EC Systems – GS-Hydro cooperation

• About EC Systems & EC Group

• Dedicated systems for industry

• Condition monitoring systems

• EC Systems – GS-Hydro R&D project

Agenda

• 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

History

• 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

Key facts about EC Systems

R&D cooperation

Selected customers

Dedicated systems for industry

We develop:

• Data acquisition &

monitoring

• Test automation

• Analysis &

diagnostics

• Visualization &

control

• Data management

• High level

software

• Low level

software

• Electronics

• Hardware platforms Microcontrollers

8/16/32 bit ARM, AVR, MSP FPGA (Xilinx, Altera),

DSP

• Standards ATEX RoHS IEC 61508 ISO 14000

Technologies (electronics)

• 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

• 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

Technologies (software)

• Environments Rational Rose .NET/ Visual C# Visual C++ Eclipse (QNX, Java) MATLAB/SIMULINK LabView CUDA

• Web-based ASP .Net Silverlight Java

Project examples

• monitoring & diagnostics for power generation units

• data aggregation and replication

• real-time database• software integration• dedicated modules• communication backbone• interfaces to other systems

DCSPLC

Power Plant Monitoring & 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

Wireless Bus Diagnostics

• Integration of info from 8

system types

• Large geographical area

• Compliance with railway

regulations

• Flexible architecture

• Reporting module

Railway Maintenance & Diagnostic Center

Condition monitoring

• VIBTransmitter – single-channel vibration monitoring and protection

• VIBDAQ – from 2 up to 16 channel data acquisition

• Signal conditioners – from 1 to 16 channels

Simple solutions

• 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

VIBTransmitter - single-channel monitoring and protection

• 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

VIBex CMS

EC Systems Diagnostic Center

• Warning against failures

• Better reliability

• Optimized maintenance plan

• Lower maintenance costs

• Less planned and unplanned downtime

Key benefits of condition monitoring

CMS Industrial implementations

• 160 wind turbines in 27 wind farms in Germany

• GL & Allianz certification

Wind turbines

• Much vibration & noise from normal, failure-free operation

• Additional measurements• Harsh operational environment

(salt, water, temperatures, explosive zone)

• Our experiences:Offshore gas platformCompressor stationsChemical plants

Reciprocating compressors

• Very complicated kinematics• 40 bearings on 10m2

• 30 gears• 3 vibration sensors

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EC Systems – GS-Hydro R&D project

Experimental model high-pressure non-welded hydraulic piping mains with function of self-diagnostics of threaded fittings

EC Systems – GS-Hydro R&D project

Main advantages:• Elimination of welding

(time savings, less explosion hazard)

• Simple mounting• Mounting on-site• Online wireless monitoring

system of the connections

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.

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.

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.

EC Systems – GS-Hydro R&D project