This application note describes how a custom data logging system from CAS DataLoggers helped an oil refinery significantly reduce the time required for leak detection in large catalytic reactor bundles.

Challenge:

As part of the normal maintenance process the refinery relied on manual pressure testing of hundreds of small tubes within a large reactor bundle. This process was time-consuming and inefficient, requiring technicians to quickly identify leaks amidst a large number of tubes. Because the refinery had to be taken off-line for this testing, downtime during maintenance sessions resulted in significant production losses.

Installation:

CAS provided two dataTaker DT80 Intelligent Universal Data Loggers each equipped with 2 Maple Systems remote touchscreen displays and 2 pressure transducers. This allowed for simultaneous testing of 4 different reactor bundle quadrants.  To perform the test, a technician at one end of the bundle would insert a plug with the pressure sensor in a specific tube then the technician at the other end would pressurize the corresponding tube. As the reactor tubes were pressurized, the dataTakers monitored the pressure and gave technicians a continuous readout of the value on the Maple display. After the tube’s pressure stabilized, users were notified and then simply pressed ‘Start’ on the display to begin the pressure data recording and a count-down timer. Users could then quickly identify leaking tubes simply by watching the pressure displays: whenever a tube’s pressure read below a lower limit when the timer expired, the alarm in the datalogger triggered, indicating a leak. As part of the program, the logger provided an identifier of the failed tube # by row and column.

Benefits:

• Real-time Pressure Monitoring: Technicians received continuous pressure readings during tube pressurization.
• Automated Leak Detection: Configured alarms notified users upon pressure drops below a set limit, indicating a leak.
• Tube Identification: The system displayed row and column data for each tube, pinpointing the exact location of the leak.
• Streamlined Workflow: Technicians could easily initiate and stop data collection for each tube test using dedicated buttons.
• Progress Tracking: The displays provided overall maintenance progress tracking.
• Data Logging and Reporting: All collected data was automatically labeled and saved for later analysis.

Results:

The data logger system significantly reduced the time needed for leak detection, leading to:

• Reduced Downtime: Maintenance sessions were completed in half the time compared to manual testing.
• Cost Savings: Minimized downtime translated to thousands of dollars saved in lost production.
• Improved Efficiency: Technicians could quickly identify and address leaks with real-time data and clear tube identification.

Conclusion:

By implementing the dataTaker DT80 data loggers, the refinery achieved faster leak detection, improved maintenance efficiency, and reduced downtime, resulting in substantial cost savings.

For more information on dataTaker data loggers, or to find the ideal solution for your application-specific needs, contact a CAS DataLoggers Application Specialist at (800) 956-4437 or request more information.

The post Streamlining Leak Detection Monitoring In Catalytic Reactors appeared first on CAS Dataloggers.

Real-Time Data Collection for Analog, Digital and CANbus Applications

In the automotive industry, Drive-by-wire (AKA X-by-wire) technology has replaced many traditional mechanical control systems with electronic and electro-mechanical control systems including brake-by-wire and electronic throttle control. This has resulted in improved safety and ergonomic designs along with more options in commercial cars. Drive-by-wire systems require rigorous testing and data collection, and for these applications CAS DataLoggers offers ADwin Real-Time Data Acquisition Systems. German manufacturer Jager-ADwin’s systems log signals from Analog and Digital sensors along with CANbus interfaces—all in real time. For more information call CAS DataLoggers at (800) 956-4437 today.

Drive-By-Wire Technology in Today’s Cars:

Modern automotive mechatronic systems employ a complex network of sensors to quickly determine the driver’s intention and to continually check system conditions. Increasingly, automotive designs use contactless sensor solutions to increase both the reliability and availability of mechatronic systems. The inductive measuring principle has proven to be highly suitable for this type of data collection application.

Here position sensors are of central importance. With this sensor technology, the momentary position of accelerators, throttles, leveling systems or turbochargers are reliably determined, all while undergoing demanding industrial environmental test conditions.

Analog, Digital, or CAN–ADwin Keeps Overwatch

The use of the various signal outputs provided by these position sensors depends on the specific measurement task or on the specific manufacturer.
For example, data can be collected from:

• Analog signals (ratiometric, current, voltage)
• Digital signals (PWM)
• CAN bus interfaces

The synchronicity of the data on all these outputs and interfaces is a key criteria in automotive production and development. To accomplish this, many users employ ADwin data acquisition and control systems which are expressly designed for automotive applications.

As a common example in a test environment, ADwin controls a stepping motor for the set point positioning and simultaneously acquires the reference position by an incremental encoder along with all signal outputs of the sensor under test. As an example, ADwin evaluates the time relation between the arrival of a CAN message, an analog signal output, and the reference position value, and then checks for compliance with the specified values. Thus the system can immediately calculate how well the DUT matches the required specifications.

ADwin: Real-Time Data Acquisition:

ADwin benefits:

• High-speed data acquisition can measure transients
• Easy to use
• Quick development time

ADwin systems can be configured individually in order to meet all test specifications.
ADwin data acquisition and control systems are commonly used for automotive test applications for ECUs and other CANbus devices, for actuators, sensors, combustion engines, field bus systems, and many more.

ADwin-light-16 and ADwin-Gold systems are low-cost solutions for applications with few I/O channels and limited expansion or configuration requirements. In contrast, the modular and expandable ADwin-Pro system is recommended for applications with many channels and flexible configurations.

ADwin applications always run in real time. ADwin’s strictly deterministic functioning principle with response times as short as 300 ns ensures that no information gets lost in testing of X-By-Wire components. This is due to the system design which incorporates a local CPU, additional analog and digital interfaces, and expansion options.

Data Analysis:

The PC can access the results on the ADwin system for further analysis and data logging. Since programming in ADbasic is simplified, users quickly gain a clear insight into their components under test. ADwin’s external SDRAM stores the recorded post-test data which has significant value to:

• ECU Manufacturers
• Systems integrators
• 3rd-party Testers

ADwin systems perform all the necessary tests and also perform post-test data analysis. Test information and measurement data is transferred to a control system and displayed on the PC through a graphical user interface (GUI). This is done via Ethernet or a Fieldbus interface. On production lines, a programmable controller is typically connected via Profibus, Interbus, CAN, serial interfaces etc. The ADwin automatically generates a table of the data and this information can then be stored as quality records in the production database.

The post Drive-by-Wire Testing Using ADwin Systems appeared first on CAS Dataloggers.