NI LabVIEW and CompactRIO Keep Power Plants Online

Author(s):
Boris Meško - VESKI
Ozren Orešković - VESKI
Ozren Husnjak - VESKI

Industry:
Energy/Power

Products:
Real-Time Module, CompactRIO, LabVIEW, FPGA Module, Software

The Challenge:
Developing a cost-effective and reliable system to monitor power plant machinery in Croatia.

The Solution:
Using VESKI’s Computerized Diagnostic System (CoDiS) monitoring software with National Instruments LabVIEW and CompactRIO to provide a continuous, LAN-compatible vibration monitoring system.

Mechanical vibrations can be detrimental to rotating mechanical components, in many cases severely reducing a machine’s operability and longevity. The continuous monitoring of vibrations and other signals is critical to predicting mechanical behavior and efficiency and usually requires continuous data acquisition and online database analysis.

VESKI, a Croatian-based consulting firm that specializes in vibration analysis and diagnostics, relies on NI LabVIEW and NI CompactRIO at the core of its CoDiS monitoring software.

When we were hired to develop a software solution that would help 11 Croatian power plants reduce the cost of generator maintenance and repair, we turned to LabVIEW and CompactRIO to build a customizable system.

Machine Monitoring and Diagnostics 

Online monitoring systems are especially necessary in power production plants, where they are used to predict malfunctions and identify irregularities in system performance. These systems can also be used to streamline routine maintenance, and thus prevent long-term and costly damage.

We installed CoDiS on more than 30 power generators throughout Croatia and Slovenia and in Lagarfoss, Iceland.  Modern industrial monitoring systems typically need features that collect data on vibration, temperature, pressure, and flow, while simultaneously maintaining accurate database management. We designed CoDiS to monitor vibrations of rotors, stator and foundations dynamics, air-gap conditions, electrical exploitation processes, power quality, and hydraulic quantities of large rotating machines. CoDiS is modular, adjustable, and can be designed and customized according to the user’s needs. The entire application is based on LabVIEW, with all analysis and database procedures created and adjusted for customized online monitoring and data acquisition.

The system depends on CompactRIO for simultaneous diagnostic functions and protection.

CoDiS consists of four components.

CoDiS-DM (permanent Diagnostic Monitoring system)

• CoDiS-TR(Transient Recorder)
• CoDiS-RT (conventional Real-Time monitoring for signaling and protection systems)
• CoDiS-RM (permanent diagnostic Rotor Monitoring)

CoDiS-DM	CoDiS-TR	CoDiS-RT	CoDiS-RM
Diagnostic Monitoring	Transient Monitoring	Conventional Monitoring	Rotor monitoring
Continuous acquisition, analysis, and database recording	Continuous acquisition and trigger analysis recording according to trigger	Continuous acquisition, analysis, and D/A conversion Protective functions	Continuous acquisition and analysis of signals on rotor Wireless transfer of all signals from rotor to stator
Implementation	Implementation	Implementation	Implementation
Detection and measurement of permanent condition change	Transient recording and detection	Application in signaling and protection systems	Application in signaling and protection systems

System Configuration

With CompactRIO and National Instruments FieldPoint, we were able to build a highly configurable system while achieving high performance and reliability. CompactRIO is powered by reconfigurable I/O (RIO) FPGA technology, functioning simultaneously as a condition monitoring and protection unit.

This monitoring system consists of:

• A measuring component, which includes all sensors and hardware used to acquire data
• A signal conditioning component
• A CompactRIO processing unit with a PDA local control unit used for data acquisition and analysis
• A central computer that houses a permanent database and analysis procedures for remote LAN users

 The system also includes communication with SCADA systems using analog or fieldbus output. 

 CoDiS includes permanent monitoring and diagnostics of:

• Relative shaft vibration
• Absolute vibration of bearing
• Axial position of rotor
• Air gap minimum values                                                                 
• Rotor pole magnetic flux
• Electrical parameters such as current and voltage
• Phase symmetry, power angle
• Total harmonic distortion (THD)
• Static and quasistatic parameters
• Temperatures and process parameters
• Hydraulic parameters (efficiency, η)
• Active and reactive power

Condition Monitoring and Protection Unit Installed in High Pressure Pumps -  Lagarfoss Island

The CompactRIO system is configured to monitor relative shaft vibration and rotation speed, while also providing overspeed protection. The system monitors two hydrogenerator units, where each generator set uses CompactRIO as a process unit.

 

Each monitoring set consists of:

• Six displacement sensors used for relative shaft vibration
• Two displacement sensors used for rotation speed
• One 9201 module for data acquisition
• Two NI 9265 analog output modules for trending of measured signals in SCADA
• One NI 9481module as an executive part of protection
• NI cRIO-9002 with a cRIO-9101 embedded, reconfigurable chassis

The CompactRIO system monitors:

• Six analog input signals in volts (three bearings in two axes, X and Y)
• Two analog input signals in volts (redundant overspeed protection)
• Six analog current output signals (SCADA trending)
• Four relay digital output signals, two for each direction (alarm and trip)

All relevant data, including waveforms and analysis results, are available as shared variables over a shared network. VESKI has been able to reduce the cost of maintenance and repairs in these power plants by up to 50 percent using NI products.

 

Author Information:
For more information on this Case Study, contact:
Boris Meško
VESKI
Ulica Dragutina Golika 63
Zagreb HR-10000HR
Tel: +38513667133
Fax: +38513667155
veski@veski.hr

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