Professional Documents
Culture Documents
Lodovico Menozzi
CM Business Development - Europe
Agenda
• Condition Monitoring (CM) Basic Concepts
• National Instruments CM Technology
– Portable and Permanent Systems
– Sound&Vibration Toolkit
– Watchdog Agent Toolkit
– Turn-Key Solutions
• NI Roadmap for CM
• Case Studies
Machines Fail
http://www.virginia.edu/romac/
http://timestranscript.canadaeast.com/gallery
allworldcars.com
kes.bham.sch.uk
5/12/2011 www.ni.com
Detected Faults
Loose Mechanical Unbalance
Bent Shaft Blade Pass /
Components
Gears Fluid Related
Slot Frequency /
EM related
Alignment
Motor
Journal (Fluid Film)
Bearings
Mechanical Rolling Element
Resonances Couplings
Bearings
What CM is? Wind
Transportation
PREDICTIVE
SAFETY
MAINTENANCE
no catastrophic
failures minimizing
downtime
PRODUCTION QUALITY
ASSURANCE CONTROL
greater improved product
Industrial Machinery productivity quality Turbomachinery
Why monitor machinery?
•
•
Safety
Prevent catastrophic failure & significant damage
Avoid loss of life, environmental harm, economic loss
• Stop unscheduled outages
• Production Assurance
Optimize machine performance
• Reduce repair time and spare parts inventory
• Predictive Maintenance
Lengthen maintenance cycle
• Reduce price and raw material consumption
• Quality Control
Increase product quality
Maintenance Strategies
Reactive Active
Run to Failure Preventive
Predictive
Proactive
Economics of Outages
Run-to-Fail
Production Preventative Preventative Unscheduled
Level Scheduled Scheduled Shutdown
Shutdown Shutdown
Preventative
Health
Maintenance
Production Time
Level Condition-
based
Shutdown
Predictive
Maintenance
Approach
Time
Predictive Maintenance can reduce preventive maintenance tasks by 15% and
have an overall effect on downtime of 1-2%. If we look at the additional
productivity of a maintenance staff of 30, the calculations would be as follows:
• Improve reliability
• Generate service revenue
• Warranty data
• In use machine data for future developments
• In use machine data for case study and
comparative analysis
What to Monitor
• Vibrations Sources
– Bearings
Machine condition
Conditions
– Gearbox Vibrations
Noise
start to
– Pumps change
– Motors
• Noise Heat
• Displacement
• Temperatures
Smoke
• Power consumption
• Rotating Speed Emerge
ncy stop
• ... Tim
10 e
2 min
2 weeks days
3 month
*Vibration applications are the most relevant for the MCM business
Who uses Condition Monitoring?
• Rolling Mills • Oil and Gas
• Ciller • Mines
• Compressors • Trasportation
Opportunities for
other buses
CompactRIO
2004
Wireless and
R Series Expansion Ethernet
Chassis 2008
2004 USB-92xx/94xx
(USB Sleeve) USB CompactDAQ
2005 2006
USB Wi-Fi/ENET
USB Carrier NI PXI NI CompactRIO
NI CompactDAQ Carrier
Compressor Gearbox
4 Radial Vibration Proximeter Probe 8 Radial Vibration Proximeter Probe
2 Axial Positioner 2 Axial Positioner
4 RTD 6 Bearing RTD
1 Suction Pressure 1 High Speed Keyphasor
1 Discharge Pressure 1 Low Speed Keyphasor
1 Flow 1 Gearbox Accelerometer
1 Inlet Temperature
1 Discharge Temperature
USB/Ethernet Machine Diagnostics
Portable Machinery Test and Condition Monitoring
Standard
Plug-and-play USB 2.0 – 100MB Ethernet
Up to 32 simultaneous channels, 24-bit A/Ds in a single chassis
Time waveform, spectrum, and order analysis
NI CompactDAQ
NI USB-
9234
CompactRIO
Machine Condition Monitoring On-Line
• On-Line Monitoring/Analysis
• 4GB SSD data storage
• GPS/IEEE-1588 Synchronization
Ethernet
Ethernet
Real-Time Reconfigurable RIO Chassis
Command Based Arch
Shared Variable
LabVIEW FPGA
Measurements Speed
Order Analysis Vibration RMS
Frequency Analysis Vibration DC
Customer Specific Analysis DMA Temperature
Process
Serial Port
Modbus Buffered Output
Speed and Vibration
9264 Buffered
Keyphasor Thermocouple
9229 Proximity
Accelerometer
Temperature
9203 4-20ma
Tachometer
Radial
9211 / 9217
Process
Prox
Output
Empty
Empty
Probe
9234
9221
Laser Probes
Accelerometer Tach Axial Prox
Probe
A Highly Productive Graphical Development Environment for Engineers and Scientists
Technology Programming
Deployment Targets Abstractions Approaches
Analysis and Visualization
Standard Signal Processing Spectral Modulation
• Rise time • 9 Windows Measurements • AM, PM, FM Demodulation
• Fall time • 3 averaging modes • THD, SINAD, SNR, SFDR • Digital Demodulation
• Frequency • 5 Digital IIR Filters • Specific harmonic level • Frequency Drift
• Period • Digital FIR Filters • Power in band • Error Vector Magnitude
• Vpp • 4 interpolation modes • Adjacent channel power • Phase Error
• Min • • Magnitude Error
Limit mask • Occupied bandwidth
• Max • • Scatter/Constellation Plots
Derivative • Peak detection
• Cycle RMS …
• Multiple/Divide Channels• Zoom FFT
• Duty Cycle Statistical Analysis
• FFT • Add/Subtract Channels • Frequency Response
• Waveform Average • Joint Time Frequency • Histograms
• + pulse width
• Channel to Channel Delay Analysis • Standard Deviation
• - pulse width • Variance
• Amplitude … • Super Resolution Spectral
Analysis • Mean, Mode, Median
• High
…
• Low
• RMS
• Area
• Cycle mean
• Overshoot
Sound&Vibration Maesurement Suite
NI SOLUTIONS
cRIO Reference Design
Distributed Machine Condition Monitoring Example
• Integration
Consultants, Integrators and Channel Partners
• Solution
Systems that solve industry- or application-specific needs
Solution
• Product
Complementary software and hardware
Technology
• Technology
Key Suppliers (Intel, Microsoft…)
Integration Product
http://www.veski.hr/en/proizvodi/codismon/
NOISE & VIBRATION ANALYZER
Industry:
Acoustic&Vibration
Products:
Sound and Vibration, LabVIEW, Dynamic Signal
Analyzer
The Challenge:
Development of turn-key, computer
based, open architecture Acquisition
and Analysis Systems for Sound & Vibration
,Electroacoustic Analysis, Dynamic Data Acquisition
Systems,
The Solution:
realizazion of “Custom System” meeting fully
compatibility with standard technologies today available
on the market, taking care of business investment.
Both R&D and Production Line applications (i.e. Q.C.)
are covered..
http://www.wintek-it.com/
Bearing Monitoring
FAG ProCheck - simple, intelligent, reliable
http://www.fis-services.com/site/en
vibDaq Solutions for TurboMachinery
Challenge
– Develop a portable vibration diagnostics tool
for turbo machinery applications
– Needs flexibility, scalability, graphics, and
advanced signal processing
NI Tools
– LabVIEW, PXI, DSA, Order Analysis, USB
DAQ
Solution
– Leveraging off the shelf technologies
Vibedaq now has a strong competitive
posture in the portable machine diagnostics
applications market
www.vibDaq.com
www.calbay.com
FLEXSTAND LOGGER
IMS WATCHDOG AGENT
The IMS Consortium
IMS Instrumentation Approach
DATA ACQUISITION / FEATURE
CRITICAL ASSET SIGNAL PROCESSING EXTRACTION & SELECTION
9
Baseline
8 Current Data
Feature 2
6
2
3 4 5 6 7 8 9
Feature 1
1
0.8
1 0.6
0.8 0.4
0.6
0.2
0.4
0
0.2
0
Signals from
External Sensors
Data Segmentation
Feature
Selection/Reduction
CWT of time synchronous signal for gearbox with broken tooth (File 105)
Time-
synchronous 61
57
Average 53
49
45
41
37
scales a
33
Wavelets 29
FFT +
25
Envelope 21
17
13
9
5
1
1000 2000 3000 4000 5000 6000 7000 8000
Time (for 1 revolution)
2. Health Assessment
Health Assessment
Logistic Regression
Statistical Pattern Recognition
Feature Map Pattern Matching
(Self-organizing Map)
Neural Network
Gaussian Mixture Model (GMM)
Raw Vibration in
each Operating
Condition
Feature Space
Raw Vibration
β18 Radarα1
Chart
α2
β17 α3
β16 α4
β15 α5
β14 α6
β13 α7
β12 α8
β11
Specialized Multi-regime
α9
Diagnostic Tool:
e.g.: Chipped-tooth β10 α10
Evidence-based
0.2
problem in first gear. β9
0.4
α11
Holo-Coefficient Diagnostics
Higher risk in high β8
0.6
α12
β7 α13
speed regimes. 0.8
β6 α14
1.0
β5 α15
β4 α16
β3 α17
β2 β1 α18
PHM Analytics for Wind Turbines (1)
Equipment Risk
PHM Analytics for Wind Turbines (2)
1
Wind Turbine Efficiency
0.8
Wind Turbine Efficiency
0.6
0.4
0.2
0
2 4 6 8 10 12 14 16 18 20
1
Wind Turbine CV History
Time
Component Risk
0.8
Health CV History
0.6
0.4
0.2
0
2 4 6 8 10 12 14 16 18 20
Time
PHM Analytics for Wind Turbines (3)
Multi-regime
Health
β17
β18 Radarα1
Chart
α2
α3
Assessment,
Holo-Coefficient Diagnosis β15
β16 α4
Diagnostics
α5
β14 α6 And
β13 α7
Prognostics
β12 α8
β11 α9
β10 α10
0.2 α11
β9
0.4
β8 α12
0.6
β7 α13
0.8
β6 α14
1.0
β5 α15
β4 α16
β3 α17
β2 β1 α18
Watchdog Agent® in LabVIEW
Signal Analysis
Performance
Particle Filter
Assessment
Performance
Prediction
Health Bayesian
Diagnosis Networks
NEW PRODUCTS & ROADMAP
NI cRIO-9075 & NI cRIO-9076
4-Slot Integrated CompactRIO Controllers
NI cRIO-9075/6 Products
• Release
• Quotable/Orderable NOW!
• Shipping June 2011
• FPGA Support
• LabVIEW FPGA only at release (no Scan Mode support)
Operating
Model Processor Memory Storage FPGA USB
Temp
• NI 9223 = 1 MS/s/ch
– NI 9222 = 500 kS/s/ch
• 16-bit resolution
• 60 VDC ch-ch isolation
• 0.03% Accuracy at 10V
WSN Measurement Nodes
Common Features
• 2.4 GHz IEEE 802.15.4 radio
• Outdoor range up to 300 m
• Up to 3+ year battery life with 4 AA batteries
Optional 9-30 VDC power input
• Configurable as a mesh router
• Industrial ratings
Operating temperature -40 to 70 ºC
50 grms shock 5 g vibration
Node AI DIO Sample Sample Rate Resolutio Features
Interval n (bits)
• Strain/Bridge Node
• Acceleration Node
• Serial Node (RS-232)
• Serial Node (RS-485)
• C Series WSN Gateway
PXI Express Dynamic Signal
Acquisition Modules
•Detect voltages from 10 V to 2.2 µV (2 amplifier
gains for measurement flexibility)
Optical Parameters
• 4 optical channels
– Up to 20 sensors per optical channel
• Fiber Bragg Grating (FBG) sensors
• Scan rate of 10 S/s
• Wide wavelength swept laser
– 1510 – 1590 nm
Platform
• PXI Express module (2 slots)
• 0 – 55 C operating range
• PXI Triggering and Sample Clock Exporting
• Windows, RT OS
Benefits of FBG Optical Sensing
• Non-conductive, electrically passive, and immune to EMI
• Resistant to corrosion
Products:
NI 9423, NI CompactDAQ, USB-9233, NI 9205,
cDAQ-9172, NI 9474, LabVIEW
The Challenge:
Developing a diagnostic network to automatically track
the status of wind turbines with centralized access so
that users can take advantage of the captured signals
for off-line analysis.
The Solution:
Using NI LabVIEW to develop an application that can
perform data acquisition and database management
and provide Web access to applications and
performing data acquisition with NI CompactDAQ to
easily condition and capture different signals on a
single device.
http://sine.ni.com/cs/app/doc/p/id/cs-12119
Embedded Measurement System for Remote
Monitoring of Wind Turbines
Industry:
Energy/Power
Products:
Reconfigurable Chassis, Real-Time Module, NI 9853, NI 9239 BNC,
Real-Time Controllers, NI 9237, NI 9401, LabVIEW
The Challenge:
Replacing existing remote monitoring systems with new monitoring systems
that are time synchronized for performing measurements at a higher sample
rate and with higher accuracy. The system will be installed on remote wind
turbines and cannot be replaced or repaired easily.
The Solution:
Developing a flexible NI LabVIEW software application based on the NI CompactRIO
platform that not only acquires measurements, but also filters analog and digital signals,
applies a timestamp, temporarily stores data to prevent data loss, and transmits data to a
database server.
http://sine.ni.com/cs/app/doc/p/id/cs-13221
Wind Turbine Assembly Diagnostics
Industry:
Energy/Power
Products:
USB-9233, LabVIEW
The Challenge:
Developing a system in accordance with ACCIONA
quality standards for the dynamic characterization of
wind turbines during the postassembly testing stage
that is powerful, reliable, and flexible in terms of
installation and use as well as within budget.
The Solution:
Integrating IEPE industrial accelerometers using NI
USB-9233 modules for data acquisition distributed
among different positions along the nacelle of a
wind turbine and connected through a USB hub to
an industrial PC, from which we can manage the
test and its results. http://sine.ni.com/cs/app/doc/p/id/cs-12777
Wind Turbine Structural and Blade Test/Monitoring
Host Computer
NI CompactRIO
Copper/Fiber
EtherCAT Automatic Synchronization Converter
Fiber
Optic
Cable
Industry:
Energy/Power
Products:
CompactRIO, LabVIEW, Real-Time Module, FPGA Module
The Challenge:
The growing demand for electricity has resulted in an increased
demand for efficiency and availability, achievable with
continuous monitoring of parameters related to machines
installed, through remote and real-time data acquisition systems
allowing predictive maintenance and fast recovery in case of failure.
The Solution:
Rapidly development of a remote machine monitoring systems able to
acquire and log all the relevant gas/steam turbine parameters.
http://sine.ni.com/cs/app/doc/p/id/cs-10231
DIAGEN, remote diagnostics system for large
electric power generators
Industry:
Energy/Power
Products:
CompactRIO, Real-Time Module, FPGA Module, LabVIEW
The Challenge
With this application you want to make an integrated hardware and
diagnostic software for remote monitoring of electric generators of high
power (20-750 MVA) constructed by Ansaldo Energia SpA (Genoa).
The Solution:
The solution adopted was to create a real-time monitoring system based
on NI CompactRIO platform can therefore safely perform in a real-time
data acquisition and a post-processing of the same effectively.
http://sine.ni.com/cs/app/doc/p/id/cs-10972
Oil Well Fracture Pump Monitoring and Analysis
using LabVIEW and NI RIO Technology
Industry:
Oil and Gas
Products:
FPGA Module, LabVIEW, Single-Board RIO,
LabVIEW Real-Time Module, CompactRIO
The Challenge:
Building an advanced monitoring system that can survive being
mounted directly to an oil well servicing pump in a rugged environment
while performing advanced analysis on sensor data.
The Solution:
Using NI CompactRIO and NI Single-Board RIO hardware along with NI
LabVIEW software to design a pump monitoring system that monitors
the operating parameters of a reciprocating pump used in well servicing
applications.
http://sine.ni.com/cs/app/doc/p/id/cs-11315
Automated Final Turbine Test
Industry:
Energy/Power, Machines/Mechanics
Products:
SCXI-1130, SCXI-1127, PXI-4070, NI TestStand,
PXI-6143, LabVIEW, PXI/CompactPCI
The Challenge:
Automating the final manufacturing tests of wind
turbine control systems to increase test coverage,
decrease test time, and address the rapidly Control Panel
growing production volume.
The Solution:
Using NI TestStand and LabVIEW with NI PXI
instruments and SCXI signal conditioning to
develop a standard automated test system for kk-
electronics that can be adapted to global
NI PXI Test System
production sites.
http://sine.ni.com/cs/app/doc/p/id/cs-12605
Online Monitoring of Nuclear Reactors Using NI
CompactRIO
Industry:
Machines/Mechanics
Products:
Real-Time Module, CompactRIO, FPGA
Module, NI 9234, LabVIEW
The Challenge:
Developing an online monitoring (OLM) solution
for boiling water reactors, which contain
machinery in hazardous and difficult-to-access
areas.
The Solution:
Using an integrated, embedded NI
CompactRIO system to develop the EWV-1 and
OLM-32 hardware to provide live, wireless
monitoring of plant assets in conjunction with
AMS’ monitoring software.
http://sine.ni.com/cs/app/doc/p/id/cs-13207
Monitoring Compressor Performance Using NI
Data Acquisition Boards
Industry:
Manufacturing
Products:
PCI-6023E, LabVIEW
The Challenge:
Designing a gas compressor data acquisition
system capable of synchronizing samples from
multiple sensors to the rotational position of
the pistons’ crankshaft and performing
measurements from field mounted meters and
thermocouples.
The Solution:
Combining high-speed data acquisition and
signal conditioning to precisely measure of
compressor performance, using a FieldPoint
network to acquire data from the
thermocouples, pressure meters, and flow
http://sine.ni.com/cs/app/doc/p/id/cs-55
meters located throughout the gas loop and
LabVIEW to process the data, calculate
performance results, log data, and generate
reports.
Facility Online Machine Condition Monitoring System
Industry:
Process Industry
Products:
PXI-8108, PXI-1042Q, PXI-4472B, CSC-3059
(a customized version of 4472B)
Application:
China Steel standardized their machine condition monitoring (MCM)
system based on PXI and PXI-4472B. Each of China Steel’s production
lines has a total of 300 to 500 accelerometers installed and they needed
a reliable distributed software architecture for data acquisition, analysis,
alarm & reporting. All system software is designed in LabVIEW and is to
be duplicated for a total of 23 production lines. Software design
consulting was a critical piece to winning the related hardware
opportunities and has helped us close sales for 32 PXIs to date (over
$510K hardware sales made so far).
http://sine.ni.com/cs/app/doc/p/id/cs-12120
Summary
• Machine Monitoring
– Saves time and money
– Improves operational reliability
– Improves data re-use for service and design
lodovico.menozzi@ni.com
www.ni.com/mcm