ICP DAS USA - King Large Scale Machinery

Large-scale Machinery and Equipment Program Profile

System Structure

As the development of today’s coal industry mature, the complexity of the machinery in this field has also grown. Meanwhile, when the coal winning machines breaks down, they requires many manpower and material resources to fix it.

Facing the competition market, manufactures are required to use high-quality products compete and keep up with development of the market. Therefore, it is essential for the coal manufactures to have a complete set of well- operational Service System and it should address the following factors:

1. Real-time monitoring for the condition parameters in a timely manner to carry out corrections to avoid losses

2. Remote monitoring maintenance of equipments to reduce maintenance costs

3. Networking provide high-quality services quickly

Beijing Wellincontrol Technology Development Co,.Ltd's remote monitor/diagnostic system are based on advance Internet technology, provide the powerful visual data analysis and management functions. Regardless of wherever the maintenance personnel may be, they can use visualization management tool to carry on the scene monitoring and failure diagnosis, as well as monitor, analysis and diagnosis the long-range production machine.

Large-scale Equipment Remote Monitoring Solution Characteristics

Key Capabilities

Provide a worldwide monitoring, diagnosis and analysis of solutions for large-scale equipments

Automatic monitoring of unusual trends, online early warning

Based on historical data, user can create mathematical models, equipment and system performance analysis of the statements

Support the operation of the equipment for years of historical data, easily achieve large-scale equipment, remote fault diagnosis and fault handling

Internet-based network deployment, making the program easier to implement

Resume breakpoint to support and data cache, and maintain the integrity of the data

Key benefits

Store-per-second speeds of more than 20,000 points

Search at any given variables or date of historical data (for 10,000 data records) within 5 seconds

Support as many as 256 concurrent clients at once to store and retrieve data

Highly efficient data compression algorithm to minimum of storage space

Powerful computing engine can carry all kinds of statistical computing

Useful and clear comparison, analysis and report

Web Large-scale Equipment Remote Online Monitor and Failure Diagnosis Central System Plan

1.Present Enterprise’s Large-scale Equipment Management Situation

The large-scale equipment units are "heart" of the plant; also it is closely related between the plant’s production safety and stability of the operation. At present many enterprises utilize is the daily inspection & weeklycycleinspects & scheduled preventive equipment running maintenance method. However, this management method cannot solve the issue of "blind overhaul" and the problems within the accident service, thus execution plan had been made to minimize the unnecessary maintenance of the good equipment and may damage the equipment while during this process. When the equipments has minor problems and not being noticed, thus not being fixed immediately, this can lead to bigger problems in the future.

Businesses have to take post maintenance, schedule maintenance and repair plan due to the current equipment condition monitoring and fault diagnosis technology has many limitations:

- Because lack of the real-time monitor’s equipment long-term performance data and the failure diagnosis, early detection of the equipment breakdown indication cannot be applied, as well as the necessary maintenance.

- In equipment failure, maintenance departments cannot be rapidly collects the performance data before and after the failure, therefore it is impossible to analyze the failure’s cause through the historical data.

- Because the equipment manufacturer and the users lack the effective exchange information and communication, therefore the manufacturer doesn’t have any knowledge of the onsite situation. Thus, the manufacturer is unable to provide the proper service for the user (like: supply of spare parts, on-site maintenance instruction etc), and cannot improve product design and manufacturing process. All these have a great impact on the user with the equipments.

In recent years to improve the management and operation of the equipment many enterprises haven taken numerous measurements, such as various types of vibration analyzer, portable diagnosis equipment and on-line diagnostic analysis monitoring system. However, due to the lack of diagnostic methods, deep knowledge of the failure mechanism and technical support, onsite diagnosis experience to integrate the diagnosis system of the inference mechanism effectively, identifying the failure reasons and guidance function, resulted in improper results of the equipment diagnostic and the actual plant maintenance.

2. To improve the Web Large-scale Equipment Long-distance Online Monitor and Failure Diagnosis Central System Plan

To perfect large-scale equipment management, and to allow equipment expert’s technical skills and experience to apply them to a wide range of fields. To do this, experts can use remote monitoring to diagnose the equipments’ problems, thus, the Internet has played a part to allow this to become realities.

Compose of the Web large-scale equipment long-distance online monitor and the failure diagnosis system, long-distance customer data acquisition terminal, historical data library server and the monitor diagnostic center server. By the Internet allow to 24/7 remote monitoring of the large-scale equipment's condition and operating mode parameter, including: equipment's technological parameter (rotational speed, load, power, temperature, pressure, current capacity and so on), the diagnostic analysis the equipment vibrating profile, the frequency spectrum, the axis displacement, the bulge difference, the biased as well as the breakdown frequency characteristic value and so on, allow immediate information of equipment condition anywhere, anytime. Breaks the enterprise and in the manufacturer device management’s blockage, convenient, widely utilizes expert's experience and the knowledge effectively and promote large-scale equipment's monitoring work.

The difference between the usual plant operating parameters with the large units of the equipment running data, such as vibration parameters etc:

- Large amount of data- each time each measuring point needs to college over thousands of data with each unit has 10,000 data

- Real-time high density collection achieves only in milliseconds

- Professional, requires a lot of calculation and analysis to be process, such as the FFT calculation, value extraction, window spectrum adjustment etc

- To ease analyzing massive data are needed by various specialized atlas, like spectrograph, the axle center trajectory diagram, total information spectrogram, the wave chart and etc

---Data Acquisition Layer

Because of the Web's remote on-line monitoring and failure diagnosis system require fast data transfer of large number of data, I/O Server Slaver+ I/O Server Master are acquired in the data acquisition level. Thanks to the large-scale and high fidelity data compression technology, it only requires 1 second to send a group of data to the long-distance monitor diagnostic center (All equipment including all the raw data points, such as the wave spectrum, such as technical parameters).

---Data Storage Processing Level

Industry storehouse server KingHistorian is responsible for receiving real-time data and continuous saving history equipment data. Also, KingHistorian provides historical data compression/restore, management and access, store with more than 20,000 variables per second and can retrieve more than 2,000 historical data.

Relational database preserves a complete state of equipment, equipment maintenance, processing failure, such as data files, equipment for the state of maintenance data because of decision-making. As follows:

- Equipment accounting records management, including: definition encoding equipment, failure code, static equipment, changes in the assets, equipment and technology curriculum vitae cards etc

- Equipment maintenance information management, including: inspection, failure records, maintenance plan (progress, resources, material, investment), project execution, progress confirmation, operation checklist, security shop form, maintenance records etc

- Data library is to build to save the specific operating mode complete state variable for normal operation, start-stop engine or breaks down and etc

- Collection of equipment failure library for future follow-up maintenance

As equipment management personnel analyzing statistic of the equipment key performance data is an important duty. Statistical data production server built-in script development kit and 50 kinds of statistical functions provide the statistical study analysis function and the keen monitor threshold tabulation. Users can specify units, designates the industry storehouse period of time to give the designation unit key through the statistical study to vibrate channel's kind of threshold value.

The easy to use- report form management server provides the report form template design function while it is compatible to Excel format. At the same time, the built-in computation engine can complete the huge report form computation work, rapidly in advance. Report server only needs fixed, time from the historical database and the relational database to read report data result to establish daily report, monthly report, annual report, equipment utilization rate, unplanned downtime, such as statistics and a series of statements to be upload onto the Web server. Then the report server can also automatically send these statements to the specified customers' email.

---Encyclopedia Web Display Layer

Superview Portal content management server’s flow chart picture editor provides a full range of exquisite gallery and animation industry connection wizard. Programming not requires being able to design lifelike dynamic interface visual images. Through the presente in figures and diagrams contact surface, opens, stops the process as well as the normal work process to the united equipment carries on the continuous monitoring and the real-time analysis. Superview Portal’s flow chart images not only can monitor equipment’s real-time running status, it can also examine the equipment history performance data, accumulation running time, start-stop times, the warning analysis etc.

Superview Portal content management server provides historical playback function, using industrial library's current and long-term preservation of historical data to recalls the equipment breakdown periods (before and after) images. Just like watching a video, the failure’s cause and solution can be easily analyzed.

Superview Portal content management server bases on the actual need of the plant equipment maintenance to rational design of a variety of data input and retrieval interface, for example: draws up various equipment to vibrate the essential data and the warning standard, limiting value, determine the classification of equipment, test parameters, frequency, prepare documents to guide operations, review the state of maintenance equipment, daily maintenance of records, online analysis of the failure records, equipment file, technical information, and other statements, satisfies equipment operation staffs’ needs who needs to know the condition of the equipments.

Superview Portal content management server provides wealthy diagnostic atlas. The special-purpose vibration analysis graph is a transient equilibrium computational procedure, with the intelligent synthesis diagnosis and other analyzing tools. Provide the speed, vibration wave, spectrum, frequency doubling of the amplitude and phase characteristics of the failure, and other data into an easy-to-diagnosis and an analysis of the vibration characteristics spectrum map, such as map, time base /Orbit chart, spectrograph etc to all levels of diagnostic equipment maintenance personnel with the vibration analysis and failure diagnosis.

Superview Portal based on role jurisdiction management establishes the jurisdiction that in the workflow, limit members to transmit the right information to the right person.

Superview Portal content management server provides an advanced B/S structure's WEB browser mode, void the need of equipment management personnel and to external diagnostic expert does to arrive personally to examine field scene by using Internet real-time and the historical data. Allow business to make the right equipment unit operation and maintenance, anywhere and anytime. The B/S structure of the Superview Portal content management server maintenance update is also very convenient; this can be done on the Web server and without the need to upgrade client side, reduce maintenance costs significantly.

Superview Portal content management server also provides that function like: discussion area, bulletin board, material downloading etc. Results in the strengthening of the communication of the diagnosis maintenance personnel, business and equipment manufacturers, promote information-sharing and experiences exchanging, and advance device management and diagnosis maintenance levels.

b. Significance of the System

- Through the graphical interface, remote real-time data display devices and operating trends; Automatic monitoring of the abnormal development, apply online alarm, render alarm report, immediate failure notice and other services.

- Large-scale and high fidelity data compression technology allows numbers of device's key parameters to transmit quickly and save to remote central data library for unified data management.

- Inquiry equipment's historical trend curve to perform equipment performance diagnose; playback past device's operation status, equipment failure to carry out complex analysis of the current diagnosis to apply replicate diagnosis on the equipment failure.

- Provide on-site equipment operation data with a comprehensive analysis and data processing, automatic calculation of key statistical data on equipment operation, and automatic operation of various types of summary statements. Offers business timely, accurate and intelligent data analysis and management tools.

- Pre-judgment of the equipment spare parts information, establishes promptly, efficient maintenance service system.

- Use collected long-term monitoring data and analysis, provide basis for the implementation of plant equipment condition-based maintenance, provides valuable analysis and suggestion for the equipment overhaul work.

- Allow sharing of the equipment's real-time and historical information by professional personnel, and be able to have a timely and comprehensive understanding of the equipment operation. Instantly, remote conference can be setup by the professional personnel to provide maintenance strategy and discover early warning equipment failure.

- Use of mass historical data warehouse's to complete equipment performance data, establishes the precise mathematical model, comprehensive analysis of actual on-site equipment operation to improve the equipment's design and manufacturing process.

- Advance, unique Web-based customer service system offers quick and professional responding.

- With B/S distributed remote failure diagnosis system allow field engineers and technical service center experts to quickly and efficiently corporate to solve the issue.

- Around the world technical service center through the WAN provides a platform for resources sharing and data analyzing. Constitute a global network of technical services consisting of global experts' knowledge and experience to solve emergency situations. Solving difficult problems, raise different national region's technical personnel and service engineer's technical level. Provide a globalize customer intelligent diagnosis service.