Most advanced Predictive Diagnostic Tool for Rotating equipment Uses Torsional Vibration, far more sensitive than traditional linear vibration. Detect Cancer at Stage ZERO! Non-invasive, user-friendly methods IOT-Ready: Monitor equipment health remotely on your mobile devices Enables on-site, over the network or remote cloud based connectivity for real time monitoring of machine health anytime and from anywhere

1. Advanced Predictive
Diagnostic Tool for Engines
and critical rotating
equipment
Neptunus Power Plant Services Pvt Ltd

2. The Context
Today’s industry
● Faces high pressure to reduce operational costs, andyet have high reliability.
● Wants to run more efficiently,waste less and be more considerate towardsthe
environment.
● New technologies are expensive and complicated to adopt and require highly skilled
people tooperate.
● Maintenance 4.0is stilla hazyterm. Few knowhow to move forward.
● However, there is abetter way to domaintenance.
● Neptunus has the right solutions foryou, and still bringsvalue to you.

3. Our Vision

4. A stitch in time saves nine…
Neptunus’ solution will enable
detection of an emerging fault
MUCH EARLIER comparedto
conventional maintenancemethods
such as linearvibration
accelerometers..So you getMORE
TIME to plan & take preventive /
corrective action.
How can we improve asset reliability?
4
Engine/Equipment
Condition
Optimized
Performance
Early
WarningDiagnosi
s
NEPTUNUS enabled
Early Stage Fault
Detection
Late Stage
Detection (Today’s
Practises leave
operatorswith
little time for
corrective action)
Audio/visual
Maintenanc
e Practises
Equipment breakdown
(No time left to salvage
the engine!
)Time available for maintenance planning & corrective action
Time Left for Corrective
Action: High
Time Left for Corrective
Action: Low
Breakdown
!

5. How?
● Use of highly advanced technology, which is easy to use and puts the
power in the hands of theoperators.
● Torsional Vibration: the most sensitive and advanced form of
vibration measurement
○ Early Warning Diagnostics of machinehealth
○ Pre-empt failures, so you can plan maintenance cycles better
○ Change onlywhat is faulty, and do it before time,to save on money
anddowntime!

6. Torsional Vibration :alphasystem
● Most advanced Predictive Diagnostic Tool forRotating equipment
● UsesTorsional Vibration, far more sensitive than traditional linear vibration.
● Detect Cancer atStageZERO!
● Non-invasive, user-friendlymethods
● IOT-Ready: Monitor equipment health remotelyon your mobile devices
● Enables on-site, overthe network or remote cloud based connectivityfor real time
monitoring ofmachine health anytime and from anywhere
6

7. The Alpha System
Principle - Measurement of Torsional Vibration and analysis of it’s
variation through statistical and mathematical computation to derive
component specific and overall engine healthindicators.
● MPUmeasures the Torsional vibration
● TDC Sensor references thecylinders

8. Torsional Vibration:Theory
Indicators
⬢ Mechanical Health
⬢ Engine Efficiency
⬢ Injection
⬢ Bearing
⬢ Misfiring
⬢ Twist Angle
⬢ Mounts
⬢ Compression
⬢ Mech. Stresses
⬢ …
alpha
system Frequency
⬢ Frequencydistribution
Time Domain
Angular
Torsional
Vibration
⬢ Acceleration
⬢ Velocity
⬢ Displacement
⬢ Mean
⬢ Variance
& ⬢ Skewness
⬢ Kurtosis

9. Torsional Vibration:Theory
A
B
Theoretical Signal (Carrier Frequency)
Measured Signal
Hilbert
Indicators
Stochastic computation of
statistical moments:
⬢ Mean
⬢ Variance
⬢ Skewness
⬢ Kurtosis
transform Phase difference betweenHilbert transform
(velocity) & carrier signal)
Angular Displacement
AngularVelocity
Magnitude of Hilberttransform
AngularAcceleration
Derivative ofvelocity
Difference signal (A-B)
Harmonics appearanceor
disappearance
phasing

10. Torsional vs Linear Vibration
Lateral Vibration Torsional Vibration
Definition Movement or mechanical oscillation
about an equilibrium position of a
machine or component
Changes in the relative angular displacement between
two points on a rotating shaft
Sensor Accelerometer ( mostly) MPU, Speed sensor,
Encoder
Sensorlocation Very critical parameter. If location is
wrong, lots of false alarm
On rotating shaft
Transmission path/Frequency
range
Right accelerometer for target
frequency range
Independent of frequency range. Normally speed
sensor works from 0-25KHz
Vibration External disturbance could change the
behavior
Independent of external vibration
Repeatability/Calibration Calibration required Not required
Result analysis Analysis compared as par ISO 10816-
3 Vibration severity chart.
not compared. In-situ real time diagnostics
Summary The measurement of lateral vibrations
is an indirect measurement of the
forces of the component that could fail.
The measurement of torsional vibrations is a direct
measurement of the forces of the component that
could fail.

11. Alpha SystemApplications
Motors

12. ● Comparestheoreticalsignalof rotationof shaftto
measuredsignal
● Puts thesignaldifferencethroughstatisticaland
mathematicalcomputation
● Algorithm helps derive component specificand overall
motor healthindicators.
● MPUmeasures theTorsional vibrationon the motor
shaft
● Gives you adetailed report without the needfor
vibrationlevel 1or 2analyzers.
● This is remarkabletechnology.
Applications: Electric Motors

13. Motor/Alternator Indicators
OVERALL INDICATORS
● Bearing/Damage
● Stability
● Electromagnetic Stress

14. Motor/Alternator Indicators
● This indicator measures unexpected stress pulses in
movement of rotatingsystem
● Potentialproblems could be shocks stemmingfromstresson rotating
shaft duringoperation:
a. Inadequatelubrication
b. Misaligned shaft
c. Insufficient bearingload

15. Motor/Alternator Indicators
● This indicatormeasures thestabilityof thespeed bymeasuringshaft speed
change inpercentage
● Potential problems could be unbalances of shaft movement due to
a. Broken rotorbar
b. Mass unbalance
c. Air gapeccentricity
d. Rotor winding failure statorwinding failure

16. Motor/Alternator Indicators
● This indicatormeasures presence of unbalance supplyvoltage or current,
single phasing, under or over voltage, reversephase, overload,etc.
● Faults under thisclassification are:
a.Underorovervoltage of current orunbalance supplyvoltage or current
b. Single phasing or reversephase
c. Overload or earthfault

17. Alpha SystemApplications
Turbochargers

18. Turbocharger: Installation
Installation :
● Two MPUsto be installed on the
Engine
● One MPUto be installed on the
Turbocharger
● One MPUfor Power Output

19. Turbocharger Indicators
● This indicatorshows unexpected shocks inmovement of rotor system
● Potentialproblems could be shocks stemmingfromstresson rotor
system during operation.Causedby
a. Contaminated or burnt-outoil
b. Corrosion ofbearings
c. Metallic particles blocking rotorsystem
d. Broken orbent blades of turbineorcompressor
e. Accumulation ofcarbon

20. Turbocharger Indicators
● This indicatormeasures speed variationof rotorsystem due to
non-smoothrotation
● Degradation of overall mechanical efficiencyof turbine,
compressor,and rotorshaft andincreaseof powerloss of engine
dueto
a. Bearing
b. Friction
c. Mechanical problems in rotorsystem
d. Low oilpressure
e. Interruptionin oilsupply

21. Alpha SystemApplications
Diesel Engines

22. Diesel Engines:Installation
Module consists of :
● Diesel EngineAnalysis
● AlternatorAnalysis
Installation :
● Two MPUsto be installed on the
Engine
● One MPUto be installed on the
Alternator
● Current Monitoring Sensoron
switchboard

23. Diesel EngineIndicators
OVERALL INDICATORS
● Mechanical Health
● Operating Condition
● Mechanical Stresses
● Stresses onfoundation
● TorsionalAngle
● Power inKW

24. Diesel EngineIndicators
●
●
●
●
●
●
●

25. Diesel EngineIndicators
●
●
●
●
●
●
●

26. Diesel EngineIndicators
CYLINDER SPECIFIC HEALTH INDICATORS

27. Diesel EngineIndicators
● The ignition timing points of anengine (measuredin degrees of the crankshaft)aremonitored by thisindicator.
● If the measured time difference between two cylinders varies from the expected time, this is an indication of
varyingcompression in one ormorecylinders.
● The cause of this time deviation is the velocity of the piston, which is dependent upon the resistance of the air
pressure during the compression stroke. If there is an air leak in a cylinder, the resistance of the compression is
lower and the air pressure itself is also lower, and consequently the piston velocity increases, which can affect the
ignitiontiming.
● This can occur from leakage in the cylinder caused by poor valve sealing, resulting from improper valve
adjustment or aworn valveguide.
● Other causes include carbon deposits on the piston rings, combustion chamber walls, or piston crown, as well as
wear or damage to the liner or piston rings, or anyother leak from which the compressed aircanescape
CYLINDER SPECIFIC HEALTH INDICATOR

28. Diesel EngineIndicators
CYLINDER SPECIFIC HEALTH INDICATOR
● This indicator expresses the quality of injection timing for every single cylinder and the regularity of the power of the
combustiblegas on each cylinder duringthe power stroke.
● It is ameasure of the regularityof the combustion overallcylinders.
● The indicator is derived from the amplitude of the 1st harmonic for 2-stroke engines or the 1st half-harmonic for 4-
stroke enginesasafraction of the overall rotationalenergy.
● Poorinjection leads to abnormalangulardisplacement of the crankshaft.
● Poor injection due to nozzle deposits, for example, typically degrades the injector spray pattern, reducing the
engine’smaximumpower andtorque.
● If the diesel fuel at the start of injection is not sufficiently atomized, it combusts with a certain delay. A low
combustion temperature at the time of the start of injection can also influence the injection timing. It is for this reason
thatacoldengine always shows acertain injection delay.

29. Diesel EngineIndicators
CYLINDER SPECIFIC HEALTH INDICATOR
● This indicator shows more serious cases of injection and is calculated in the same way as the injection timing
indicator.
● Conditions which could trigger this indicator include: complete shutoff of fuel to a cylinder, no atomization of the
fuel,ortoo much fueldeliveredto aparticular cylinder.
● Poor injection condition is also correlated to the twist angle. If the frequency component of the twist angle at the
1st harmonic for 2-stroke engines or the 1st half-harmonic for 4-stroke engines is exceptionally high, it is a sign of
poorinjection condition.

30. Diesel EngineIndicators
CYLINDER SPECIFIC HEALTH INDICATOR
● This indicator gives an indication of the damage and dynamic behavior of the moving parts of the
engine, such as the mainbearings, connecting rod bearings, and the pistonassembly.
● It is calculated from the 4th stochastic moment of the angular displacement, angular velocity, and
angular acceleration of the crankshaft. It can be influenced by bearing play, friction, deformation or
misalignment of the rack aisle, poorlubrication, etc.

31. Trend Monitoring Capability
40% Equipment
Load
60% Equipment
Load
70% EquipmentLoad

32. Alpha SystemApplications
Torque

33. TORQUE IS CALCULATED BY
MEASURING THE PHASE SHIFT
BETWEEN SENSOR A & SENSOR
Applications: Torque

34. Applications: Torque
● alphatorque is used to determine static
and dynamic torque on shafts of all
diameters and speed ranges.
● No electronic parts have to be installed
on the shaft. The system is easy to
install, both on new installations and
shafts thatarein operation.

35. Torque: Indicators
● StaticTorque
● DynamicTorque
● Torsion
● Power
● Shaft Health

36. Torque: Indicators
Power
This indicator displays powertransfer
done by theshaft
Shaft Health
The shaft health is impacted by a variety of
parameters like bearings, gearboxes, the
propulsion systemetc.

37. Alpha SystemApplications
Bearings

38. alphaBEARING Indicators
● This indicator measures unexpected stress pulses in
movement of rotatingsystem
● Potentialproblems could be shocks stemming from stress
on rotatingshaft duringoperation:
a. Inadequate lubrication
b. Misaligned shaft
c. Insufficientbearing load

39. alphaBEARING Indicators
● This indicator measures the stability ofthe speed by
measuring shaft speed change inpercentage
● Potential problems could be unbalances of shaft
movement due to
a. Broken rotorbar
b. Mass unbalance
c. Air gapeccentricity

40. Remote monitoring of plant assets
Advanced Predictive Maintenance solutions with cloud connectivity
for monitoring critical equipment health on real time basis from any remote location

41. Remote monitoring architecture

42. Direct Benefits of the Alpha System
● Considerable savings in fuel consumption &overallefficiency
● Pinpoint faults during troubleshooting to trigger regularcourse
corrections through trendmonitoring
● Extend Overhaul intervalssafely
● Eliminate catastrophic machinebreakdowns
● Reduce Operational and Downtimecosts
● Eliminate Breakdowns and the concept of overhaulscompletely
● Indicate overall health of theequipment
● ROI in less than sixmonths

43. To know more, please contact
Neptunus Power Plant Services Pvt Ltd
Email :info@neptunus-power.com
Call :+91 9594410707