System Overview

AN6800 system - unit vibration online monitoring and analysis fault diagnosis system, is a set of high-speed, fully automatic machine operation status of the online monitoring system. It is mainly used for condition monitoring of large rotating machinery (steam turbine generator sets, hydro turbine generator sets, compressor units, water pumps, fans, motors, etc.) in the industrial field. Through the real-time collection and analysis of the vibration signal and related status parameters of the unit, the system can identify the status of the unit in time, find the early signs of failure, and judge the cause of the fault, the severity of the fault, and the development trend of the fault, so as to eliminate the hidden danger of the fault in time and avoid the occurrence of destructive accidents.

System composition

The AN6800 system consists of a data acquisition server (sensor, analog-to-digital AD conversion), an upper-level analysis computer (engineer station), a database server, monitoring, analysis and diagnosis software, and a remote networking system.

The system has the characteristics of distributed data acquisition and centralized control and management through the network, and a number of monitoring equipment on the site are respectively arranged with data acquisition servers (one unit and one collection system), which are transmitted to the database server (one database server in one factory) through the network。 The on-site data acquisition server and the display and analysis terminal are completely separated, and the on-site data acquisition server can automatically collect data, record the main status parameters related to equipment security, and transmit them to the display terminal for graphical analysis of the data. The entire system is network-integrated and integrates real-time data acquisition and processing, online data analysis and storage, expert support, and troubleshooting. Users can diagnose the operation of the unit in advance through the system, and find and solve the abnormal phenomena caused by the unit during operation, such as rotor imbalance, misalignment, bearing damage, frame looseness, shaft bending, shaft cracking, etc.

System structure

The AN6800 system consists of a field acquisition service section located at the front, and a remote display terminal analysis section connected to the factory LAN. Various sensors installed on the site convert and transmit the physical signals of the unit status to the data acquisition box, which collects and analyzes the signals, and then sends the digital signals to the database server located in the central control room. Operators can directly observe the real-time data transmitted from different units, and can also analyze the status of the data from the database server and diagnose faults. The results of the analysis and diagnosis will be released through the network, and the engineer, chief engineer and relevant leaders of the plant can understand the operation status of the unit through the workstation connected to the network. The remote display analysis and diagnosis terminal can also analyze, diagnose and study the operating status of the plant unit through the results transmitted over the Internet.

System features:

The system has a multi-user distributed structure, users can remotely log in, remotely control, and conduct real-time monitoring, data acquisition, analysis and diagnosis of the units running on site.

The system has real real-time, and the system can continuously and dynamically monitor, record, analyze and store the mechanical status of the unit, establish files for the long-term operation and change trend of the unit equipment, and automatically form a comprehensive database of the unit status.

Synchronous sampling: The synchronous sampling design is introduced to make the measurement results of each channel synchronously comparable, so that the correlation between the measurement signals is clearer, and the reliability of the analysis results is higher.

Automatic recording of dynamic processes: The system can automatically capture and store transient processes such as opening, stopping, load shedding, and accident shutdown, and automatically analyze their parameters.

Concise output interface: graphic display interface, concise and easy to understand, data calculation, analysis and other complex problems in the background of the system, so that the operator can get rid of the difficulty of understanding advanced knowledge, simplify the use of the system.

Highly reliable software platform: The Windows 2000/XP operating system and SQL2000/2008 database are advanced and reliable. The system is networked, and users can see real-time monitoring results at workstations anywhere on the intranet.

It can manually set various parameters to ensure the normal operation of the system, and meet the needs of adding and modifying monitoring parameters in the future without changing the software.

Data management: The condition monitoring software uses Microsoft's SQL Server large network database to manage and store the collected data, and the system data can be backed up or restored at any time. Advanced database technology and data management level are synchronized with the international level. Due to the use of open network database, users can monitor and analyze the running status of the machine at any terminal of the network, the accuracy of data acquisition is high, the time of data collection is accurate to milliseconds, and the data storage depends entirely on the capacity of your hard disk.

Trend analysis: It can analyze the trend of any one or more parameters relative to a certain parameter.

Vibration analysis: Powerful vibration analysis functions, including time domain analysis (waveform diagram, total vibration diagram, trend diagram, shafting simulation, axis trajectory diagram, bar diagram, status list), frequency domain analysis (spectrum diagram, waterfall diagram, side frequency, frequency doubling, frequency band alarm, etc.), variable speed analysis (Bode diagram, polar diagram, cascade diagram) and comparative analysis, etc.

Compensation and frequency doubling analysis, the system provides you with graphical compensation analysis (the compensated graph will automatically remove the defects of the shaft itself, which is conducive to the analysis of vibration by experts), frequency doubling analysis, the system provides you with graphical analysis of various frequency doublings, and experts can determine which direction of the shaft may have failed according to the change of phase and amplitude.

1. Fault diagnosis: online diagnosis and offline diagnosis are used to automatically diagnose common faults of equipment.

2. Event list: record the details of alarm events and switch events.

3. Report printing: provide printing function for all kinds of charts.

4. Graphic magnification, restoration and roaming, which can be clearly analyzed.

5. The interface is flexible, supports 4-20mA and relay output, supports Modbus RTU/TCP protocol, OPC protocol, and can be easily connected with the system of the third-party manufacturer on site.

6. Provide dynamic balance calculation and expert diagnosis system.