guardian angel brochure b
DESCRIPTION
On line condition monitoring for automotive and industrial plantTRANSCRIPT
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Guardian is a fully featured monitoring software package for rotating or reciprocat-ing machinery and other types of plant. It can handle both dynamic measurements, typically vibration, and process measure-ments such as temperatures and pressures. The software operates with the ICONET industrial network to provide a highly flexi-ble distributed data acquisition system.
The Guardian application includes all the common functions for plant monitoring, including alarming, trending, analysis and data archiving.
The visual interface is entirely mimic driven giving clear indication of plant status at a glance. A simple hierarchy and intuitive controls combine to set new stan-dards in ease-of-use. Mimics and the inter-nal database are easily modified allowing a straightforward upgrade path from a hand-ful of points to hundreds.
If its Simple, Operators will Use it The Guardian application has been de-signed to monitor plant with the minimum
amount of operator involvement and inter-vention. Overall plant status can be seen by simply glancing at the front screen mimic. Any excursions above pre-set alarm limits are reported immediately, and these are ac-knowledged and cleared as required. All system activity is automatically recorded in a log so that a complete history of plant op-eration is maintained. Operators can even enter their own notes and observations.
The traffic light display at the foot of the screen shows the status of all measurement points. If a point goes into alert or alarm, that portion of the mimic changes colour accordingly, thus giving clear and unambi-guous reporting of machine problems.
Faults Pinpointed and Clari-fied A mouse click brings up a measurement screen that provides further details of the highlighted problem. Here, it is possible to tell whether a problem is, for example, shaft or bearing related. It pinpoints the precise area of the machine needing to be looked at.
If several alerts or alarms have occurred simultaneously, these can be reviewed in turn.
Trends and Levels Once a problem has been identified on a machine, the next question is inevitably How long can we leave it running? This is where trending comes in. The rate of deterioration can be assessed, and compari-
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Inside:
Guardian 1
Angel 3
Iconet 4
System Specifications 7
Training 9
Guardian
Special points of inter-est:
Guardian monitors all machines at low cost
Iconet controls how the nodes talk to each other
Angel ensures that all data is transmitted back to our office for prompt, timely monitoring and analysis
PDC Systems
PreDiCon Systems GuardianAngel
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sons made with previous occurrences on this, and other machines. Flexible comparison and overlay fa-cilities are available.
System Configuration
Configuration of measurement points has been made easy with a single screen entry for each point. This is what you see is what you get in its simplest sense. For larger systems, a database editing facility is available enabling a short-hand method of entering hundreds of points.
Scan rates and data storage criteria are fully programmable to optimise system perform-ance.
Data Archiving
The Guardian software is designed to carry out its monitoring tasks for months and years with a minimum of system mainte-nance. Large amounts of data can be re-corded over extended periods, and so straightforward data reduction methods are needed. Guardian provides highly flexible data archiving methods to ensure that the system operates efficiently and without overloading the host computers storage facilities.
Archiving can be programmed to occur automatically at pre-set intervals. In this case, no operator intervention is required, and the system will sift out the important data for safe-keeping while removing un-eventful information.
Global Access
The combination of Guardian and ICONET hardware enables the full power of the internet to be utilised. Remote access via telephone and internet is possible enabling data to be examined from virtually any-where. The system even allows the possi-bility to go live to a single measurement point from anywhere in the world!
Security&System Diagnostics
Guardian incorporates a two-level security system to ensure that system parameters can only be changed by authorised person-nel.
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Guardian is designed to carry out its monitoring tasks for months and years
GuardianAngel
Further Analysis
Additional analysis tools are available to determine the exact cause of a problem. Full time and spectral analy-sis displays can be called up with the ability to overlay and compare with other historical data.
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Angel Over Guardian
Data Transmitted Over The Internet
The value of any monitoring system is not in the equipment it is in the data. The data from a portable data collection system starts to lose value immediately after it is collected because it is already out of date. To ensure full value from a portable monitoring system the engi-neer must be absolutely certain that all of the failure mechanism durations on the monitored machines are shorter than the data collection interval. If the data is old or if the analysis is wrong then there is no value in the monitoring system. If the data is new and the analysis is accurate you have full value continually
The value of any monitoring system is not in the equipment it is in the data. The data from a portable data collection system starts to lose value immediately after it is collected because it is already out of date. To ensure full value from a portable monitoring system the engi-neer must be absolutely certain that all of the failure mechanism durations on the monitored machines are shorter than the data collection interval. If the data is old or if the analysis is wrong then there is no value in the monitoring system. If the data is new and the analysis is accurate you have full value continually
At set intervals, the Angel portion of the system transmits all data to our offices (the default is every midnight) via the Internet. At the start of work the next day our engineers examine the data in Guardian. The allocated engineer for your system then examines the log file for alarm events and carries out a full analysis of the data which has gone into alarm. If any corrective action is required the PreDiCon engineer calls his contact in your organisation either by phone, e-mail or fax depending on
your preference. Every week you re-ceive a summary of the condition of all of your monitored equipment. The data under analysis is always less than one day old and you can be sure that trained and experienced engineers carry out the analysis. Your system will give you full value for all of its opera-tional life.
PDC Systems has implemented PdM solutions for many industries encompassing many PdM vendor solutions. We have installed and operated systems of all sizes with PDC Systems installed systems win-ning joint first and first runner up in the last inde-pendent PdM awards. All PdM services are per-formed by engineers with experience in implement-ing multiple vendor and technology solutions. PDC Systems is not tied to any particular vendor and can give completely independent advice. Outside of the vendors themselves we have setup more off-line vibration, on-line vibration and ther-mographic systems from many different vendors in a variety of applications than anyone we know.
Complex vibration analysis is carried out by our engineers
A data collection node as used by Angel over Guardian
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If the data is new and the analysis is accurate you have full value continually
GuardianAngel
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System Architecture
urement data on-line, absolutely anywhere.
You are now think-ing:
LOCAL ...
PLANT-WIDE ...
GLOBAL ...
The quality of data monitored by the system is only as good as the measurement devices that are connected to it. Guardian has automatic diagnostic facili-ties for checking the integrity of acquisition nodes and even the transducers connected. Failing accelerometers and open cir-cuits or shorts on their con-necting cables can be identified.
Imagine a flexible network sys-tem that can be used to gather vital information on your ma-chinery. One which can be in-corporated into your existing Ethernet networks in the plant and which can be accessed lo-cally or remotely. Imagine this
can be set up by anyone who knows how to set up an Ethernet system and imagine it is so affordable that it can fit into your budget with ease.
You are now thinking of ICONET on Ethernet.
But dont let your imagination stop there. Think what you could do if you could access data directly from your meas-urement points anywhere in the world via the Internet. Now you can realise how ICONET on Ethernet captures the power of the global communi-cations revolution and enables you to call up real time meas-
Sixteen multiplexed ana-logue inputs
Sixteen ICP supplies for accelerometer interfacing
Optional AC/DC coupling Accelerometer bias voltage
check Bearing condition meas-
urement Type 2 Sixteen analogue inputs,
multiplexed in pairs for
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System Description
Wide Choice of Inputs
ICONET on Ethernet sets out to interface to just about any sen-sor type that is encountered in the field of machinery monitor-ing, Typical transducers for vibration measurement are accelerometers and eddy cur-rent probes, and these are two of the types that can be used for so-called dynamic meas-
urements. Often, process measurements such as tem-peratures and pressures need to be monitored. These so-called static parameters can also be accommodated.
There are three types of node in the ICONET on Ethernet se-ries, called Type 1, Type 2 and Type 3. The types of signal input that each can accommo-date are summarised below: Type 1
View the Condition of your Ma-chinery Clearly and Precisely
GUARDIAN System Monitors Connah's Quay Cooling Tower Fans
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Imagine a flexible network system that can be used to gather vital information on your machinery.
GuardianAngel
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Acquisition Modes
Bearing Measurement
example, to acquire data only from machines that are running.
Event Triggers for Syn-chronised Measurements
Two of the trigger input chan-nels can be used as event trig-gers. These are used to syn-chronise measurement se-quences between nodes on the occurrence of an external event. In addition, the ITA-1 incorporates a high-drive syn-chronising output. This can be connected to the event inputs of a number of other nodes (as in a master-slave concept) ena-bling synchronised data gather-ing between nodes on a system. This operates independently of the Ethernet network.
(Continued from page 4) simultaneous acquisition (X-Y, orbit etc)
Standard interface to eddy current probes
Type 3 Twenty multiplexed proc-
ess measurement inputs Modules available to inter-
face to thermocouples, RTDs, pressure sensors (bridge type), 4-20mA etc
Speed and Trigger Chan-nels
Each node type is fitted with the same trigger/tacho inter-face. This comprises four digi-tal inputs that can be set as isolated or non-isolated. Any trigger input can be tagged to any of the analogue input chan-nels allowing maximum trigger-ing flexibility. A trigger input
can be used for any of three purposes, namely: 1. tacho input for measuring
machine speed (also incor-porating a divide-by-N Counter for taking inputs from gear teeth or similar);
2. once-per-rev sensing for time synchronous averag-ing;
3. input to digital phase-lock function for order analysis.
Full pre-trigger and post-trigger sampling facilities are provided.
Gated Measurements
Two of the trigger input chan-nels can be used to gate meas-urements from the analogue input channels. Only when a pre-determined logic level is present on a digital input will data acquisition take place. This feature can be used, for
Bearing Condition Meas-urement
The Type 1 node incorporates an on-board hardware demodu-lator for the detection of bear-ing defect signals. These are passed over the network to be presented either as an overall value of bearing condition or as a spectrum highlighting actual bearing defect frequencies. In this way, bearing problems are differentiated from shaft related problems.
Watchdog Function
A watchdog function is incorpo-rated that monitors the opera-tion of the nodes. If, for exam-ple, the supply voltage drops, the watchdog will automatically reset the node when power is restored. No user intervention is needed in the event of a power interruption. An RS232 serial port is available for diagnostic purposes.
The above modes can be modi-fied in the application. For ex-ample, the mode could be switched from Mode 1 to Mode 3 when live data is required.
Acquisition Modes
To optimise system perform-ance in time critical applica-tions, three acquisition modes are supported.
Mode 1: Data on Demand the node is instructed to acquire data, store it, and await a download instruction from the host computer.
Mode 2: Data Ready Flag the node is instructed to acquire
data, and then sends a Data Ready flag to the host com-puter indicating that acquisition is complete and new data is available.
Mode 3: Data Broadcast the node sends data to the host computer as soon as acquisition is complete without waiting for a command.
Scrollable regions for elongated systems
A flexible network system
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Modules available to interface to thermocouples, RTDs, pressure sensors (bridge type), 4-20mA etc
GuardianAngel
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Fast Node Control
Low Cost
Hardware & Fitting
the typical installation diagram. The ICONET part of the net-work can then be linked into 100Base-T Ethernet networks through standard switches or can be linked to the PC run-ning, for example, Icons GUARDIAN or other compatible software directly. Several PCs running GUARDIAN can be con-nected to the local network and remote PCs running GUARD-IAN can interface with the sys-tem also through a switch from the plants Ethernet highway. For larger Ethernet applications, routers can allow global access to the system. In effect, three levels of access are possible: Local, Plant Wide and Global. Both UDP/IP and TCP/IP proto-cols are supported.
Fast Node Control
In order to obtain maximum data throughput, channel con-figurations (and the sequence in which they are called) are downloaded to the node and stored in flash memory. The node is then instructed to exe-cute a stored sequence of measurements, (and keeps ro-tating through if required). A large number of configurations and sequences can be stored in the node so that, if the order or configuration of measure-ments needs to be changed, this can be done with a short com-mand instead of having to download a new set of instruc-tions.
Standard Ethernet
ICONET on Ethernet uses the latest Ethernet technology en-suring compatibility with exist-ing Ethernet systems. Commu-nication is possible within the systems own environment, across switches and routers, and across the Internet. Stan-dard off-the-shelf hubs and PC adapters can be used through-out. Each node has a unique MAC address. Physical connec-tion is 10Base-T using the stan-dard RJ45 plug and socket ar-rangement. For optimum per-formance, Icon recommends a dedicated local Ethernet net-work is used to connect the nodes to the PC as shown in
Enclosures
ICONET is available in a number of enclosure types. The stan-dard is powder-coated mild steel, but stainless steel and high-impact plastic are available at small additional cost.
Nodes can be fitted with power supplies for mains input at any voltage, or can be configured for a number of standard fac-tory dc voltages. Power con-sumption is very low, thus put-ting negligible load on existing power systems.
Wireless Operation and Internet
Being fully Ethernet compatible, ICONET on Ethernet can be con-nected in to standard wireless LANs (including the IEEE 802.11 standard). In addition, nodes can communicate live over the Internet anywhere in the world.
Low System Cost
ICONET is purely a data capture system. It does not attempt to analyse data in the field at each node the power of the mod-ern PC is used to do this at a fraction of the cost. This keeps the hardware cost to a mini-mum.
Installation costs are also low. The small number of points per node minimises sensor wiring
costs while the network wiring uses low cost CAT5 Ethernet cables and standard Ethernet components. It may even be possible to use existing Ethernet network cabling at effectively no cost.
Excellent construction with simplicity keeps costs down
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Standard off-the-shelf hubs and PC adapters can be used throughout.
GuardianAngel
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Human Machine Interface
Mimic driven interface
Main and sub mimic levels
Trend plots
Trace plots (time, spectrum and orbit)
Point and click operation
Pop-up alert and alarm notification
Graphic colour change on alert or alarm
Traffic light indication of point status count
Interfacing Features
Interfaces to ITA-1and ITA-2 nodes
Up to 4,194,304 sensors possible
Multiple reading types from sensors possible (eg. accel, velocity and g from accelerometers)
Virtually unlimited sub mimic levels
Operates under Windows NT or 2000
Uses standard Ethernet interface
System Features
Periodic network checking
Network check on demand
Bias voltage check for accelerometers at user definable intervals
System log and network log
Log search facilities
Log print, serial output and shared file options
On-line help and user accessible HTML help
Measurements with ITA-1
ICP devices (eg. accelerometers)
DC voltages
AC coupled signals
Tacho speed inputs from 1/rev or gear
Measurements with ITA-2
X-Y signal pairs (eg. orbits)
DC or AC inputs in 0 to 24V range from standard eddy current (proximity) probes
Tacho speed inputs from 1/rev or gear
Results
Scalar measurements
Overall and derived measurements
Spectrum graphs for acceleration, velocity, displacement and gbrg
Spectral Bands
Orbits
Phase measurements
Trigger synchronised readings (sync, pre and post available)
Orders spectral display using phase lock loop
Gates available to check data integrity
Alerts and Alarms
Main and sub mimic colour change
Pop up alert/alarm box
Acknowledge function
Clear function (only if condition clears)
Log entries automatically generated
Traffic light indication of total alerts/alarms
External Outputs
External relay activation
Point Selection
From mimic hierarchy
From Explorer function
From pop-up alert/alarm box
Review of trends Live mode
Live trend graphs
Time scale zoom in/out
Multiple trend view of historical data (up to 5)
Access to live trace (eg. spectrum)
Review of Trends Browse Mode
Cursor on trend(s)
Timescale zoom in/out with cursor centred
Multiple trend view (up to 5 trends)
Point highlight for overlay
Multiple trend overlay (up to 5 of same type)
Access to trace overlays
Point delete function
Hardcopy print-out
Analysis of Results Spectra
Current spectrum view
Acquire / hold facility
Real-time mode for instant analysis
Single, dual, harmonic and sideband cursors
Spectral overlay up to 5 spectra, selected from trend screen
Zoom
Hardcopy print-out
Optional grids
Auto peak detect
Line or bar display
Choice of Hz, CPM, RPM
Analysis of Results Orbits
Current orbit view
Acquire / hold facility
Real-time mode for instant analysis (Continued on page 8)
Specifications
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(Continued from page 7) Angle / magnitude cursor
True and measurement angle
Overlay up to 5 orbits, selected from trend screen Zoom
Hardcopy print-out
Optional grids
Auto peak detect
System Set-Up
Security key protected (2 levels)
Full control over measurement parameters
Adjustment of alert and alarm levels
High, low, in-window and out-of-window alert and alarms (spectrum and spec-tral bands)
Furthest from a datum alert and alarms available
Selectable storage frequency depending on normal / alert / alarm status
Averaging of results selectable
Tell user after X consecutive fails option
Selectable signal gain
Band set-up and naming up to 10 bands
Trigger set-up for phase lock loop, trigger and pre and post trigger
Match any trigger channel to any input or inputs
Selectable sifting strategy highest, lowest, furthest from or typical
Up to 12 machine relay alarms settable
Email recipients for alert and alarm settable by machine
Settable gates to check data integrity
Override logging to capture sample data on all points
Database Management
Automatic database sifting, backup and file export at selectable intervals
Associated Applications
Ability to run Iscope1 real time spectrum analyser utility Ability to run Iscope2 real time X-Y (orbit) utility
TYPE 1 N OD E
Analogue Sixteen M ult iplexed Ana logue Inputs ICP Power fo r Acce lerom ete rs on A ll C hannels AC/DC Inpu t C oup ling O ptions Fu ll An ti-A liasing Program m able HP Fi lters O n-board H ardware Integ ra tor Program m able Ga in in Range 1 to 1000 O n-board Bearing Dem odula tion Func tion
Triggers Four D ig ita l T rigger Inputs 5 -24Vdc Range, Isola ted o r Non-Isolated Averag ing , Pre and Post-T rigger Functions T rigger, T acho and O rder Ana lys is Func tions Even t and G ate T rigger Op tions
Process ing 16-b it AD C Sam ple Ra te to 51.2kHz W atchdog Func tion 10Base-T E the rne t In te rface U DP/IP and TCP/IP Protocol Support
T YPE 2 NODE
An alog E ight Synchronous Pairs or Sixteen S ingle Input Configurations
Input Range Compatible w ith S tandard Edd y Current P robes
P rogram mable DC/AC Coupling for Optim ised DC Gap and Vibration M easurement
F ull Anti-A liasing P rogram mable HP Filters P rogram mable Gain in Range 1 to 1000 F ault Protected Inputs
Channel-to-Channel Common M ode D ifference to 40V
T riggers As Type 1 Node
Pro cessing Dual 16-bit ADCs Sam ple Rate to 51.2kHz W atchdog F unction 10Base-T Ethernet Interface UDP/IP and TCP/IP Protocol Support
T YPE 3 N O DE
An a log T we nty S tatic Ana lo g Inp uts C onfigurab le M od ule T ype s, inc lu ding
T h erm oco up le , RT D, 3-W ire B rid ge , 4 -20 m A
O n-Boa rd E xcita tion Sup ply 17 2d B Inp ut Se nsitiv it y Ra n ge
P ro gra m m ab le G ain in Ra n ge 1 to 10 0 Auto m a tic DC O ffs et Rem ova l T wo Iso la ted R e la y O u tpu ts R S23 2/R S48 5 Co m m un ica tio ns C ha nn el
T rig g ers As T yp e 1 N od e
Pro c es sin g 22 -bit AD C Auto m a tic Re m o val o f 50/6 0 Hz M a in s-
Borne In terfa ce W atc hd og F un ctio n 10 Ba se-T E therne t Inte rfac e U DP/IP an d T C P/IP P rotoc ol Su p por t
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PdM Training PDC Systems. has devel-oped a modular approach to training PdM technology us-ers, aimed at developing an effective PdM program. We focus not only on the tech-nology and how to interpret data, but we also provide help in program set up and tracking your PdM goals.
Courses can be tailor made to suit your individual re-quirements and are held either at our comprehensive training facility or at your plant.
Training courses start from as little as $200 per student.
Modules I. PdM Management 1 day
a. Maintenance strategies b. Project management c. Choosing the right technologies d. Integration into maintenance e. Procedures f. Reporting
II. Basic Vibration Analysis 2 day a. Frequency -v- time domain b. How the FFT works c. Examples of basic defects d. Transducers e. Accelerometer mounting f. Measurement parameters
III. Advanced Vibration Analysis 2 day a. Resonance b. Dynamic range c. Frequency calculations d. Effects of windowing e. Amplitude demodulation f. Phase g. Fault analysis h. Single plane balancing i. ODS
IV. Two Channel Analysis 1 day a. File capture of vibration data b. Variable speed machines c. Triggering d. Measurement parameters e. Capture and display options f. Two-channel functions g. Impact testing
V. Industrial Thermography 2 days a. Infra red theory b. Qualitative thermography c. Radiometric thermography d. Fault analysis e. PdM integration
VI. Passive Ultra Sound in PdM 1 day a. Ultra sound theory b. Detecting leaks c. Electrical applications d. Mechanical applications e. Integration into spectrum analyzers
VII. Potential Failure Analysis 1 day a. Identifying potential failures b. Determination of applicable technologies c. Definition of suitable measurement parameters
Vibration analysis can be very difficult to analyze. Why not get the experts to carry out all of the work for you and present you with a simple set of results and recommenda-tions after every visit? Our engineers are the best in the business and we will ensure that the reports give you good, practical advice.
After each visit for off-line or every day for on-line remote, you will receive a verbal report immediately if anything is dangerously close to failure followed up by a formal email, fax or written report.
On-line remote monitoring systems will provide a same day verbal and e-mail report and a full condition analysis every month.
PDC Systems 23-25 Windermere Road
Blackpool FY4 2BX United Kingdom
Phone: +44 (0)1253 400541 Fax: +44 (0)1253 400552
Email: [email protected]
Condition Monitoring Engineers
Were on the web. http://www.predicon.net
PDC Systems
Classroom or on site training
Specialized training courses
IIX. PdM on Rolling Element Bearings 1 day
a. Bearing construction b. Elastohydrodynamic lubrication c. stages of bearing failure d. Failure modes e. Fault frequency generation f. Vibration examples of common defects g. Tribology
IX. PdM on AC & DC Motor 1 day a. AC motor construction b. Failure modes c. Generation of electrical frequencies d. Vibration examples of common defects e. Motor current analysis f. DC motor construction g. Failure modes h. DC drives i. Vibration examples of common defects j. Thermography
X. PdM on Pumps 1 day a. Centrifugal pumps - theory of opera-
tion b. Centrifugal pump construction c. Positive displacement pumps construc-
tion d. Failure modes e. Vibration examples of common defects f. Performance analysis
XI. PdM on Fans 1 day a. Theory of operation b. Failure modes c. Vibration examples of common defects d. Performance analysis e. Adjusting bedplate resonance
XII. PdM on Large Stamping Presses 2 day a. Press construction b. Failure modes c. Specific monitoring problems d. Sensors & installation e. Defining vibration measurements f. Using advanced vibration techniques