How do you monitor and control electrical machine performance?

In addition to what mentioned above, using infrared camera and vibration measuring device through routine inspection regime could help in spotting earlier failures.

To prevent errors and fault, my opinion are : 1. For the cencors, meters, or any measurement unit should have to connected thru integrated system PLC or Scada advance, it will give real time report. 2. Use PLC or DCS that are able to Upgrade or doesn’t have limitation to make sure the system cover for a long time period (at least 15-20 years coverage) 3. Make a program for predictive maintenance routine for 6 months/12 months period, and always do corrective action report for any repair/replacement action this will help your team in the future as reference 4. Not only Upgrade the system, you also have to Upgrade skills of your maintenance team to make sure they have knowledge about your latest monitoring and control equipment

While practicing proper maintenance procedures regularly it is important to consider what do meters and sensors measure and act what these devices detect to maintain acceptable machine performance. Keep a continuous log of machine maintenance record, what are faults detected, problems, etc. how it's been diagnosed and repaired on a regular basis. Also take into account wear and tear, etc. in order to minimise downtime or even possible plant shutdown due to inefficient machine performance.

Imagine a pressure sensor on a hydraulic system—it's like having a gauge that tells us how smoothly fluids flow. Now, picture a temperature gauge in an industrial oven—it warns us if things are getting too hot. These tools provide data that engineers use to make improvements and avoid breakdowns.

The sensor's output should be use in a condition monitoring program to be useful and in order to design of a preventive maintenance effectively.

Speed regulator , which controlled the speed by taken feedback via encoder. Torque regulator, control torque by limiting current feedback taken by internal CT(current transformer).

Sometimes, these devices not only improve the stability of the machine, but also help to have a better control in the power network (AVR, Governor and PSS in Generators).

Controllers & regulators can be used to improve the performance of electrical machines in a variety of ways, such as Controllers and regulators can be used to optimize the operation of machines to improve their efficiency. e.g., a VFD can be used to adjust the speed of an AC motor to match the load requirements to reduce energy consumption. They can be used to protect electrical machines from damage and to ensure that they operate within safe limits. Controllers and regulators can be used to prevent accidents and to ensure that electrical machines are operated safely. For example, a PLC can be used to interlock multiple electrical machines to prevent them from operating simultaneously if this would be unsafe.

For Controllers voltage or frequency and regulate it in the generator , you have to put it on off loud , after you have to adjust voltage, and for speed of the generator that depend to fuel and can be adjust by governor of the generator.

advanced controllers can monitor the system for faults, such as overcurrent, overvoltage, or overheating. When such conditions are detected, the controller can take immediate actions like shutting down the system or activating protective measures to prevent damage or accidents. using SSRs and/or optocouplers when switching increase the speed response and the reliability along with the isolation between different circuits ..

I deal with algorithms all the time. Moreover, I develop them for relay protection. I want to say that the creation of an algorithm is always a balance between functionality and realizability. You always want to take into account as many factors as possible, to make the algorithm more efficient, versatile and safe. But the paradox is that the more complex the system, the more fragile it is. It just has more elements that can break and lead to the collapse of the entire algorithm. It turns out a paradox that the more reliable you try to create an algorithm, the less reliable it is. It is a great art to find the line at which to stop.

30 years back we were already busy with predicting problems in machines so we could save costs by letting certain machines in average maintenance level for medium complex products and a few machines in top notch condition for the most complex products. This was in high temperature (1450°C) sintering kilns for electronic products. By analyzing temperatures and power levels in kW to each heating element for a certain process we could predict after some time problems weeks before they actually happened. This helped the inexperienced maintenance staff in new factories enormously, it also increased the output of the factory and it saved costs and stress on the maintenance staff.

Communication and Networking are definitely becoming an integral part of electrical and mechanical systems. Having access to monitor, control and intervene remotely in the working process of machines is definitely a game changer. I reckon the cost of implementation of networking systems might still be an issue and adaptability is solely tied to budget availability. However, there are new innovations in this regard regularly and emphasis should be placed on cost-effectiveness to further accelerate the proliferation of networking integration in all categories of electromechanical machine applications.

Sometimes I think about how late network technologies were adopted in the electric power industry and am horrified: many of the protocols used were created decades ago! I agree that the term obsolescence is not entirely applicable to the electric power industry, that electromechanical relays can work for more than 50 years and fully perform their functions. Unfortunately, the responsibility lies with the innovator, who often has to act out of the box. But the scientists of the 1930s and 1960s were just such innovators! They were brave pioneers! Therefore, one should not be afraid to experiment, for example, digital protocols provide many more opportunities for self-diagnosis. We have a great future ahead of us and we need to be worthy of it

choosing the right communication between systems and devices considered to be the most important role to manage a product. depend on the application and the best use case and critical parts within the project. Wired connections : many protocols has different criteria, short distance with high data transmit SPI , longer distance with higher data like Ethernet, or lower data transmission and fewer connections like I2C .. or CAN bus .. wireless communication : short range and high data transmission WiFi or Lora WAN that provides longer range with lower data transmission.

Implement SCADA (Supervisory Control and Data Acquisition) systems to gather, process, and display real-time data from sensors. SCADA software allows you to monitor the machine's performance remotely, set alarms for abnormal conditions, and make informed decisions.

Standards and regulations are important for number of reasons. They help to ensure the safety and reliability of electrical machines. They also promote compatibility and interoperability between different machines and components. Also, standards and regulations can help to reduce costs by streamlining the design and manufacturing process. Some standards and regulations for electrical machines are: IEC 60034: Performance requirements and test methods for rotating electrical machines. IEC 60079-0: Requirements for construction, testing, and marking of Ex Equipments in explosive atmospheres. ANSI/NEMA MG 1: Design, manufacture, and testing of industrial motors and generators. OSHA 1910.213: Installation and maintenance of electrical machines.

Motor protection switches are proven technology for motors. Only a fixed speed is required If variable speeds are required, frequency converters are usually used. For motors, I need a monitoring system such as KTY in the windings to prevent overheating and thus a reduction in service life

In addition to the factors mentioned above, there are a number of other things to consider when monitoring and controlling the performance of electrical machines. Such as: Environmental conditions like ambient temperature, humidity, and other environmental conditions can affect the performance of electrical machines. Electrical machines should be inspected and maintained on a regular basis to ensure that they are operating properly. This includes tasks such as cleaning, lubricating, and replacing worn parts. Operators should be trained on how to properly operate and maintain electrical machines. This includes knowing how to identify and respond to problems. Keeping records of the maintenance and inspection history of electrical machines.

Depending on the type of machine and their functions, various conditions monitoring ( e.g. Vibration, thermography, current signatures etc. as Stated already) and performance analysis can be incorporated into the machine. These will give useful data in helping to achieve the objective as mentioned .

Predictive Maintenance revolutionizes the control and monitoring of electrical machine performance. Through data analysis, it anticipates component issues. Advanced algorithms learn from historical data, honing their accuracy over time to predict failures. By scheduling proactive maintenance, breakdowns are averted, minimizing downtime and optimizing resource allocation. This technique significantly boosts the efficiency and durability of electrical machines across industries.