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Condition monitoring systems

rotor dynamiCs

sound and vibration analysis

Condition Monitoring and Machine Diagnostics

monitoring systems

Condition monitoring

rotor dynamiCs

Condition Monitoring and Machine Diagnostics for Industrial Plants


The engineering firm Kerntech is a flexible service provider. Working in close collaboration with industry as well as with applied research. Our aim is to provide the customized monitoring solutions you need to run your plant safely and efficiently
Our excellence is
- Vibration and loose part monitoring - Special measurement and test engineering - Design, development, and implementation of automatic machinery monitoring, programs for early failure detection, and trend analysis - Measurement, control, and display systems - Nuclear-thermohydraulic stability measurements
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- correlation of physically different signals (neutron flux, pressure, temperature, etc.)

Systems and programming


We offer custumized program and system development services for a wide range of measurement and monitoring requirements. For example, this could involve the automatic signalling and supervision of operational parameters. measurement and monitoring systems / automatic monitoring systems Application-oriented development of vibration and loose parts monitoring systems. We offer: - Development and design - Installation of additional instrumentation - Realization of special measurements - Display and visualization of status signals, test results and trend charts - Integration in existing data networks, maintenance, and remote maintenance systems benefits: - Improved production rate by running the machines at low-wearing conditions - Avoidance of progressive damage through an early warning system - Improved informational basis for concerted maintenance tasks

Loose parts monitoring


loose parts monitoring Impact sound measurements on externally accessible components and installations of temporary accessory instrumentation including signal processing: - Detection of impacts at compo nents of primary and/or secondary circuits (e.g. conduits, steam generators, reheaters, and pumps)

Loose parts monitoring within the pressure vessel of boiling water reactors during power operation for the: - detection of impacts between fuel elements, instrumentation lances, and the single tubes of the lances

Special measurements
short-term and flexible measurements with additional or already existing instrumentation. With on-line evaluation and on-site result reporting on the: - determination of control circuit parameters - field measurements and documentation of the start up of new or replaced components - determination of diagnosis parameters to prevent future damage - determination of fluid resonances in piping systems - long and short term trend tracking of operating parameters (such as temperature, pressure, flow rate, etc.)

Fig. 1: Shock tests for the determination of solid borne sound in a nuclear power plant Fig. 2: Self-contained breathing apparatus training at the fire station Fig. 3: Stain Gauges application on an vibrating pipeline

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sound and vibration analysis

Individual data acquisition and control programs


Measurement and data analysis software tailored to your specific area of application. We offer: - Measurement and control programs customized to your specific needs (e.g. pumps, rotating machinery) - Support and advice on the selection of hardware - Program development in LabView (National Instruments) or C++ - Applications for stationary measuring systems as well as compact mobile solutions on laptop or embedded-PC basis Benefits: - Test benches require customized data acquisition systems - we develop efficient solutions according to your needs - Fast program development based on the programming language LabView, particularly designed for measurement problems - High performance applications through machineoriented programming in C++

Power plant measurements


analysis of the standard reactor instrumentation signals following the german nuclear safety standards Commission specification (Kta 3204) for the documentation of components of primary and secondary circuits of the pressurized water and boiling water reactors. instrumentation in use: - In- and out-core neutron flux - Thermocouples - Pressure sensors - Flow rate test points - Travel sensor and accelerometer analyzed components: - Pressure vessel - Core barrel and core shroud - Fuel assemblies - Instrumentation lances - Circulating pumps - Shaft adjustments and sealings

Fig. 1: Shows a display unit for the continuous supervision of parameters in a steam turbine (turbine stress evaluator) and how it is deployed in power plants Fig. 2: Run-up test to determine the structure resonance Fig. 3: Nuclear-thermohydraulic stability measurements by means of a decay-ratio trend

Industrial display equipments


We develop customized display and monitoring units for the process and operating surveillance.
Floating Spectra vertical vibration at the bearing motor side driving shaft of the pump (A10)
240 210 180
166 Hz APSD Accelaration [(m/s)/Hz)] 1,000E-5 1,778E-5 3,162E-5 5,623E-5 1,000E-4 1,778E-4 3,162E-4 5,623E-4 1,000E-3 0,001778 0,003162 0,005623 0,01000 0,01778 0,03162 0,05623 0,1000 0,1778 0,3162 0,5623 1,000 88 Hz

Oscillation and alternating pressure measurements


In addition to the rotor dynamical observations of vibrations of turbo-machinery, we also examine their fluid dynamical causes. This means the investigation of components such as pumps, turbo charger, axial and centrifugal compressors, turbo-engines and steam turbines. Typical fluid dynamical phenomena, which may generate vibrations on those components, are e.g. rotating stalls, surge, acoustic resonances and cavitation.

frequency [Hz]

150 120 90 60 30 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 Fig.06

50-53 Hz 29,6 Hz

We offer: - Small series and individual manufacturing - Supervision and control of test stations, assembly lines, and adjustment settings of the machinery etc. - Development of different computing and control platforms: industrial PCs, flat/panel PCs with touch screen, compact and robust box computers, PLC and micro controller solutions - Also as field bus system for remote supervision or as measuring instrument/for data acquisition in areas difficult of access

Pipe vibrations
Excessive pipe vibrations induce unwanted load and may cause severe problems. With regard to this, vibration analyses are a useful tool to increase efficiency by detecting and avoiding unfavourable excitation mechanisms. Whether or not the pipe vibrations are within the permitted limits can be verified by measurements of vibrational acceleration, speed and displacement. An effective vibration reduction is only possible if the excitation mechanisms are known. Hence, a multi-

time [s]

Vibration diagnosis
Nuklear-Thermohydraulische Stabilittsmessung, Lanze 20 Position 44-25
100 75 50 1,0 0,9 0,8
St ab 14 -1 9 s au St ab 38 -3 5 au St s 34 -1 5 au s ab 18 -3 9 au s -1 0 s au ab St YU

th. Leistung Summensignal (YQ00X011) th. Leistung (YQ31X080)

Decay Ratio

0,7 0,6 0,5 0,4 0,3 0,2 0,1 0,0 0,70 0,65 0,60 0,55 0,50
03:45 04:00 04:15 04:30 04:45 05:00
Ebene A (YQ31X077) Ebene D (YQ31X080) Mittl. Decay Ratio ber alle Messpos. + /- Sigma

We provide vibration monitoring solutions tailored to the specific needs of nuclear power plants as well as to conventional facilities. measurements including on site assessment according to international standards such as iso 10816, iso 7919 and asme ansi om-3.

Freq. [Hz]

P th [%]

Mittl. Frequenz ber alle Messpos. + /- Sigma

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Fig. 1: The bearing diagnosis enables early failure detection of bearings Fig. 2: Measurement of blade vibrations of turbo chargers Fig. 3: Vibration analysis of a multiphase pump

channel vibration analysis is advisable also when excessive pipe vibration is already ascertained. Unlike simple hand held vibrometers, these multi-channel measurements allow for the modal and frequencyselective analyses required to do a technical assessment. Pipe vibration can be traced back to inhomogeneous flows which cause vibrations at the natural frequency of the pipe. Those vibrations at the natural frequency may lead to high oscillations already by minor excitations. Pipe vibrations may also be caused by pumps, compressors and fluid resonance.

- Mobile stand-by duty: As trouble shooting or continuously to prevent problems - Multi phase spiral pumps in oil-production industry: we offer on-site vibration measurements on the oilfield - Chemical industry: Condition monitoring on pumps with magnetic clutches by magnetic field analysis

Strain gauges
Strain gauges offer a possibility to analyse the dynamic load on a structure which could lead to deterioration of the component. Thus, the relevant force time history can be determined. Modal and vibration analyses help to determine the natural mode of the components. Based on those measures treatments for vibration level reduction can be established.

Bearing diagnostics
Defect bearings are one of the foremost reasons for outages of machinery. Supervision of roller bearings can predict oncoming disruptions opening up for preventive maintenance and loss avoidance. We offer: - Customized solutions: Regular bearing diagnostic services and supervision through alarm systems - Development of measuring and analysis systems for continuous supervision; applicable on-site or to the remote maintenance - Preparation of status reports and expert opinions - Root cause analysis in case of repeatedly fastwearing bearings benefits: - Cost reduction: Bearings diagnostics enable the prevention of unexpected and expensive machinery failures. Furthermore, they offer a possibility to reduce premature replacements of bearings. - Reliability: Undetected bearing defects may cause significant damage. Bearing monitoring, eventually in combination with vibration control, is a way to minimize or obviate risk

Shaft vibration
100 75 50 25
S (p-p)Max = 90 m

30.05.2002 19.05.2006 13.06.2006 limit A/B limit B/C limit C/D

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S (p-p)Max = 180 m

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Monitoring and diagnosis of pumps


Pumps are critical elements in the operating process of many industrial systems. Our range of services includes what you need to operate pumps safely and efficiently. We offer: - Noise-based detection of cavitation - Bearing diagnostics - Trend and long-run monitoring - Vibration monitoring: Sourcing and measures in case of excessive vibrations

0RL12V053

Orbits of a feed-water pump with limits according to DIN ISO 7919

Validation and measurement of the natural mode of a CSM-56B engine on MTU test bench

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staFF members

Dr. Jrgen Fiedler


Diploma in experimental physics Doctor of engineering Ten years of experience as research assistant in nuclear technology involving non-destructive testing at the University of Hanover Experienced expert in measurement and analysis of vibrations

Dr. Bernd Hellmich


Diploma in experimental physics Doctor of engineering Two years of experience as research assistant in nuclear technology involving non-destructive testing and three years in turbo machinery at the University of Hanover Seven years of experience in aerodynamics, acoustics and technical mechanics

Dr. Joachim Runkel


Diploma and thesis in engineering 18 years of experience as research assistant in nuclear technology involving non-destructive testing and four years in fluid flow engines at the University of Hanover
International known expert in the field of neutron noise analysis

Normann Pla
Diploma in theoretical physics Four years of experience in machine monitoring systems Software development in LabView

Olga Novikova
Diploma in engineering in Charkow, Ukraine
One year of post graduate studies in Germany

Lars Andraschek
Training as electronics installer systems engineering Certified developer for PLC (programmable logic controller) Implementation of measurements for machinery and equipment condition monitoring Realisation of fine mechanical and electrical made-to-order production

Four years of experience in engineering and documentation

Sebastian Brandt Training in the Siemens AG as electronics installer - systems engineering Certified developer for PLC (programmable logic controller) Implementation of measurements for machinery and equipment condition monitoring Realisation of fine mechanical and electrical made-to-order production

Sergiy Yakovenko Diploma in automation engineering Bachelor of Science in applied informatics Three years of experience in programming and controlling of test stations Software development in LabView

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How to find us...


Leave the A2 at the AS Bad Nenndorf exit (38) towards Barsinghausen and follow the B65. Leave the B65 and drive straight ahead following the L391. Turn to your right on Nienstedter Strae (L401) after about 3-4 kilometres. Follow this road for approximately 70 meters before turning left in the street Neue Rehre. Leave the Neue Rehre and turn to your left in the Steinradweg. You find your destination on the right side at the Forsthaus.

Kerntech GmbH Am Forsthaus 8 D-30890 Barsinghausen tel. +49.511. 67 66 88 73 Fax +49.511. 67 66 88 88 vanity: 0700-KERNTECH E-mail: fiedler@kerntech.de hellmich@kerntech.de runkel@kerntech.de info@kerntech.de www.kerntech.de Executive director: Dr. Jrgen Fiedler HRB Hannover 59019

References: in particular we have many years of work experience with: eon-Kernkraft eon Kraftwerke vattenfall mtu vW sincor richter Chemietechnik

Certified according to DIN EN ISO 9001:2000

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Layout: Bernd.Schuster@xxsdesign.de

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