ComPro 2000 in Action

Roy Douglas Carbone of America WMEA 2009

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

Drag-line Hoist Generator Profiles

HG# 1 4 TIR 4.0 1.4 MBTB 0.4 0.3

This is the information you need to be able to make the right decision! ComPro 2000 measures contact-free and dynamically!

3.3

0.4

Overlay Window shows the first 3 revolutions.

Average profile of the first 3 revolutions Raw adjusted Data Scale Window to +/- 5 mils manipulated to clearly show the first 3 revolutions
1200.5

HG#1 Track 4

New 6-Channel ComPro Now you can measure a complete M-G Set 2000MP for the Surface Mining with only 2 shutdowns! Shut-down the Industry 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. 2. 3. 4. 5. 6. Aircraft Starter Generator Funfair Elevator Ride P&H Shovel 8200 Dragline Coteau Dragline 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 ComPros Motors were profiled live with dragline in motion Varying Speed
(ComPro Acquisition Speed is very fast hence no problem)

8200 Dragline Schematic

SM#1
SM#2 SM#3 SM#4 HM#1 HM#2 HM#3 PM#1 HM#4 DM#4 DM#1 DM#2 DM#3

PM#2

HG#1 / SG#1 / HG#2 HG#3 / SG#2 / HG#4

DG#2 / SG#3 / DG#1 DG#4 / SG#4 / DG#3

Commutator TIR / MBTB Table

# SG#1 SG#2 SG#3 SG#4 DG#1 DG#2 DG#3 DG#4 HG#1 HG#2 HG#3 HG#4 TIR 2.6 1.6 MBTB 0.2 0.2 # SM#1 TIR 2.4 MBTB 0.3

SM#2
SM#3 SM#4 DM#1 DM#2 DM#3 DM#4 HM#1 HM#2 HM#3 HM#4 PM#1 PM#2

2.6
4.4 2.2 1.6 1.6 0.8 1.8 2.2 4.8 5.3 1.5 2.0 2.1

0.3
0.3 0.1 0.4 0.5 0.3 0.2 1.3 1.3 0.4 0.4 0.9 0.6

5.9 7.3

0.4 1.6

2.7 4.3 8.2 3.3 3.9 3.9

0.7 0.4 1.3 0.4 0.5 0.9

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 coms 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)

2 More Examples of

1045kW Hoist Generators

HG#7 Track 4

1200.5

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?