Insulation Monitoring Application of Waste Treatment Power Plant
Application of MIR500 insulation monitor in waste incineration power plant
Background of the Waste-to-Energy Plant Insulation Monitoring Project
For an environmental energy company, the stability of key equipment, such as pump stations and flue gas rooms, is crucial to production safety and environmental compliance during the waste treatment process at its waste-to-energy power plant. Insulation monitoring is crucial for preventing equipment leakage and ensuring operating conditions. However, traditional manual inspection processes are cumbersome and require lengthy approval processes, making them difficult to meet real-time monitoring requirements. Furthermore, manual on-site operation increases staff workload and increases the risks of working in special environments. Furthermore, insufficient monitoring frequency and efficiency hinder the overall efficiency of waste treatment operations.
In August 2025, during insulation monitoring work at a waste-to-energy power plant, on-site inspections and customer research showed that the complex terrain and obstructions, such as structures, made rewiring data transmission difficult. This was costly and challenging, necessitating a wireless data transmission module. However, the five waste sites where the module needed to be installed were scattered and distant. Long-distance transmission not only significantly attenuated the signal, resulting in unstable and delayed monitoring data transmission, but also, due to environmental interference, weakened the signal, leaving some sites in "blind spots" or even disconnected altogether. Ultimately, this prevented managers from promptly detecting insulation risks in the motor windings, making it difficult to ensure safe operation of the equipment.
Sikcon technology -MIR500 Insulation Monitoring Module Solution
To address the wiring difficulties of the waste-to-energy power plant's wired solution and the signal issues associated with data transmission, the client selected Sikcon' MIR500 insulation monitoring module. To address the pain points of signal attenuation, unstable data transmission, and delays caused by the scattered and long distances between the five sites, Sikcon developed a targeted solution, employing wireless data transmission modules and adding signal relay stations in between the five sites. These relay stations centrally collect monitoring signals from each site and transmit them to the master site, effectively eliminating signal loss associated with long-distance transmission and ensuring stable data transmission.
At the same time, during on-site adaptation testing, it was discovered that the original 500V insulation monitoring module, the MIR500, could damage the waste-to-energy plant's inverter. Sikcon quickly adjusted its solution, replacing it with a 50V MIR500 insulation monitoring module. Ultimately, they successfully achieved comprehensive and stable insulation monitoring of the inverter, its downstream reactors, and motors, fully meeting the plant's equipment operation and monitoring needs.
Comparison of the advantages of MIR500 and traditional manual inspection
Compared to traditional manual testing, the MIR500 insulation monitoring module offers significant advantages: 24/7 continuous monitoring without delay, addressing the blind spots of traditional periodic manual testing (e.g., monthly). Sensors automatically collect data, resulting in more objective and reliable results, avoiding the reliance on manual intervention and subjectivity inherent in traditional manual testing. The module eliminates the need for on-site personnel, effectively preventing accidents and addressing the significant safety risks associated with traditional manual work in tunnels. It provides immediate warnings of faults and supports automatic linkage control (such as power cutoff), addressing the delays in fault detection and timely resolution associated with traditional manual testing. Remote monitoring reduces manual intervention and overall costs, overcoming the high labor costs and operational disruptions associated with traditional manual testing.
The MIR500 insulation monitor is a specialized monitor designed to automatically measure insulation resistance during power outages for motors below 690V. It measures the insulation condition of motor circuits before operation and issues prompt alarms, providing a solid foundation for stable production system operation.
MIR500 Main Functions:
1. Insulation Resistance Measurement and Display: The MIR500 monitors the motor's insulation resistance in real time, accurately assessing its insulation performance and ensuring it remains within a safe insulation range, ensuring stable motor operation.
2. Power-Off Activation: The MIR500 automatically monitors insulation resistance after power is removed. Users can customize the post-shutdown cool-down time and monitoring interval.
3. Measured Voltage Display: The monitor clearly displays leakage current and adjusts the measurement voltage to meet the monitoring needs of motor systems of varying sizes.
4. Polarization Index and Dielectric Absorption Ratio Calculation: The polarization index (PI) and dielectric absorption ratio (DAR) are used to accurately uate insulation material performance.
5. Motor Power-On Residual Current Monitoring: Real-time monitoring of residual current changes during motor operation helps prevent abnormalities.
6. Measurement Signal Customization: The measurement voltage supports DC500V/50V.
7. Multiple Measurement Modes: Manual and timed measurement are supported to meet the diverse needs of different application scenarios.
8. Flexible Measurement Time Settings: Customize measurement time based on actual needs, further improving measurement efficiency.
9. User-Friendly User Interface: Equipped with a backlit LCD display, the device intuitively displays various parameters for easy operation.
10. DIN Rail Mounting: Enables quick installation and maintenance, saving installation time and costs.
11. MODBUS RTU/TCP Communication: Supports MODBUS RTU and MODBUS TCP communication protocols, facilitating system integration.
12. Adjustable Response Delay: Set the response delay based on actual needs to effectively prevent false alarms.
13.Dual Independent Alarm Relays: Each relay is equipped with a changeover contact, supporting normally open (NO) or normally closed (NC) operation.
