PROAC IVE Diesel Generator Health Monitoring system (DGHMS)

Product overview Why continuous monitoring is crucial?

The DGHMS is a compact, rugged data acquisition and control
system. It is an ideal system for continuous monitoring of critical Parameter if not
Consequence
monitored
operating parameters of a generator system and automated
control of its operation based on signals received from the PC . Cooling water Excessive expansion of components
temperature/pressure resulting in failure
The system is designed where continuous availability of power is a
Wear and scale formation
critical requirement such as manufacturing industries, large
commercial complexes, hospitals, techparks, Theatres The system Crank case pressure Engine block blow off
provides direct connectivity to many sensors such as strain gauge, Wearing of piston rings/ cracks in
thermocouples, thermistors, piezoelectric transducers among
piston crown
others.
Possible explosion of the engine

System architecture Exhaust gas Burning of exhaust valves resulting

ANALOG
TEMPERATURE
temperature in damage to turbocharger
DIGITAL
Excessive damage to piston
COUNTER
TIMER and cylinders
SENSORS

DIESEL GENERATOR SET MEASUREMENT SIGNAL CONDITIONING STAND ALONE REAL TIME SYSTEM Bearing temperature Crankshaft seizure
SIGNAL/SENSORS /ACTUATORS DATA ACQUISITION MODULES WITH INBUILT CONTROLLER AND
MEMORY FOR DATE STORAGE
Lube oil temperature/ Overheating of piston top and seizure.
The Scope of our system includes pressure
Ÿ Continuous monitoring of parameter
Ÿ Data logging and display Engine speed Connecting rod bushings, rod
Ÿ Raising alarms when the DG set malfunctions bearings, main bearings could be
Ÿ Emergency shut down (ESD) damaged
Ÿ Extendibility of current implementation
Automated control of components based of requirements. Wear/ Tear in fuel line, Results in slow and steady damage to
Condition monitoring of component vibrations, turbocharger the machinery
displacement, wearing among others.
Data Acquisition modules Bearing clearance Large impact on vibration and noise
The modules used for data acquisition is offers wide range of
of machine
flexibilities for desktop, portable, industrial, and embedded
Avoid misalignments in
applications with a variety of major buses and form factors
shafts, blocks or connecting rods
including USB, PCI, PCI Express, PXI, PXI Express, wireless, and
Ethernet.

Compact DAQ Compact RIO PCI/USB/Ethernet

Ÿ Plug-and-play simplicity of USB to Ÿ Small, rugged embedded control and Ÿ Data transmission over dedicated
sensor data acquisition system high-speed serial lanes.
Ÿ Fast and accurate measurements in a Ÿ Featur es embedded r eal-time
Ÿ Provides high-speed, dedicated
small, simple, and affordable system processor for reliable stand-alone or
distributed operation bandwidth to devices in the system.
Ÿ Combining the ease of use and low
Ÿ Integrates an embedded FPGA chip Ÿ Simplified Remote monitoring
cost of a data logger
t h a t p r o v i d e s t h e f l e x i b i l i t y,
Ÿ Performance and flexibility of modular per formance, and reliability of
instrumentation. custom hardware.
Ÿ Exploits PLC ruggedness and PC
functionality under an open, flexible
software architecture.

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 Application software
The Health Monitoring System Software designed using LabVIEW is
a robust one having high precision data acquisition capabilities,
powerful data logging and control. The software has been
customized to a degree that provides the users with a flexible
interface to the systems.

Features of DGHMS
Graphical system Design environment Easy and flexible GUI for interpretation of results

Ÿ Readily accessible advanced engineering functions. Ÿ Custom diagrams which creates a virtual representation
Ÿ Provides direct interface with several third party instruments. of the machine on site.
Ÿ Code can be easily tailored and reused for many applications. Ÿ Historical data logged onto system can be viewed in the
Ÿ Professional user interfaces with exhaustive range of controls. form of graphs, charts, XY graphs.
Ÿ Alarm descriptions in front of the user as soon as
generator malfunctions.

Allows monitoring on the LAN and Web Reduce Breakdown through Predictive Maintenance

Ÿ Efficient use of Publish-Subscribe-Publish (PSP) protocol in
labVIEW enables monitoring on LAN
Ÿ Any number of users can simultaneously monitor the system
while a single user can control the system at a particular time
instant.
Ÿ Continuous monitoring of vibration, displacement, speed
characteristics of the machine helps schedule a well planned
maintenance activity

General technical specifications

Data acquisition device Miscellaneous features

Ÿ Analog input General measurement from transducers. Ÿ Highest performance RS232 and RS485 serial interfaces for
communication with industrial devices.
Thermocouple or millivolt, 2-, 3-, or 4-wire RTD, Built-in signal
conditioning between channels, 50 and 60 Hz noise rejection, 16-bit Ÿ Modules to communicate over Fast Ethernet, Wide Ultra SCSI.
resolution, Input ranges configurable in software for each channel,
2,300 Vrms bank isolation for transient, Overvoltage protection, -40 to
Ÿ High resolution ADC's make it well suited for audio and vibration
analysis applications.
70 °C operating range. the machine
Ÿ Capable of measuring high-speed strain and voltage inputs creating a
Ÿ Digital I/O - Monitor proximity and limit switches, pushbutton switches,
ideal platform for automotive applications.
thermostat outputs, relay closures, power circuits, and TTL devices,
control indicator lights, external relays, and CMOS and TTL devices. Ÿ Intelligent diagnostics and maintenance.
Programmable power-up states and digital I/O watchdogs for safe
operation in control applications, 5, 30, and 60 V digital I/O devices with Ÿ Industrial specifications for harsh environments.
various options for optical isolation, Change detection to trigger a read
operation automatically when a digital line changes state, Control and Ÿ 50 g shock, 5 g vibration, -40 to 70 °C.
optimize the machine
Ÿ Analog Output - To control valves, gauges, and other industrial actuators
Voltage, current outputs, and current sinks, 12 or 16-bit resolution
Up to 1 MS/s waveform generation on multiple channels,
8 or 16 digital I/O lines

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