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display). Uses knowledge base compiled by John S Sohre. Continuous online vibration and process data can be acquired from any machine. The diagnosis of the fault is almost instantaneous. The important vibration data be trended over any interval of time. Orbit plot, waterfall plot, can be plotted. An integrated signal analysis toolbox is provided.
TG Vibration Signals
Transducer
Signal
Conditioning
FDAS
Process Signals
OSBUDD
(Operator Support and Back Up Data Display) Displays processed data in various format Trend of important vibration parameters Expert system diagnostic results
Plots:
Analysis:
Assistance:
Expert System
Each fault produces a typical frequency pattern (signature) Sohres Database as knowledge base Direction and type (shaft/brg) of predominant vibration taken into account Expert system estimates probability of each fault, lists five most probable ones.
Check-Mate identifies
Unbalance. Off-set misalignment. Angular misalignment. Bent shaft. Looseness. Unequal foundation stiffness. Coupling lock-up. Bearing problems-preload, looseness, inner race, outer race, ball train defects. Gear defects-tooth wear, misalignment, eccentricity, broken or worn tooth/teeth, hunting tooth faults.
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Check-Mate identifies
Sub-synchronous bearing instability. Electrical faults-cracked rotor bars, eccentric rotor. Rubs-rotor, axial. Belt problems. Cavitation. Oil whirl. Dry whirl. Check-mate identifies faulty readings caused by a loose or damaged sensor.
DSA International Corporation 4580 Marineview Crescent North Vancouver, BC V7R 3P5 Canada phone: 604-986-0936 fax: 604-986-0935 email: alees@dsaint.com
Accepts data from any data source, not just Bently Nevada condition monitoring hardware. Provides tools to capture and use condition data, historical data, baseline data, nameplate data, asset properties, lessons learned, and other relevant information. Provides tools to link documents and files, write reports, and to exchange data with other systems. High-end data analysis tools for diagnostics and root cause analysis are also part of System 1 SYSTEM 1TM is designed to be modular and scalable.
Cont
Using this platform, a solution can be built to support a wide range of user scenarios in many industries such as
Power generation Pipelines Refineries Marine Oil and gas Waste water treatment Food and pharmaceutical Semiconductor manufacturing Petrochemical Pulp and paper Metals and mining
MasCon/ ProCon
NAIDENS (an SKF group Company) MasCon/ ProCon online system monitors and diagnoses various process and machine component conditions, and provides automatic advice for correcting existing or impending conditions. MasCons in-built hardware auto-diagnosis system continuously checks all sensors, cabling and electronics for any faults, signal interruption, shortcuts, or power failure. Any malfunctions triggers an alarm, and in the case of system power failure the system will automatically restart when the power returns.
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MasCon/ ProCon
Data is transferred via TCP/IP. It can be sent to company for quick help and action. 32 different sensors, signal and measurement configuration can be accommodated. Individual conditions for warning and alarm may be set for each point. By using expert guide, in-built software, One can add the new machines using simple mouse clicks. The frequency bands, resolution, defect frequencies, machine diagnosis are generated automatically. Damaged machine components are identified independently of the measurement point position.
Cont
Warnings and alarms are indicated in machine picture by yellow or red color measurements. Measurements are made by mouse click over desired point with overdue measurement indicators. Remote access via modem or internet is available. Selected reference spectra may be fixed and automatically matched with new or earlier measurements. Early detection of bearing faults using DPE (digital peak enveloping). Triggering alarm levels may be set to adjust automatically to load level and rotational speed.
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CONDITION MONITORING
SENSORS Vibratory system Signal Acquisition
Knowledge base
Residual Life
Signal Processing Loading History
Gear blank digs into pinion and withdraws once in one rotation Second gear teeth mesh
xcos(t)
xacos(at)
Time for 1 revolution of gear First gear teeth mesh Time for 1 revolution of gear Time (sec) Time (sec)
Time (sec)
modulation frequency i.e., rotational speed of the gear - a carrier frequencies i.e.,gear mesh frequency -
xa x cos( a )t a cos( a )t 2 2
Charge Amplifier
Computer
VIBRATORY SYSTEM
ITEMS a) Charge based accelerometer (piezoelectric) b) ICP type Accelerometer c) Charge Amplifier (required only for charge type accelerometer) d) Analog to Digital Converter Card e) Labview Software for acquisition & subsequent signal processing.
COST IN RUPEES (Rs) 20,000 to 50,000 15,000 to 40,000 1,00,000 to 2,00,000 25,000 to 1,20,000 (depending upon number of channels & sampling rate) 80,000 onwards (basic version could cost more for pvt industry. 1,00,000 approx
program
Lapto p
ITEMS Portable Data Acquisition system (OROS, PULSE (B&K), Pimento with Virtual Lab (LMS), etc.
COST IN RUPEES (Rs) 18,00,000 roughly for 8 channel Data Acquisition System
Summary
Knowledge about the system Selection of transducers, acquisition system Features of signal processing and problems/issues associated with it Data representation techniques Interpretation Experience knowledgebase update