
– Resolution 2,32 micro-inch
Transducer Calibration
Calculation of the Sampling
Frequency
200 points / bar
HG# TIR MBTB
1 4.0 0.4
4 1.4 0.3
7 3.3 0.4
Drag-line
Hoist
Generator
Profiles
This is the
information you
need to be able to
make the right
decision!
ComPro 2000
measures
‘contact-free’ and
dynamically!
HG#1 Track 4
1200.5
Raw Data
Window
manipulated to
clearly show the
first 3 revolutions
Overlay
Window shows
the first 3
revolutions.
Average profile
of the first 3
revolutions
Scale adjusted
to +/- 5 mils
New 6-Channel ComPro
2000MP for the Surface Mining
Industry
•Now you can measure a complete M-G Set
with only 2 shutdowns!
•Shut-down the M-G set
•Lock-Out Tag-Out
•Fit a ComPro transducer to each machine
•Set the air-gaps
•Start the M-G set
•Acquire the 6 commutator profiles
•Shut-down the M-G set
•Lock-Out Tag-Out
•Remove the transducers
Case Studies
1. Aircraft Starter Generator
2. Funfair – Elevator Ride
3. P&H Shovel
4. 8200 Dragline
5. Coteau Dragline
6. Motor Repair Shop - Florida
Aircraft Starter Generator• The Challenge
– 15,000 RPM
– 2” Diameter
– 40m/s or 8,000
fpm
927kHz / 2 sec acquisition /
7MB file / 10,000 RPM /
1541 Revolutions
Funfair – Elevator Ride
• The Challenge– 600V DC Motor 1,000 HP
– Directly Coupled • ($7,000/set of new Coupling
Bolts)
– TIR limit 3 mils, to be measured every 3 months
– Limited number of revolutions in either direction (Double Drum Winder)
– 1 RPM
– 2AM
Acquisition of 3 revolutions
took 6 minutes
Sampling frequency set at
2000 Hz to limit the file size
File size about 4 MB
P&H Shovel
• The Challenge– Productivity
constraints
– Motors difficult to uncouple
– Varying Speed
– Live profiling required
4100A Rear Hoist Track #1 & #4
8200 Dragline in Canada
• The Challenge
• Profile all 12 Generators and 14 Motors in half a day– We used 3 Single
Channel ComPro’s
– Motors were profiled live with dragline in motion
– Varying Speed• (ComPro Acquisition
Speed is very fast hence no problem)
8200 Dragline Schematic
SM#1SM#2 SM#3
SM#4
PM#1 PM#2
HM#4 DM#4
HM#3
HM#2
HM#1
DM#3
DM#2
DM#1
HG#1 / SG#1 / HG#2 DG#2 / SG#3 / DG#1
HG#3 / SG#2 / HG#4 DG#4 / SG#4 / DG#3
Commutator TIR / MBTB Table
# TIR MBTB
SG#1 2.6 0.2
SG#2 1.6 0.2
SG#3 - -
SG#4 5.9 0.4
DG#1 7.3 1.6
DG#2 - -
DG#3 2.7 0.7
DG#4 4.3 0.4
HG#1 8.2 1.3
HG#2 3.3 0.4
HG#3 3.9 0.5
HG#4 3.9 0.9
# TIR MBTB
SM#1 2.4 0.3
SM#2 2.6 0.3
SM#3 4.4 0.3
SM#4 2.2 0.1
DM#1 1.6 0.4
DM#2 1.6 0.5
DM#3 0.8 0.3
DM#4 1.8 0.2
HM#1 2.2 1.3
HM#2 4.8 1.3
HM#3 5.3 0.4
HM#4 1.5 0.4
PM#1 2.0 0.9
PM#2 2.1 0.6
HG # 2
Coteau – Feedback on the use of the
ComPro200MP
• Can you give us some info on how often you do the profiles, how long it took you?
– We perform the profiles at least yearly on our pre annual pm.
– We also perform the profiles whenever there is a lot of burning and arcing on the com’s
– We have found that the profiler has helped us greatly with the reduction of down time it takes to complete a profile of a motor or generator.
– On motors we are no longer splitting the couples and shutting the machine down for only minutes to set up the profiler instead of hours to split and couple the couplers.
– On generators we simply shut the set down air gap all of the sensors and start up the set and within minutes we have profiled the entire gen set.
• What Difficulties do you encounter?
– The only difficulty that we have come across is trying to train employees on how to navigate the computer software. We have found that the more technologically advanced employees pick up the software quickly.
– We have found that we can manage our comms closer than just on a yearly basis and feel that the profiler is our number one tool in solving arcing and burning on comms.
Swing Gen #1 4/28/2009
Swing Gen #1 10/7/2009 (6 months later)
1200.5
HG#7 Track 4
2 More
Examples of
1045kW Hoist
Generators
1200.5
HG#7 Track 4
GE788 Helically Grooved
Commutator?
• Sorry, not
suited to
ComPro
at this
time!
•ComPro 2000 – Dynamic Profiler
•6-Channel ComPro 2000MP for the
Surface Mining Industry
•CL Profiler Profiler for contact profiling
CL Profiler Contact Type Output
Special Thanks
• Randy and Ross at Coteau
• Skip at ‘Funfair’
• Dave at P&H Milwaukee
• P&H MinePro Gillette
• Jon and Jim of Rio Tinto
• All COA ComPro Users
Questions?