24/02/2015

Data Analysis

Scheme of work and assessment plan - update

Topic
Date

17:45h - 19:15h

03/02

Introduction to Unit

Failure and breakdown

10/02

Failure and
breakdown

Monitoring

24/02

Data analysis

Data analysis

03/03

Vibration

Unit 24 Assignment
Review

10/03

Leak detection

Corrosion and Crack

detection

17/03

Temperature

Review

24/03

Review

Assignment Review

19:30h - 21:00h

31/03

Easter break

07/04

Easter break

Assessm
ent

Out

Data Analysis
Data analysis:
computerised systems
data acquisition techniques
use of generic computer software (such as spreadsheets,
databases)
fault analysis/diagnosis
plant down time analysis
data storage techniques
high-speed data capture
trend analysis
expert systems
condition monitoring integrated within normal plant and
machinery control
data acquisition systems

Data Analysis
Manual Systems

Data Analysis
Computerised Systems

Avoid unplanned downtime Early

failure detection helps avoid
unplanned machine downtime, and
effectively solves runnability
problems. Rolls, bearings, gears and
other drive train components produce
low-level signals at an early stage
when a fault is developing, but is not
yet apparent to operators or
maintenance personnel.
The Sensodec 6S system can
immediately detect even these early
signs of defects with sensitive highquality vibration sensors designed for
monitoring in a paper machinery
environment. Fast measurement
cycles, speed-adaptive alarm
handling and advanced analysis tools
make these signs fully apparent to

Data Analysis

Overview shows that a warning (yellow) in two points in one of

the briquetting machines. The 24 month trends show that
vibration level in 1000-3000 Hz range has slowly risen
compared to the red alarm limit line.

Metso specialist Aarno Kernens analysis of this spectrum

showed why the vibration level has increased, there are clear
bearing fault harmonics around 1300-1900 Hz.

Data Analysis

Data Analysis

Data Analysis

Data Analysis

Data Analysis
Sources and systems
Data acquisition begins with the physical phenomenon or physical
property to be measured.
Examples of this include temperature, light intensity, gas pressure, fluid
flow, and force.
Regardless of the type of physical property to be measured, the physical
state that is to be measured must first be transformed into a unified
form that can be sampled by a data acquisition system.
The task of performing such transformations falls on devices called
sensors.
A data acquisition system is a collection of software and hardware that
lets you measure or control physical characteristics of something in the
real world. A complete data acquisition system consists of DAQ
hardware, sensors and actuators, signal conditioning hardware, and a
computer running DAQ software.

Data Analysis
A sensor, which is a type of transducer, is a device that converts a
physical property into a corresponding electrical signal (e.g., strain
gauge, thermistor).
An acquisition system to measure different properties depends on the
sensors that are suited to detect those properties.
Signal conditioning may be necessary if the signal from the transducer is
not suitable for the DAQ hardware being used. The signal may need to
be filtered or amplified in most cases. Various other examples of signal
conditioning might be bridge completion, providing current or voltage
excitation to the sensor, isolation, linearization.
For transmission purposes, single ended analog signals, which are more
susceptible to noise can be converted to differential signals. Once
digitized, the signal can be encoded to reduce and correct transmission
errors.

Data Analysis
A sensor, which is a type of transducer, is a device that converts a
physical property into a corresponding electrical signal (e.g., strain
gauge, thermistor).
An acquisition system to measure different properties depends on the
sensors that are suited to detect those properties.
Signal conditioning may be necessary if the signal from the transducer is
not suitable for the DAQ hardware being used. The signal may need to
be filtered or amplified in most cases. Various other examples of signal
conditioning might be bridge completion, providing current or voltage
excitation to the sensor, isolation, linearization.
For transmission purposes, single ended analog signals, which are more
susceptible to noise can be converted to differential signals. Once
digitized, the signal can be encoded to reduce and correct transmission
errors.

Data Analysis
Data acquisition and control systems need to get real-world signals into
the computer. These signals come from a diverse range of instruments
and sensors, and each type of signal needs special consideration.
Some data acquisition techniques:
Voltage signals (voltage, conditioned transducer, level and flow
measurement)
High impedance probes (concentration measurement)
Current signals (current and conditioned transducer
measurement)
Power signals (power supply, current and voltage measurement)
Thermocouples (temperature measurement)
Resistance (temperature, displacement and light level
measurement)
Strain gauge bridges (strain measurement)
Excitation (force, pressure, relative humidity, temperature, level,
light level, concentration and vibration measurement)
LVDTs (displacement measurement)
Encoders (angular position measurement)
Counter-Timers (speed and flow measurement)
Digital signals (on/off measurement)

Data Analysis
Analog I/O card:
Up to 64 Input Channels per Board
Programmable Sampling Rates to 50M SPS
GPS Synchronization
Auto-Calibration
Multi-Board Synchronization
Sigma-Delta and Delta-Sigma Analog I/O
Resolutions from 12 bits to 24 bits
IEPE Compatibility

Data Analysis
Manual Data Acquisition (Measurements)
Automatic Data Acquisition
Analog-to-Digital Converters (ADCs) transform an analog voltage to
a binary number (a series of 1s and 0s), and then eventually to a
digital number (base 10) for reading on a meter, monitor, or chart.
Accuracy vs. Resolution of ADCs
ADC Accuracy vs. System Accuracy

Data Analysis

The straight line in each graph represents the analog input voltage and the
perfect output voltage reading from an ADC with infinite resolution. The step
function in Graph A shows the ideal response for a 3-bit ADC. Graphs B, C, D, and

Data Analysis
Sampling
Nyquist Theorem: Transforming a signal from the time domain to the
frequency domain requires the application of the Nyquist theorem. The
Nyquist sampling theorem states that if a signal only contains
frequencies less than cutoff frequency, fc, all the information in the
signal can be captured by sampling it at a minimum frequency of 2 fc.
This means that capturing a signal with a maximum frequency
component of fmax requires that it must be sampled at 2 fmax or
higher.
However, common practice dictates that while working in the frequency
domain, the sampling rate must be set more than twice and preferably
between five and ten times the signals highest frequency component.

Data Analysis
Sampling

Data Analysis
Signal Filtering

Data Analysis
Digital Filtering

Data Acquisition Techniques

Case Study

Data Acquisition Techniques

Case Study

Data Acquisition Techniques

Case Study

Data Acquisition Techniques

Case Study

Data Analysis
Data analysis:
computerised systems
data acquisition techniques
use of generic computer software (such as spreadsheets,
databases)
fault analysis/diagnosis
plant down time analysis
data storage techniques
high-speed data capture
trend analysis
expert systems
condition monitoring integrated within normal plant and
machinery control
data acquisition systems

Data Analysis
Data analysis:
computerised systems
data acquisition techniques
use of generic computer software (such as spreadsheets,
databases)
fault analysis/diagnosis
plant down time analysis
data storage techniques
high-speed data capture
trend analysis
expert systems
condition monitoring integrated within normal plant and
machinery control
data acquisition systems

Data Analysis
Data analysis:
computerised systems
data acquisition techniques
use of generic computer software (such as spreadsheets,
databases)
fault analysis/diagnosis
plant down time analysis
data storage techniques
high-speed data capture
trend analysis
expert systems
condition monitoring integrated within normal plant and
machinery control
data acquisition systems