Vibration measurement

Inobalt's vibration measurement technology is intended for users involved in vibration monitoring and analysis and damage diagnostics.
The technology meets user requirements not only because of its user-friendliness and cost effectiveness but also because users can integrate it into their systems of process monitoring.
Users will experience for themselves that Inobalt products have more to offer than other products on the market. One of the technology's special features is its ability to perform the system's main functions independently within the Expert Vibro device itself even when PCs and networks have failed.

Many medium sized companies are using Inobalt's vibration measurement technology. The Expert Vibro system offers users a range of functions to meet their specific requirements.

Examples of applications

Monitoring vibrations in steam turbines and air gaps
Damage diagnostics in marine transmissions, bearings and shafts
Acquisition and monitoring of combustion chamber vibrations in gas turbines
Monitoring and signal evaluation at test stands
Mobile vibration measurement technology (measurement case)

Hardware

With its Expert Vibro device, Inobalt have successfully combined the processing of complex functions with high levels of flexibility in a user-friendly system. Vibration measurement systems can now be used where they had previously been economically infeasible. The device is equipped with a high powered, dual core FPGA processor based on ARM technology giving users ample reserves of processing power.

Software

The Vibro software option from ProfiSignal enables users to portray online and offline FFT, cascade, time-signal and orbit diagrams. Process data and vibration data can be monitored and evaluated in a single system.
The system offers users diagrams with a range of analysis functions. Customized documentation can be created with a report generator.

Connecting to data networks

A special feature is Expert Vibro'sProfiMessage LAN interface which enables it to connect to data networks.
Users can connect Message devices to a LAN socket and then access and evaluate measurement data from any authorized PC on the network.
Secure process monitoring and data acquisition
The independently operating Expert Vibro devices guarantee users secure and continuous data acquisition and monitoring. The security of Inobalt`s technology is based on an internal data storage capability as well as independently operating monitor functions in the Expert Vibro device. Inobalt has done everything to overcome the effect that failure-prone data networks can have on process monitoring.

Vibration measurement and process data in a single system

Solutions for process and vibration monitoring usually require two separate, independent systems. This creates higher purchase costs, higher operating costs, and higher system-maintenance costs. Installation space may also become an issue.
The design of Inobalt systems overcome such problems. Inobalt systems enable users to acquire process and vibration data in a single compatible system. This gives users obvious benefits including user-friendliness and practicality plus a compact design requiring minimal installation space.

Expert Vibro module

The compact, industrial-grade, modular design of Expert Vibro devices, with detachable clamps and rail mountings, enable their easy installation in cabinets and housings.
Expert Vibro devices can acquire vibration signals such as speed, acceleration and direction as well as typical process data such as pressure, temperature, flow and rotation.
Vibration data is recorded and aggregated directly within the Message devices as meaningful characteristic values and FFTs. Alarm functions monitor characteristic values. In the event of a malfunction they can transmit text messages, faxes, or emails and trigger digital outputs.

Benefits of Inobalt products

• Synchronous and parallel acquisition from up to 48 vibration signals per device
• Simultaneous acquisition of vibration and process signals
• Independent operation to give secure vibration monitoring
• Can be deployed as a subsystem of a process control system
• Extremely cost effective
• Can determine characteristic values (Peak-Peak, Gap), order analysis
• Data logger memory for independent and long-term acquisition of machine data
• Monitoring/alarms (text message, email, fax)
• PROFIBUS-DP or Modbus RTU/TCP interface to enable reporting to main control systems
• Analysis of online / offline measurement data at a desktop PC
• Evaluation using orbit, FFT, cascade and Yt diagrams
• Calculation of envelope frequency spectrum and vibration speed
• High powered vibration diagnosis system with integrated data memory for independent, long-term data recording capability
• Universal connection for acceleration, speed, and distance sensors
• Compact design and compact channel feeds enabling easy installation within cabinets

Monitoring and process overview

Inobalt's process monitoring has been designed for industrial and academic users involved in the generation, operation and optimization of processes. Inobalt products are used also by system integrators to develop turn-key solutions.

The many Inobalt applications being used in many different industries provide Inobalt with a wealth of experience in batch and process engineering.

Users achieve real benefits by using Inobalt systems, both for small and large installations. These benefits are delivered by Inobalt's Message hardware and its patented and award-winning ProfiSignal measurement and automation software.

Networking capability 

Machinery and plant components etc. can be linked into a single system via a LAN. Individual machines, ovens, etc. can then be operated and monitored from any PC on the network. Data can be evaluated and the results presented in reports.

Basic functioning

• Secure process monitoring
• Managing and automating processes
• Acquiring high-resolution data and adaptive recording
• Data server design depending on the size of system
• Operating and monitoring machinery using visualisation views at the machine and at any networked PC
• Measurement data evaluation in intranet and internet
• Documentation via dynamic reporting functions
• Connection to third-party equipment via standard interfaces
• Data transfer to specialized analysis programs
• SQL interface to link company database systems

Hardware

The devices can be connected via a LAN to data networks. The devices are equipped with TCP/IP addresses to enable LAN integration. They can then be located anywhere across an intranet network.

LogMessage

LogMessage devices (for up to 30 channels) can function as stand alone units by performing basic functions such as monitoring, control and data recording within the device itself. They can therefore function continuously even in the event of PC or network failures.

A special feature are inputs with isolation voltages of up to 650 VDC. These enable, for example, the measuring of temperatures when thermocouples are directly connected to live electrical components.

ProfiMessage

ProfiMessage devices are designed as modular master/slave systems and are suitable for systems using high numbers of channels (>30).

Software

ProfiSignal Klicks contains user-generated modules that contain all the functions required for process engineering systems.

DataService

The DataService is the hub for all incoming and outgoing data. It manages all data traffic and records high-resolution data adaptively and securely to measurement databases. The DataService also enables authorized PCs to communicate with each other across the network and is compatible with systems that use centralized data servers.

User-generated applications

Users wanting to develop their own applications using ProfiSignal Klicks should refer to "Klicks - The automation software for technicians, scientists and engineers" .

Benefits of Inobalt products

• Special ProfiSignal Klicks procedures to facilitate parameter/recipe input. Especially beneficial for batch processes
• Operation from any networked PC. PCs can be located directly at the installation or anywhere on a network
• Special procedures for the dynamic generation of reports
• Data security via GB-sized memory and independent and stand alone data logging
• Data recorded with date/time stamp
• Optional centralized data server
• Measurement data evaluation worldwide via internet
• Secure monitoring functions
• Data compression using Devistore. Highly efficient use of data memory
• Diagnostic data storage at high resolution with pre and post histories
• Operation and monitoring during runtime from any networked PC
• Data evaluation (on-/offline) during runtime
• No requirement for extra transducers/ potential isolation
• Digital inputs configurable as switch/frequency/counter inputs
• Patented analog inputs prevent hazardous earth loops that can distort measurement readings
• Fully network-compatible hardware and software
• Alarms via text messaging/email/output
• Diverse interfaces and protocols for connecting external hardware, e.g. weighing equipment, analysis equipment, displays etc.
• SQL interface to link in-house database systems

Process and vibration monitoring from a single system

Inobalt provide highly effective solutions for user requirements in process and vibration monitoring. Such solutions use ProfiMessage hardware with the ProfiSignal Klicks Vibro option.

AlarmManagement

A comprehensive system for alarm management is available via the AlarmManagement option. This option enables alarms to be triggered, and displays alarms with dates, times and commentary texts.

Data acquisition & data logger

Inobalt products are being used widely in industry and academic institutions to acquire and evaluate measurement data. Inobalt also helps system integrators to generate turn-key systems.

Users will enjoy working with the latest technology utilized by Inobalt's hardware and software products. Inobalt products are better at meeting user requirements than other products on the market and their user friendly hardware/software packages have won over many users.

Patented analog inputs prevent data corruption and reassure users on the security of their measurement data. Additional potential isolation is unnecessary. Channels can be individually configured for different types of sensor and do not require any additional transducers. Acquisition is possible for both high density (up to 100,000 values/second) and slow channels (e.g. temperature measurements). This capability has proven in practice to be highly advantageous.

Inobalt products provide the most efficient method to get from sensor connection to trend output. The system operates as plug&play and enables users to quickly commence acquiring and evaluating their data.

The compact hardware design is hallmarked by easily accessible connectors. The Delphin data logger can function independently and requires no PC support. It can store up to two billion data values, each with a time and date stamp. Data can be transferred at any time and has adaptable methods of data storage. This avoids data redundancy and significantly increases data storage capacity.

Versatile online software channels are a unique feature of Delphin data loggers and can be used to perform calculation, monitoring and logical procedures. Software channels can be configured according to user requirements and run independently within the logger.

Inobalt's hardware and software package is especially beneficial to users. The ProfiSignal Go software is included free of charge with Expert Key or LogMessage devices. It is powerful software for measurement data acquisition and evaluation.

ProfiSignal Go has already impressed many different customers through its practicality and user friendliness.

The ProfiSignal Go software is included in the package. Customers prefer ProfiSignal Go to other, more expensive software. A clear benefit is the instantaneous switching from online monitoring to offline evaluation.

ProfiSignal Go offers all the functions that users need to run their systems effectively.

Drivers and interfaces are available to enable data import/export to external hardware and software. Laboratory equipment (e.g. scales, analysis/output devices) can be connected via RS232/RS485 interfaces. The required protocols are included. PROFIBUS and Modbus are used for data transfer between process control systems. The following are available with the delivery of Expert Key and LogMessage devices:
LabVIEW™
DASYLab™
OPC-Server
OPC Client
Modbus TCP-driver
OCX-driver

Test, trial and automation

Inobalt develop products for users in industry and academia involved in developing their own systems for inspection, testing and automation. Inobalt products also enable system integrators to develop their own turn-key solutions.

The user friendly and fully compatible hardware and software and drivers have made many users very happy. Users can perform their tasks more easily and with more success than is possible with other products. Inobalt products can be used for applications with small numbers of channels (e.g. bounce testing on switches) or for applications with thousands of channels (e.g. turbine testing). A further area of activity is the monitoring and automation of experiments in laboratories and testing facilities.

Inobalt's own application engineers are available to help users develop the systems they require. Inobalt also cooperates with a network of system integrators. Inobalt's hardware and software has patent protection. Inobalt delivers systems that function better and with greater ease than those from competitors.

Hardware

Inobalt distinguishes between indoor laboratory applications and outdoor field systems, as well as between systems with just a few channels and those with many channels. Indoor systems (laboratories, test systems) are suited to Inobalt devices without internal data storage - such as the Expert Key devices). Inobalt recommends LogMessage devices for outdoor field systems. ProfiMessage is suitable for systems with more than 60 channels, for both indoor and outdoor applications.

The ProfiSignal Klicks automation language

Get to know the appeal of ProfiSignal Klicks. ProfiSignal Klicks has been granted many patents. ProfiSignal Klicks can be used to:

• Automate, visualize and and operate experiments
• Acquire, monitor and evaluate measurement data
• Enable users to monitor and operate processes through visualization procedures
• Automatically generate reports
• Generate parameter views for entering parameters (e.g. recipes) for series testing
• Utilize the SQL interface to integrate company database systems

Klicks enables the easy generation and maintenance of applications. No specialist IT knowledge is required. Users do not have to learn a programming language. Lead times, from the initial idea to a functioning application, can be drastically shortened. Users are not required to learn and type in commands. Instead they select programmable instructions from context menus. Specialist knowledge in not required.

"Klicks - The automation software for technicians, scientists and engineers" explains how users can develop their own applications using ProfiSignal Klicks.

Interfaces and drivers

Inobalt products are equipped with drivers and interfaces to enable systems to import/export data to external hardware and software. Laboratory equipment (e.g. scales, analysis/output devices) can be connected via RS232/RS485 interfaces. The required protocols are included. PROFIBUS and Modbus are used for data transfer between process control systems. The following are included with Expert Key and LogMessage devices:
LabVIEW™
DASYLab™
OPC-Server
OPC Client

Research/ Measurements/ Testing

Company's Inobalt measurement solutions are mainly used in product development, research and maintenance.

Inobalt has a wide selection of devices from transducer to the high-end analyzers. Typical measurable values are temperature, vibration, pressure, rotation, force, torque, strain and noise. Systems are widely used in vehicle- and defense industry, universities, research institutes, electronics and in machine building applications.

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Process Monitoring in a Brewing Plant

Application / Problem:

The customer decided to install a Delphin LogMessage data logging system to monitor the consumption of:

• electrical energy
• CO2 for beer carbonizing process
• steam flows
• sewage flows
• fresh water

The objective is to install an easy to configure real time monitoring system with reporting capabilities to monitor the consumption of the parameters mentioned above.

Proposal / Solution / Hardware:

The analog inputs are interfaced with different steam, CO2 and sewage flow meters via 4-20 mA signals. The interface of the 2 water flow meters from Siemens MAG 8000 was realised through the Modbus RTU interface. The Modbus registers where easily created on the 2 serial COM ports of the LogMessage device. The customer is also using the internal calculation channels to calculate consumption indicators. For example the integrator channel is used to totalize the electrical energy and CO2 consumption of the brewing process. The functional design is shown below.

The process supervisor has a PC with a ProfiSignal Klicks software application to monitor the live data of the process. The mimic interface was easily developed with the ProfiSignal software and is shown below.

Benefits:

The advantages of the LogMessage installation are the following:

• The LogMessage with universal analog and digital inputs can easily record all analog 4-20 mA signals and also the digital inputs from the energy meter with pulse output.
• The LogMessage devices support many serial interfaces (RS232, 485, 422) and the MAG 8000 flow meters could be easily interfaced via Modbus RTU protocol.
• The internal calculation channels for alarm monitoring and totalizes (integrator channel) give the operator live readings of key consumption indicators.
• The internal logger memory with 1 GB capacity is storing the process data for backup functions. The live data is also archived in the DataService Configurator online data base.
• The ProfiSignal Klicks software also enable the operator to generate different reports and statistics of the process.

For more information please see: LogMessage >>

Marine diesel engine turbocharger test bench

This customer is one of the world's leading manufacturers of large diesel engines, turbochargers and complete drive systems. The company manufactures diesel engines for shipping, power generation, and heavy road and rail vehicles - with power ranges from 116 to 9000kW. Turbocharger performance determines overall engine performance fuel consumption and emissions. They are subjected to high levels of thermal and mechanical stress. They can rotate up to 90,000 rpm, are exposed to temperatures of up to 750 ºC and a pressure ratio of 5.0.

Customer requirement:

Two existing turbocharger test benches where upgraded with the latest TopMessage and ProfiSignal data logging systems from Delphin Technology. The test bench is designed to test the most critical areas and to optimize the robustness, efficiency and operation of the components. The customer was also considering more advanced test scenarios with more inputs in the future and therefore a modular system was required to have the ability to upgrade the system easily with more I/O channels.

Solution:

For this test bench application about 80 analog signals and about 20 digital I/O channels where required. The analog inputs record pressures, volume flows, valve position, and temperatures. The counter inputs measure rotation speed. The system was installed in a control cabinet with the following modules.

Hardware:

1 TopMesage Master with 1 GB memory and ProfiBus DP Slave interface;

3 TopMessage Slave extension units;

6 ADVT modules with 90 Analog inputs for temperature & pressure measurement;

1 DIOT module for digital I/Os pulse & speed measurement.

Software:

ProfiSignal Basic with 250 channel input for HMI mimic building.

A high level of accuracy was especially necessary for the temperature measurements (+/- 0,2 K). The ProfiBus-DP Slave interface of the TopMessage was important to integrate the system to the PLC system which is controlling the overall test cycle.

Benefits:

The customer considered the following benefits for this project:

The first test run was performed after 2 days of installation. The installation and configuration of all the sensors was easy as no additional converter and signal conditioning unit was required. The system is very reliable. The configuration of individual mimics and HMI screens could be done easily.

More information: TopMessage >>

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Ship building and repairing

Diesel Particulate Filter Testing on Vehicles with GPS Logging

The company Twin-Tec develops and manufactures a wide range of diesel particulate filters and catalysers for automotive applications. Many elderly vehicles have no diesel particulate filters. Many car owner are interested in adding the particulate filter to the exhaust system in order to protect the environment and to benefit from reduced vehicle emission taxes.

The filter installation will substantially reduce the taxation. The German government encourages all owners to retrofit filters through financial incentives. Twin-Tec is therefore developing many different retrofit filters for many different brands and each filter requires a testing on the road under driving conditions to determine the filter efficiency.

Application / Problem:

The problem is that virtually every new filter requires a new design because of the variety of exhaust systems and their varying temperature and pressure operating levels. During test drive filter temperature, pressure, engine speed, idle times, vehicle position and speed need to be measured accurately and reliably to ascertain that the filter meets the required standards. In order to record the test data Twin-Tec decided to use a TopMessage data logger in combination with a GPS sensor to record measurement data from the filter in combination of vehicle position information.

Proposal / Solution / Hardware:

For this logging application the Twin-Tec is using TopMessage data logger with ADVT and DIOT modules. The whole system is installed in a weather proof enclosure and the sensors are interfaced to the enclosure through special connectors. The following photos show the test system.

During the test drive all test data is recorded to the internal memory of the TopMessage data logger. The speed of the engine (rpm) is recorded through a separate speed meter (DAB 500 from AVL) which is providing TTL pulse output. The pulses are then recorded by the counter and inputs of the DIOT module. The live data is visualised through a mimic interface of the ProfiSignal Basic software.

In order to record the vehicle speed and direction a special NEMA driver for a GPS sensor was developed. This driver is interface to the TopMessage through serial RS232 port. The GPS information like speed, direction, altitude a separate COM channel is created and all the data is stored directly in the 1 GB TopMessage data logger memory.

After the test drive is finished, all the data is analysed with the ProfiSignal software. It is also possible to convert the GPS data into a KLM file which can be loaded by Google Earth to plot various measurement channels like vehicle speed, filter temperature or pressure of position or engine speed.

Summary of Benefits:

Twin-Tec is using now 5 Data Acquisition systems to run the diesel particulate filter testing. The main advantages for them are:

• The 1 GB internal memory provides storage capacity for several thousand test drive kilometres.
• Easy to configure ProfiSignal software to show live reading during the test drive.
• The interface of the GPS sensor also gave Twin-Tec valuable additional information about vehicle speed in combination with engine RPM and particle emission.
• The universal analog inputs made it very easy to connect the temperature and pressure sensors.
• The small and compact size of the data logger of (200x73x118 mm) made it very practical for the installation in a small enclosure.
• In internal calculation and logic channels where used to trigger data logging when test conditions are reached.

For more information please see: TopMessage >>

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Data Acquisition on Packaging Machines in the Pharmaceutical Industry

This customer is manufacturing packaging machines for pharmaceutical products. The machines produce containers like ampoules, bottles, vials or single-use syringes which contain the appropriate medical products as well. These machines have to be compliant to the FDA standards.

Application / Problem:

The customer is manufacturing complete customized machines and production lines for high volume production of many different medical packaging systems. In order to verify the proper functioning of the production line the manufacturer is performing a quality test before the plant is delivered to the customer. The objective of the test measurement is to confirm that the equipment is working to its standards and that that the sterilisation processes is also meeting the required standards. In the past the acceptance test measurement and documentation was based on a mainly manually data recoding process and the report was also manually generated in Excel. The customer was looking for a solution to simplify the data recoding and to automated the report generation.

Proposal / Solution / Hardware:

The customer decided to take Expert Key 200 data acquisition systems and to order a customised ProfiSignal Klicks application for the data acquisition process and the automated reporting.

The data acquisition project is based on a universal ProfiSignal application which is independent of the connected data acquisition hardware. The user can record data from the analog inputs of the Expert Key and record values from the machine PLC system via OPC server at the same time. The data recoding application is based in measurements from dedicated thermocouple and pressure sensors which are connected directly to the Expert Key 200 unit and on temperature and pressure readings from the Siemens S7 PLC which are interfaced to the DataService Configurator via OPC Server.

The functional design:

The application is divided into 2 separate ProfiSignal Klicks programs:

1. Program is dedicated to record the data from the Expert Key unit and the machine Siemens S7 PLC via OPC server.
2. Program is dedicated to analyse the recoded data and to automatically generate a test report.

Recoding Application:

Reporting Application:

Benefits:

The interesting feature of this apparition is that the ProfiSignal Klicks application was developed in a way that the customer can record data of any hardware which is connected to the DataServiceConfigurator. The customer can connect channels from any DAQ device like Expert Key, TopMessage, LogMessage, ProfiMessage or any third party devices from (VTI, HBM, PSI; Adam Module, DataTranslation etc..) which are supported by a driver. The ProfiSignal application records data from the Expert Key hardware and reading from the PLC via the OPC interface into one HDS data file. The user can also perform an offset calibration of each channel if required. The data recoding is performed completely independently from the data analysis and report generation.

The Report is generated from the recorded HDS file. The Report is of course tailed to the requirement of this specific customer and the application also calculates special key indicators which show whether the production equipment is working correctly and meets the sterilisation requirements in terms of temperature level and duration. The quality of the sterilisation process is expressed by the F-value.

The Key benefits:

• The Expert Key is used as a universal high speed DAQ system to verify the performance of new packaging systems.
• Also maintenance technician in the field us the Expert Key to determine the performance of the equipment during operation.
• The data recoding application is separated from the data analysis application which gives the customer more flexibility.
• The whole solution is able to record data from DAQ modules and also from the Siemens S7 PLC via OPC server into one data file.
• The report generation is fully automated and standardised to save time and to reduce errors compared to the previous Excel reporting system.

For more information please see: Expert Key >>

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Pipe Fitting Test Bench – Rotary Flex Test

The company is a leading hydraulic tube and fitting manufacturer in India. The company is developing many different pipe fitting systems and is exporting 90% of the products worldwide.

Application / Problem:

In order to ensure high product quality it is required to perform pressure and leakage test of each production lot. The test engineers are performing a rotary flexure test of the hydraulic joints and fittings according to the ASTM F -1387 standard. The customer required a universal data acquisition system in order to monitor and automate the test bench application.

Proposal / Solution / Hardware:

For this test bench application the customer decided to use an Expert high speed data acquisition system in combination with ProfiSignal software.

The test are performed in the following sequence:

• The hydraulic joints are mounted to 12 mm diameter tube which is 6 inch long.
• This tube is then mounted to a support rest on one side and to a rotating spindle on the other side.
• Then the spindle is rotating at a speed of 1750 rpm. While the spindle is rotating the pressure inside the tube is raise up to 25 bar.

This test is then running for 10 to 15 minutes to measure the twisting forces of the tube and to measure also the pressure level. If the pressure is declining the test engineer has an indication about leakages of the fitting seal rings.

The following picture shows the physical setup of the test bench.

The functional design is presented below.

In order to operate the test bench the test engineer uses a ProfiSignal Klicks applicationwith the following user interface (main screen).

The engineer can specify the part number of the product which is test. With a separate button he can then start the data logging and the test cycle. During the test the live data of speed (RPM), strain (Torque), deflection and pressure is displayed. At the end of the test a report is generated which shows a strip chart of all test data and a data table with all measurement values is available as well.

Benefits:

The advantage of the Company's Inobalt Expert system is:

• The Expert Key 100L has universal analog and digital inputs for measurement of ration speed (pulses) and analog signal (mA, V, mV, TC, RTD) at the same time.
• The Software ProfiSignal Klicks is a very easy to use development system for mimic building (HMI) and the programming for the data recording and reporting.
• The USB interface makes the configuration and set up of the whole system very easy.

For more information please see: Expert Key >>

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Data Logging on non stationary water treatment plant with Remote UMTS Access

The customer is a leading manufacturer of water treatment equipment for cooling water, boiler water, process water and pure water. The water treatment equipment for process water treatment is often installed on trailers or in containers and is rented out to customers for temporary water treatment assignments.

Application/ Problem:

For the no stationary applications (trucks & containers) the customer required data logging system with remote access to read live data and stored data. The objective is to have permanent access to the treatment system and to monitor the equipment performance and to receive alarm notification when system performance is going out of specification.

Proposal/ Solution/ Hardware:

The customer decided to install a TopMessage data logger with ADVT and DIOT module and a MoRoS UMTS router on the truck to record 12 analog and 8 digital signals (pressure, flow, temperature, system error) of the process water treatment system. With the UMTS router the customer could access the remote located truck at any time. The strength of the TopMessage data logger is also that the internal alarm and event channels perform a continuous system monitoring and report with the UMTS wireless bridge immediate alarm notification to the central head office when threshold levels are violated.

The functional design is presented below.

Benefits:

The installation of the Inobalt TopMessage in combination with the UMTS routergave the customer the following benefits:

• Remote access to live data of the process water treatment unit with permanent process supervision.
• Access to the system independently where it is installed.
• Alarm notification in case of problem and abnormal process status.
• Easy connection of the analog sensors and digital status inputs.
• There was no not to have any PC installed on the remote system as the Data Logger is also taking over al Monitoring and control functions of the treatment system.

For more information:TopMessage >>

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Equipment and machinery production

Data Logging on Natural Gas Dehydration Plants with Remote UMTS Access

Application / Problem:

The dehydration plant is located in a remote location and the customer needed a standalone data acquisition and logging system to record production and process data of the plant and to have also remote access to the recorded data.

Proposal / Solution / Hardware:

The customer decided to implement on two dehydration plants Delphin data logging systems. In the plant a TopMessage data logger with 1 GB internal memory and one ADVT module with 15 analog inputs and one IOIT module with 24 digital inputs for status monitoring were installed. The data logger is interface via Ethernet (LAN) to a MoRoS UMTS router to provide remote access functions. The complete system is fitted to an explosion proof box with EX barriers in the hazardous area of the plant. The TopMessage data logger is interfaced to three tank level transmitters with analog output signal (4-20mA) and to 3 gas volume conversion devices from VEGA through a Modbus RTU interface.

The functional architecture of application:

The local plant operator is based in the save area and has a local monitoring PC with a ProfiSignal Klicks installation. The operator has the following mimic panel to monitor the performance of the dehydration plant.

With the UMTS router the control room operator at head office has at any time remote access to the data from the TopMessage data logger and can see live data and download data from the logger memory. The data download can be automated by using the scheduler function of the DataService Configurator. The dehydration plant is covered by an EDGE G2 mobile communication network.

The following diagram shows data from of the dehydration plant.

Benefits:

The TopMessage data logger with UMTS router was the ideal solution for this application as all requirements could be covered:

• The TopMessage has a small size of (200 x 118 x 90mm) which make the system handy for an installation in the explosion proof box.
• TopMessage is supporting many serial interface standards so that VEGA Scan EK220 volume conversion units could be interfaced.
• With the UMTS router remote access could be configured.
• The UMTS router is also providing networking functions for local PCs and printers.
• User friendly ProfiSignal Klicks software to develop an operator user interface (mimics) and reporting functions.

For more information please see: TopMessage >>

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Coker Valve Monitoring in the Refining Industry

This customer is world leading in the manufacturer of valve systems for many different industries. The company manufactures ball, needle, control, gate, choke and many other types of valve systems from small to very large diameters.

Application / Problem:

This application is about a very specific data acquisition project. One of the its customer is running a tar sand refinery and uses a special 3 way switching valve in order to control the tar sand flow into the different coking towers. In the past the operation of the valve was not always reliable and caused very costly shutdowns of the refining process.

Proposal / Solution / Hardware:

In order to monitor the correct operation of valve the customers decided to install a Delphin TopMessage data logger to record all data during the valve movement. A TopMessage data logger with an 8 channels ADFT module with synchronously fast sampling analog inputs was selected. The system measures the 3 phase engine current consumption, voltage. The strain sensor measures force and torque during the movement of the valve. The analog inputs are configured for 1 kHz sample rate each. The installed sensors are:

• 1 x Strain gauge for torque measurement
• 3 x Motor current probes
• 1 x Motor voltage transducers
• 2 control circuit voltage transducer

The TopMessage data logging system is installed in an explosion proof box in the EX zone close to the valve control unit. The data transfer is realised through a wireless Ethernet radio.

The internal logic channels of the TopMessage are configured in a way so that the data storage is activated on certain threshold levels of engine current consumption. This in build logic functions allows the user to configure the TopMessage device with event based logging functions.

After the valve has finished its move an event trigger automatically downloads the data from the logger via the wireless Ethernet network to a PC in the central control room for data analysis and post processing with the ProfiSignal Basic software.

The TopMessage data logger is recording all data of each valve movement. The DataService Scheduler is automatically transferring the data to a central PC for data analysis. The data analysis and post treatment is performed with ProfiSignal Basic software. The customer is specifically interested in the engine current consumption and the strain/torque profile during the valve movement. The strain/torque profile and the current consumption give a clear indication if the value is working correctly and if any maintenance action should be scheduled.

Summary / Benefits:

• The Logger has a small dimension which makes the unit ideal for installations in explosion proof boxes with limited space.
• The TopMessage data logger is logging all 7 channels at 1 KHz sample synchronously straight into the 1GB internal logger memory.
• The internal logic channels ensure that only relevant data during the valve movement is logged.
• The scheduler function of the Datservice Configurator software is automatically downloading the data to a PC over the WLAN Network.
• Post processing of Data files to calculate RMS values over current is performed with the ProfiSignal Basic Software.
• The customer has an easy monitoring system to check valve status and schedule preventive maintenance actions before valve operation fails.

For more information please see: TopMessage >>

Gas and oil industry

Preventative Maintenance in Hydro Power Plants

Investments in new very efficient power plants and upgrading existing damps to improve asset utilization, is common practice today.

Company's Inobalt Message devicesare frequently used in hydropower plants for turbine condition monitoring. One integrated system is available to cover the measurements and diagnostic analysis.

The system is efficient, cost effective and reliable. Over 100 units are installed all over the world.

Hydro power – environmental friendly The hydropower industry is an environmentally friendly energy source. With a contribution of 19% to global energy production, hydropower is the largest source of renewable energy. It is ranked fourth in electricity generation and has become an increasingly important mainstay in power production.

It protects our earth's fossil fuel reserves, it is always available, it does not run out, it does not produce waste and it does not add to global warming. From rivers and reservoir lakes, a total of 15 billion MW could be generated annually. Currently only 20% are used. Therefore the demand for hydroelectric power is expected to grow of the next few years.

Areas for Application:

Today the customers require that the plant is operating reliable and continuously with very few downtimes. In order to increase equipment availability a vibration and condition monitoring system is a prerequisite.

Inobalt has an answer to those demanding requirements and provides a comprehensive and flexible system which can be adapted to individual applications.

The message device is acquiring vibration and process signals and PLC / Profibus communi-cation data synchronously. The integrated AMDT/V2 module enables vibration analysis and monitoring in combination with other digital and anlog IO modules from Inobalt.

The devices are easily integrated into the existing company network via an Ethernet connection. The measurement data is than accessible to any department depending on the access rights. The huge advantage of the Inobalt Message devices is that that one comprehensive system covers all measurement, monitoring and alarm management functions. The powerful diagnostic analysis functions give a clear indication of the current status of the hydro turbine and pin points to any area with a rising problem. The early detection of technical problems prevents the system for major damages and gives an indication where to focus on during the next maintenance stop.

The modular concept of the Message devices enables the customers to develop tailor made solutions. The devices can be adapted individually to any number of inputs. The equipment is usually DIN rail mounted and fitted to control cabinets.

Software for Monitoring & Diagnostics

Inobalt offers the ProfiSignal software which provides a full development environment to configure easily individual HMI screens to give the operator in the control room a maximum overview of the equipment status. The powerful software channels inside the device can be used to configure many alarm functions with the ability to switch outputs or to regulate the equipment or to initiate emergency shut downs.

The integrated event channels can report any limit violations e.g. through SMS or e-mail messages. For larger applications it is recommended to configure an Alarm table for a consolidated overview of the plant status.

The device provides an internal data storage capacity of 1 GB with 128 Mio records. The software package provides a convenient analysis through a seamless transition between online and historical offline data. However, for permanent monitoring the online trend plotting and evaluation is most appropriate.

Portable Systems

Inobalt offers also many different products to cover the requirements of the maintenance and commissioning engineers in the hydropower sector. Very popular are the custom-made mobile measurement cases for vibration and process analysis. The system records vibration, process and performance data for the duration of the commissioning and final approval phases. Sensor connectors are available as required with 4 mm plugs, screw terminals and thermo or BNC connectors in common usage. Message devices are protected against earth loops and are therefore secure against errors occurring during data recording. Sensor inputs are true differential and consequently ensure a high level of accuracy.

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Compressed Air Systems Management

In times where energy conservation is a top priority for all progressive enterprises, the measurement of flow rates and consumption is becoming more and more important. However, measurement is just one step forward, in order having a complete picture of the gas and compressed air consumption in a factory a permanent monitoring, an graphical/statistical analyzes and a convenient reporting is required. For this purpose, we propose a solution that will help you to reduce a consumption of gas and compressed air.

Acquiring measurement data

Features

• Communicates with up to 32 remote units (DS 300)
• Communicates through Ethernet, RS-485, RS-485/ Ethernet gateway
• Unlimited recording size (up to maximum files size of windows)
• All sensor values can be displayed online
• User can add his own plant schematics as a background picture to the online screen
• Alarm monitoring and recording of alarm history
• Graphical analyzes of up to 10 channels on one screen and up to 4 different physical units
• Export to MS-Excel
• Optional consumption report generator for convenient reporting and analyzing

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