OPG Presentation: Wireless Condition Monitoring. MDCI Group Thursday Sept 30 th 2010

Transcription

1 OPG Presentation: Wireless Condition Monitoring MDCI Group Thursday Sept 30 th 2010

2 Presentation Topics Uptime Solutions Overview / Vision Current Products Future Products Engineering Development WAM System Components WAM System Configuration /Set ups WAM Customer Benefits WAM Measurements, Displays, Reports, File Export WAM Specifications Applications Demonstration (After Lunch)

3 Established, 1992 by Allan Fitzgerald High-tech condition-based solutions for Industry several manufactures, interactive line card available Originally based in BC (Abbotsford) Now based in Brighton, Ontario Twenty Distributors/ Resellers Worldwide Seven Distributors/ Resellers in Canada

4 WIRELESS ASSET MONITORING MANUFACTURING DIVISION UPTIME SOLUTIONS Division headquarters in Jacksonville, FL and a Design center in Austin, TX. Jacksonville, Florida Austin, Texas Spectrum Contact: Wes Dettwiler: wesd@spectrum-insruments.com Distributor Contact: Andy Woodcock: Andy.w@wcdts.com

5 Uptime Solutions Division Key Personnel Technology (Jim Girardeau) 25 years industry experience in advanced speed signal processing Specialist in RF and radio communication Advanced training in engineering and project management Has managed multiple large projects spanning across multiple remote sites. M.S. Degree in Electrical Engineering Industry..(Tim Rohrer) 20 years experience in the Pulp and Paper industry 3 years wireless system experience (installing, training, trouble shooting) Assisted in designing, and testing wireless vibration systems BS. Degree in Geology with a minor in Computer Graphics 3 years wireless/vibration monitoring software training

6 Uptime Solutions Company Vision: Use the latest technology, to develop new solutions to old problems. Commitment- To produce high quality products that reach beyond customer expectations that are reliable, consistent and competitively priced WAM Product Goals Introduce 1 new WAM product per quarter

7 Current Products WAM-661 Transmitter Node WAM-2 Transceiver Base Station Translator (Data transfer into other PdM Programs) TC 1 Thermal Amplifier (Thermocouple Amplifier for WAM) Pathfinder Condition Monitoring Software suite WAM-761 WAM Node (Currently in Beta Testing) REO Sentinel (Portable monitor for the transport industry)

8 Future Products Planned 35 Channel Wireless Box (Q4 2010) 32 Simultaneous inputs plus Tachs Ethernet Capabilities Wireless Camera (Q1 2011) Wireless Accelerometer (Q2 2011) Range Battery life Wireless Data Collector (Q3 2011)

9 WAM System Components 1. Input Sensors and sensor cables 2. Transmitting Nodes 3. Transceivers Receiving Base Stations 4. Software Included: - db Editor - On Line Monitor - Pathfinder PdM 5. Translator (Optional) Data transfer into other PdM programs 6. Software Gateways (Optional) - OPC and/or PI Historian

10 Input Sensors ICP Type Accelerometers / Velometers Proximity Probes (-24 VDC supplied) Process Inputs Thermocouples, Flow, Strain Gage, etc through Process Inputs.

11 WAM The modern solution to monitoring. 3 ¾ 4 ¼ WAM-621 / WAM-661 / WAM-761 Acceleration / Displacement via BNC Connection Includes but not limited to Temp/Pressure/ Flow 24 volt DC power Range, optimum working range within ¼ mile or less Serial Number plug and play

12 Transceiver Transceiver Is the device connected to the computer and communicates to the WAM node. One transceiver supports communicates with many WAM nodes.

13 Software Pathfinder database analysis reporting exporting capabilities

14 Standard Software Pathfinder Software License unlimited number of seats based upon the Canada Post Mailing Address PI Historian Gtateway process information real-time data historian allows for viewing of real-time and look back at data from years ago OPC interfacing Open Connectivity Current and emerging OPC Specifications include: Data access, alarms and events, batch, data exchange, historical access, security, xml-da, complex, commands, unified architecture

15 Translator Translator allows data to be transferred to any data collector functions like a multi-channel switchbox (manually selected) data can then be transferred from the data collector to its corresponding software package readings are collected at the computer database location data collection time is substantially reduced

16 Select the sensor location that you. Click the PLAY button Press the store button on your portable data collector/ analyzer Repeat for each additional location

17 WAM System Set Up Monitoring Sensors- Sensors are connected to the WAM nodes via BNC/Pin Point connectors Radio- Data is sent via radio from the WAM units to the Base Station(s) Base Station is directly (USB) connected to local PC and to remote PCs through LAN, WAN, Cell Phone Network link, Satellite, etc. Mesh Network-allows the nodes to talk to one another to increase transmission distances. Software- Displays Spectrums, Waveforms, Trend Data, Temperature Display based on continuous collection and stores data based on selectable storage criteria. WAM Power requirement: 24 VDC Main Office Bearings Motors WAM Node Base Station Computer Reliability Office Pumps Home Office

18 Standard Configuration This configuration is used when the local PC is generally accessible and convenient. The local PC is setup close to the WAM units. To IP network Local PC (Pathfinder SW) usb Base WAM WAM WAM A local PC connects via USB to the base station. The base station communicates to the WAM units over wireless The WAM driver and Pathfinder analysis SW run on the local PC Ethernet or WLAN is used to connect to the corporate IP network.

19 Extended Range WAM Configurations This configuration is used when the WAM units are too far from the Base station, but can reach each other. Repeaters can also be used to extend the WAM s range. To IP network Local PC (Pathfinder) usb Base rf WAM rf WAM rf REPEATER Each WAM unit can forward data from another unit to the base station, or a lower cost repeater can forward data. rf WAM

20 Remote Analysis Configuration This configuration is used when the local PC is difficult to work near; it is setup once, and the Pathfinder SW is configured to run across the IP network at a remote site. The advantage to this is that graphic operations can run on the remote machine, and databases can be stored on the remote machine. This is particularly important if the IP network to the WAM Server PC is slow. REMOTE PC (Pathfinder SW) Ethernet/WLAN To IP network Local PC (WAM Server) usb Base WAM WAM A remote PC connects across an IP network; the Pathfinder analysis SW runs on this remote PC. WAM The base station and local PC are located close to the WAM units.

21 Satellite/Cell Phone Remote network This configuration is used when there is not any IP network near the server. In this case, an industrial PC can be located near the WAM network and use satellite or cell phone to communicate to the server. This incurs a monthly expense. REMOTE PC (Pathfinder SW) IP Network CELL/ Satellite Local PC (WAM Server) usb Base WAM WAM The local PC connects to the analysis SW via cell phone or satellite connection. WAM

22 Summary The WAM Server and PC must be located close to the WAM units. The WAM Server can run on a dumb or stealth PC with no screen or keyboard. The PC can communicate with the IP network via Ethernet, WLAN, cell phone, or satellite. Cell phone and satellite require subscription fees. The Pathfinder Analysis software can run on a remote PC or the same PC as the WAM Server. If the network connection to the WAM Server is slow, then it is better to run the Pathfinder SW remotely.

23 WAM Benefits Safely acquire data in unsafe or hard to reach locations (cooling water towers, pulverisers, draft fans, blowers, etc.,) Greatly reduced labour hours and lower cabling costs for on line data collection. Higher Operations reliability due to continuous acquisition rather than the 1 per month portable collector standard. Can easily act as a temporary trouble shooting system for problematic machinery Use the presently mounted accelerometers or proximity probes that are collected on your termination or switch boxes. The Pathfinder software license allows site data access to all workstations (even those without your PdM software) Enables you to input the wireless vibration data into your present PdM software (no matter whom) if desired

24 Measurements, Displays, Analysis, Reports, Export Formats. Measurements Vibration Stead State Machinery (WAM-661; WAM-761) Transient State (WAM-761) ICP Transducers (Accelerometers Velometers) Prox Probes Process Thermocouple VDC for Strain, Flow, Pressure, etc., etc.

25 Trends

26 Waveforms

27 Spectra

28 Trend Coordinated Spectrums and Waveforms

29 3 D Waterfalls with coordinated cursor appointed trends, spectrums and waveforms

30 Orbits

31 Transient State Measurements

32 Modal Analysis Modal information determines overall health of structure and provide 3D views of structure movement. Software export into MEScope program. Results of modal analysis: Dynamic Testing of Alfred Zampa Memorial Bridge, Conte et al., JOURNAL OF STRUCTURAL ENGINEERING ASCE / JUNE 2008

33 Alarm Display

34 Reports Latest Measurement Based on overall Based on frequency Scheduled Weekly, monthly Alarm Overall Spectra Alerts

35 Pathfinder Export Capabilities Copy Plot Data Text File to Outside Programs: Translator Export ot any other PdM program Copy Plot Image Image File to Outside Programs Special Formats to 3 Party - MEScope. Lab View, Math Lab, etc at extra cost.

36 WAM Specs Common to all Nodes: Radio Frequency: MHz ISM or /and b/g 2.4 GHz bands Power: 24 volt DC Operating temp limits: -40C through 85C Sensor power supplied: Standard ICP or Prox Probe Power FFT resolution: 100 through 3200 lines all inputs - up to lines with limited inputs Spectral windows: Hanning and Rectangular Averaging types: Linear

37 WAM Spec s s Continued Common to all Nodes ADC: Sample Rate 40 khz per channel 20 bit amplitude resolution Tachometer / Trigger channel: One per node, BNC input Enclosure dimensions: 4.45 X3.83 X2.31 WAM 661 & 761 Enclosure material - Anodized aluminum, waterproof, IP 67 Connections: RPSMA for the antenna; standard BNC for the vibration & Tach inputs; Axial Multi-connector for Process and Power

38 WAM Spec s s Continued Common to all Nodes Agency approvals: FCC certified RF protocol: Spread spectrum Frequency Hopping Outdoor Distance: Line of sight up to 1.0 Km at reduced throughput rates. Indoor Distance: RF: Requires site test Other communications technologies: Unlimited Vibration Amplitude Range: Sensor range dependent

39 WAM Specs Uncommon to all Nodes

40 Pathfinder Analysis Parameters Waveform RMS: The Root Mean Squared of all amplitude values in the waveform. This is a good overall vibration level indicator. Waveform Peak: The highest individual absolute value found in the waveform. This is a good way to detect impacting. Waveform Peak to Peak: The distance between the highest value and the lowest value in the waveform. This is a good way to detect impacts that cause spikes in both directions. Waveform Crest Factor: This is the ratio of waveform peak to RMS. This is a good way to detect the relative strength of impacting compared to the rest of the vibration signal. Total Spectral Energy: This is the Root Sum Squared of all amplitudes in the power spectrum. This yields results similar to Waveform RMS, but it allows you to select any amplitude factor (RMS, Peak, or Peak to Peak). Spectral Band: This is the Root Sum Squared of the amplitudes within a specified frequency range of the spectrum. This is probably the most useful parameter type, since it can detect any fault that causes increased vibration at a known frequency. The frequency range can be specified in Hz, CPM, or even Orders (1 order = tachometer speed). This parameter type also allows software integration of amplitudes (e.g. converting acceleration to velocity). Integration is not recommended for bands including low frequencies (5 Hz or less) because the integration process can cause even small amounts of noise at these frequencies to be amplified to very high levels. Tachometer Speed: This is the speed of the measurement point's tachometer. Having this as an analysis parameter allows you to view trends of speed over time. Peak Amplitude: This is the 'true peak' amplitude at a specified frequency in orders. This can be used to detect unbalance, and makes a good complement to a Peak Phase parameter at the same frequency. Peak Phase: This is the phase (measured against direction of rotation) associated with the 'true peak' at a specified frequency in orders. Bias/Gap Voltage: This is the DC component of the vibration signal. For displacement probes, this represents the 'gap' between the probe and the machine surface it is measuring. For accelerometers powered by the PATHFINDER system, this represents the 'bias' voltage. Bias voltage should typically be in the neighborhood of +12V. Values near 0V or +24V indicate a sensor or wiring failure. Note that measuring this type of parameter requires switching the system from AC mode to DC mode (just like reading from process channels) and can cause problems with transient data capture.

41 Options Hardwired WAM s are Available Ethernet RS-232 RS-485 Via cell IP networking for remote sites

42 Customer Base International Paper GA, AL Georgia Pacific FL, GA. Smurfit Stone (2) FL, Kapstone Paper SC, NC Mosaic Mining (4)FL, LA Stowe Woodward GA, LA, VA,WA, NC, Canada, Applications Problems Solved Lumpbreaker Line Shaft Calendar Barring Bearings Motors Pumps Gearbox Water Cooling Towers

43 Applications Currently monitoring 1,000+ data points. Line Shaft -Water Cooling Tower Bearings -Dryer Felt Rolls Motors -Press Rolls Pumps -Roll Covers Gearbox -Bowed Rolls Calendar Roll Machine Frame Separator Air Handler

44 Paper Machine Installation

45 HSB Pumps

46 PM Fourdrinier

47 Applications Mobile Equipment Mining Heavy haulers Steel Cranes Temporary Trouble Shooting

48 Reference Contacts Kapstone Paper Smurfit Stone International Paper Allied Reliability Stowe Woodward

49 Benefits SAVING MONEY & TIME!!! Labor Saving Reduced Downtime

50 Demonstration System: On On Site at OPG Kipling Office, Thursday Sept 30 th after Lunch

51 Thank you very much for your attendance