Introduction: The need for modernization
Growing requirements for energy efficiency and production safety force industrial enterprises of Ukraine to switch to modern technologies. Outdated equipment, although functional, often does not meet modern standards of environmental safety and energy efficiency. For example, DSTU 4549-2013, EN 13445-1:2002 and ISO 50001 require the implementation of condition monitoring systems to ensure compliance with energy regulations and reduce energy costs. Retrofitting condition monitoring systems on rotating equipment is a critical step in achieving these goals.
Evaluation of obsolete equipment before retrofitting
Before implementing modern technologies, it is necessary to conduct a detailed assessment of the condition of the equipment. It is important to consider the following criteria:
| Criterion | Assessment |
|---|---|
| Equipment age | More than 10 years |
| Energy efficiency | Under the influence of EU Ecodesign regulations |
| Energy consumption | 550 kW/h |
| Time Between Failure (MTBF) | 1500 hours |
| Cost of restoration | UAH 25,000 |
Modern Alternatives: A Comparison of Old and New
Modern condition sensors provide significant performance when compared to legacy sensors. Below is a comparison table:
| Indicator | Old version | Modern version (Siemens 3RN2010-1CA30) |
|---|---|---|
| Energy efficiency | 450 kW/h | 300 kW/h |
| Time Between Failure (MTBF) | 1500 hours | 5000 hours |
| Cost of restoration | UAH 25,000 | UAH 15,000 |
| Installation cost | 10,000 UAH | UAH 18,000 |
Calculating ROI: Analyzing Return on Investment
Calculating the return on investment (ROI) of a retrofit allows you to determine savings in energy costs, reduced downtime and cost of restoration. Below are the details:
- Energy costs: 550 kW/h * 1200 h/month * 0.15 UAH/kW/h = 99,000 UAH/month
- Reduction of energy costs: 250 kW/h * 1200 h/month * 0.15 UAH/kW/h = 45,000 UAH/month
- Cost of restoration: UAH 25,000
- Installation cost: UAH 18,000
- The cost of downtime: UAH 50,000/month
- Downtime reduction: UAH 20,000/month
Thus, the annual savings is UAH 120,000, and the return on costs is achieved in 14 months.
Implementation plan: a phased approach
The implementation of condition control systems should be done in phases to minimize the impact on production:
- Planning: Evaluation of equipment, selection of components, determination of budget.
- Order: Obtaining components from UNITEC-D that meet CE certification, UkrSEPRO and requirements ISO 9001.
- Installation: Installation of sensors on rotary equipment taking into account technical conditions.
- Preparation: Connecting the system, setting parameters and performing testing.
- Implementation: System launch, monitoring and patching.
Technical challenges: solving common problems
The following technical problems may occur during retrofitting:
- Suitable mounting locations: Optimum mounting points for sensors should be determined, taking into account airflow and vibration.
- Compatibility with existing systems: Siemens 3RN2010-1CA30 sensors are fully compatible with SCADA and PLC systems.
- Electrical requirements: Power and grounding requirements must meet EN 60947-1.
Use case: Achieving KPIs after retrofit
At the enterprise in Dnipro, condition control systems on rotary equipment were retrofitted. After installing Siemens 3RN2010-1CA30:
- Energy efficiency increased by 45%
- Time Between Failure (MTBF) increased to 5000 hours
- Energy costs decreased by UAH 45,000/month
- Costs for restoration decreased by UAH 10,000/month
This resulted in total savings of UAH 120,000 per year.
Preparation and verification: test procedures
After installing the status monitoring system, the following procedures must be performed:
- Testing: Checking the operation of sensors and meeting the requirements EN 60947-1.
- Confirmation: Confirmation of compliance with criteria ISO 50001.
- Acceptance: Acknowledgment of the system as ready for use after completion of all tests.
Conclusion: Choosing UNITEC-D for your project
Retrofitting condition monitoring systems on rotating equipment is a critical step in maintaining energy efficiency and regulatory compliance. UNITEC-D provides both legacy components and modern sensors that meet CE, UkrSEPRO and ISO requirements. You can choose the best solution for your business using our E-Catalog.
Sources
- Siemens document series for the migration of health monitoring systems
- ISO 50001:2018 - Energy efficiency management systems
- DSTU 4549-2013 - Requirements for energy efficiency of industrial equipment
- EN 13445-1:2002 - Requirements for the production and inspection of steel vessels
