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?