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National Instruments Products for Oil and Gas Condition Monitoring

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Overview

This document addresses the main components of oil and gas condition monitoring and presents National Instruments monitoring solutions. Oil and gas monitoring encompasses monitoring for 

control applications as well as preventive measures. Preventive monitoring is necessary to extend life cycles, schedule maintenance, and predict fault conditions. The following list of preventive

monitoring types covered in this document is not an all-encompassing list. Depending on your application, you may need to use other types of preventive monitoring.

Table of Contents

Overview of Oil and Gas Condition Monitoring Systems

Hardware - Measuring the Physical Signals

Software - Data Recording and Processing

Overview of Oil and Gas Condition Monitoring Systems

The oil and gas industry is at the forefront of technology adoption as it looks for new ways to access and refine ever more hard to reach oil supplies. With this increase in technology, however,

comes an increase in the number of critical machines used in exploration, production, transport, and refinement. Condition monitoring offers the ability to reduce cost of ownership for these critica

machines by predicting failures before they occur, which allows proper maintenance to be effectively scheduled.

 An oil and gas condition monitoring system is built around the asset being monitored, with the measurements chosen based on the parameters most likely to indicate failure. A typical block diagr

for an oil and gas condition monitoring system is shown in Figure 1. Sensors and hardware are used to acquire physical signals, and then software is used to analyze these signals into a

meaningful machine condition and predict failure.

Figure 1. Block Diagram Showing a Typical Oil and Gas Monitoring System

Hardware - Measuring the Physical Signals

You can measure a variety of physical signals off your assets of interest, from vibration and strain to temperature and oil quality. By measuring these different signals together, you can generate a

better picture of the assets state.

National Instruments offers two main platforms for reading in the signal from these different sensors: C Series and PXI. C Series is an industrial, portable form factor that is ideal for distributed

monitoring or portable diagnostics. PXI offers a higher-performance, higher-channel-count system for use in test setups or much larger monitoring systems.

C Series PXI

Rugged operating spec (temperature and shock)

4- to 32-channel systems

Portable or fixed implementation

USB or Ethernet based (NI CompactDAQ or CompactRIO)

Embedded processing, storage, and control

Sample rates at more than 50 kS/s per channel

High performance and processing

High-channel-count systems (500+)

Solid-state hard drives for rugged data storage

Ethernet, Modbus, RS232, and many other industrial buses

Sample rates at more than 200 kS/s per channel

 

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Use the to build your own systemCompactRIO Advisor  embedded

Use the to build your own systemNI CompactDAQ Advisor  portable

Use the to build your own systemPXI Advisor  high-performance, high-channel-count

Vibration

Vibration monitoring is one of the most important aspects in oil and gas monitoring because it helps determine the condition of rotating equipment. This is especially important for pumps,

compressors, drills, and various types of turbomachinery. Depending on the application's frequency range, you can use either position sensors (0 to 36,000 CPM), velocity sensors (36,000 to

60,000 CPM), or accelerometers (60,000+ CPM) for measuring vibration. These sensors are rigid mounted to the asset and return an analog voltage signal proportional to the instantaneous motio

they sense. For more information on accelerometers, read the Sound and Vibration Transducers Guide.

For rotating equipment, the sensor data must undergo order analysis to display vibration signals in terms of the harmonics of the asset being monitored. These harmonics provide insight into the

performance of various components of the machine and allow for easier diagnosis. For more information on order analysis and signal processing, read the Software section below.

 Additionally, vibration measurements can be made on nonrotating equipment, usually to indicate unexpected movement on pipelines or other static assets. By measuring vibration, you can predbe alerted to, and quickly react to any changing conditions that may threaten your asset.

To measure a vibration sensor, your data acquisition device should have

High sampling rates to fully capture the vibration signature

High dynamic ranges to detect small vibration changes

Simultaneous sampling on all channels so data can be directly compared and phase matched

 Antialiasing filters to prevent unexpected vibration measurements

For measuring vibration, National Instruments offers two major platforms that meet all of the above requirements.

C Series

For industrial distributed and portable systems

PXI*

For high-performance, high-channel-count systems

NI 9234

51.2 kS/s

102 dB dynamic range

4 simultaneous channels

2 mA IEPE excitation

NI PXIe-4496

204.8 kS/s

114 dB dynamic range

16 simultaneous channels

4 mA IEPE excitation

*Note: You can choose from a variety of PXI modules for these applications. For higher-channel-count and even better performance options, click .here

Oil Lubrication Quality

Oil is a key component in wind systems because improper lubrication can reduce efficiency and cause increased friction, resulting in heat and increased vibration that lead to mechanical failure.

Most bearing and gear wear results from incorrect oil lubrication. Monitoring of oil lubrication usually consists of oil contaminant particle counting and moistness measurements.

You can use oil particle counting to determine the quality of oil and verify the existence of contaminants. These contaminants can come from either dirt and grit introduced into the system or from

metal shavings and other particles that corrode and break off internal machine parts. Contaminant particles cause excessive wear, initiate rolling element bearing fatigue, and clog filters. Particle

counters usually communicate with the RS232 protocol.

Moisture measurements indicate the amount of water contamination in oil lubrication, which causes premature component failure and oxidization of the oil lubricant. Oil moisture sensors return the

measurements through either an analog voltage or current or, similar to the particle counters, through RS232.

For measuring oil quality with both RS232 protocol and voltage input, National Instruments has the following offerings.

 C Series

For industrial distributed and portable systems

PXI Express*

For high-performance, high-channel-count systems

RS232 ProtocolNI 9870

4 RS232 serial ports

NI PXIe-8430

8 RS232 serial ports

Voltage Input

NI 9205

-10 to 10 V analog input

32 single-ended or 16 differential inputs

NI PXIe-6341

-10 to 10 V analog inputs

16 analog input channels

Current Input

NI 9203

-20 to 20 mA analog input

8 analog input channels

NI PXI-6236

-20 to 20 mA analog input

4 analog input channels

*Note: You can choose from a variety of PXI modules for these applications. For higher-channel-count and better performance options, click .here

Strain

Strain measurement is largely used for structural monitoring in the oil and gas industry. The large structures holding up various oil and gas assets are critical to the performance of the machines

they carry and can serve as a warning of an out-of-balance machine.

For measuring strain, National Instruments offers two major platforms that meet all of the above requirements.

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C Series

For industrial distributed and portable systems

PXI*

For high-performance, high-channel-count systems

NI 9237

50 kS/s

4 simultaneous channels

Quarter-, half-, and full-bridge completion (with NI 9944/45)

Selectable excitation

NI PXIe-4330

25 kS/s

8 simultaneous channels

Quarter-, half- and full-bridge completion built in

Programmable excitation per channel

*Note: You can choose from a variety of PXI modules for these applications. For higher-channel-count and even better performance options, click .here

Acoustic

 Acoustic monitoring is increasingly used to detect gas leaks in pipes. When high-pressure gas leaks into the atmosphere, the pressure differential creates a high-velocity flow with a unique acou

signature both in the air and in the solid material making up the pipe. There are measurable frequencies created in both the audible frequency band (12 to 20 kHz) and in ultrasonic frequencies

above the normal range of human hearing. Being able to detect these leaks and respond to them quickly not only saves product but also is a significant safety issue.

 A microphone sensor has many of the same data acquisition requirements as an accelerometer:

High sampling rate to fully capture the vibration signature

High dynamic range to detect small vibration changes

Simultaneous sampling on all channels so data can be directly compared and phase matched

 Antialiasing filters to prevent unexpected vibration measurements

For measuring acoustics, National Instruments offers two major platforms that meet all of the above requirements.

C Series

For industrial distributed and portable systems

PXI*

For high-performance, high-channel-count systems

NI 9234

51.2 kS/s

102 dB dynamic range

4 simultaneous channels

2 mA IEPE excitation

NI PXIe-4496

204.8 kS/s

114 dB dynamic range

16 simultaneous channels

4 mA IEPE excitation

*Note: You can choose from a variety of PXI modules available for these applications. For higher-channel-count and even better performance options, click .here

Temperature

Temperature is another measurement that you can use for preventive and predictive maintenance. When machines begin to fail, they often have increased friction, which is converted to heat. Heais not only a signature of machine failure but also a contributor to further failure.

You can measure temperature with a variety of sensors, but the most common sensors are thermocouples and resistance temperature detectors, or RTDs. These sensors often require signal

conditioning because of their low output ranges. An ideal data acquisition device for temperature sensors should have

 Amplification to increase the low output range of the sensor 

Cold-junction compensation to convert the relative sensor readings to an absolute temperature

50/60 Hz noise rejection, which eliminates environmental noise

For measuring temperature, National Instruments offers two major platforms that meet all of the requirements above.

C Series

For industrial distributed and portable systems

PXI

For high-performance, high-channel-count systems

NI 9211 or 9213

16 thermocouple channels

Built-in cold-junction compensation

24-bit ADC for 0.2 °C measurement sensitivity

NI PXIe-4353

32 thermocouple channels

8 built-in cold-junction compensation channels

24-bit ADC for 0.2 °C measurement sensitivity

 

Summary

The following is a summary of the recommended NI C Series and PXI modules for the various measurements that could be required by an oil and gas condition monitoring system.

  C Series PXI

Vibration NI 9234 NI PXIe-4496

Oil Quality (RS232) NI 9870 NI PXIe-8430

Oil Quality (Voltage) NI 9205 NI PXIe-6341

Oil Quality (Current) NI 9203 NI PXI-6236

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Strain NI 9237 NI PXIe-4330

 Acoustics NI 9234 NI PXIe-4496

Temperature NI 9211 NI PXIe-4353

Use the to build your own systemCompactRIO Advisor  embedded

Use the to build your own systemNI CompactDAQ Advisor  portable

Use the to build your own systemPXI Advisor  high-performance, high-channel-count

Software - Data Recording and Processing

LabVIEW

For oil condition monitoring, NI LabVIEW software combines advanced signal analysis with a user-defined GUI (graphical user interface). Additionally, LabVIEW provides the tools for all of the dat

acquisition from the various NI hardware platforms and can even perform data logging and database communication.

LabVIEW offers the flexibility of creating a monitoring system that is perfect for your application while providing all of the standard processing features you find in any other analysis environment,

such as statistical analysis, fast Fourier transform (FFT), and root-mean-square (RMS) measurements.

To learn more about using LabVIEW for condition monitoring, view the webcast .Using LabVIEW for Embedded Condition Monitoring and Machine Protection

Sound and Vibration Measurement Suite

For more advanced analysis than that provided by LabVIEW, take advantage of the NI Sound and Vibration Measurement Suite. This suite offers order analysis, waterfall plots, envelope analysis

and more add-ons to LabVIEW. To learn more about the Sound and Vibration Measurement Suite, click .here

Figure 2. Orbit Plot and Analysis in LabVIEW

Figure 3. Waterfall Plots for Run-Up and Run-Down Analysis

 

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