1. Introduction
Many industrial enterprises of Ukraine operate rotary equipment whose service life exceeds 20 years. Outdated control systems and the lack of up-to-date diagnostic tools lead to unpredictable stoppages of production lines, high costs for emergency maintenance and overspending of energy resources. Modernization through retrofitting (installation of modern condition monitoring sensors) is a necessary step to achieve energy efficiency goals, defined, among other things, by European Ecodesign directives, and increase production reliability.
2. Assessment of the state of the outdated system
Before starting the modernization works, it is necessary to carry out a technical audit of the existing equipment. Below are the evaluation criteria that determine the priority of retrofitting.
| Evaluation criteria | State (low priority) | Status (critical priority) |
|---|---|---|
| Vibration level | Corresponds to ISO 20816-1 | Exceeds ISO 20816-3 norms for the corresponding class |
| Bearing temperature | Stable (up to 60°C) | Frequent fluctuations, > 85°C |
| Lubrication condition | Automated | Manual, no level control |
| Equipment age | < 10 years | > 20 years, spare parts limited |
3. Modern alternatives
Replacing old monitoring systems with modern digital solutions allows data to be integrated into SCADA or IIoT systems. As a control interface component for upgraded systems, it is recommended to use controls such as the Siemens 3SB10016BCO6 (code 41523236) to indicate system status.
| Characteristics | Outdated technology | Modern technology (Retrofit) |
|---|---|---|
| Diagnostic method | Planned, visual control | Continuous monitoring (Vibration/Temperature) |
| Detection of defects | After failure | Prediction (Predictive Maintenance) |
| Interface | Analog pointer devices | Digital controllers with display (e.g. Siemens 3SB10016BCO6) |
| Data integration | Absent | OPC UA / Modbus TCP protocols |
4. Calculation of ROI (Return on Investment)
For example, let's take an industrial pump with a capacity of 100 kW, which works 6000 hours a year. Cost of electricity: 0.12 EUR/kWh. The cost of an hour of downtime: 250 EUR.
- Energy efficiency: Optimizing work allows you to reduce energy consumption by 4% (24,000 kWh/year). Savings: 2,880 EUR/year.
- Downtime reduction: Retrofit prevents 1 emergency shutdown (40 hours). Savings: 10,000 EUR/year.
- Retrofit costs: Sensors, controllers (incl. Siemens 3SB10016BCO6), installation, commissioning: EUR 8,000.
Result: Total annual savings — 12,880 EUR. Payback period: approximately 7.5 months.
5. Implementation plan (Roadmap)
- Technical audit: Determination of critical nodes according to ISO 13373.
- Design: Selection of vibration sensors, temperature and control components (Siemens 3SB10016BCO6).
- Purchasing: Cooperation with suppliers such as UNITEC-D for the selection of analogues and original components.
- Installation: Performance of work during scheduled equipment shutdown to minimize losses.
- Commissioning: Setting of trigger thresholds and integration into the control system.
6. Technical difficulties
The main challenges include the limited space for installing new sensors, the effect of electromagnetic interference on signals and the need to adapt old housings. Solution: use of wireless sensors (Wireless HART) and shielded cables according to electromagnetic compatibility standards.
7. Case: Modernization of the pumping station
Before retrofitting, the pump had an MTBF (time before failure) of 4,000 hours. After installing vibration sensors and automated temperature control, the MTBF increased to 12,000 hours. The number of emergency stops decreased from 3 to 0 per year.
8. Commissioning and validation
Acceptance tests are carried out according to ISO 10816. It is necessary to check the accuracy of the sensor readings, the correct operation of the Siemens 3SB10016BCO6 indicators and the absence of false activations of the protection system.
9. Conclusion
Retrofitting of monitoring sensors to outdated equipment is an effective method of increasing reliability without the need for a complete replacement of the main components. This allows the enterprise to comply with modern energy efficiency standards. Consult the UNITEC-D E-Catalog for selection of required components and technical advice.
10. References and Standards
- ISO 20816: Mechanical vibration. Measurement and assessment of machine vibration.
- ISO 13373: Condition monitoring and machine diagnostics.
- Directive 2009/125/EC (Ecodesign).
