Online monitoring systems VI 02 2007

M&B ESIWhat kind of different permanent monitoring systems are available?. Continuous monitors signals from transducers continuously Polling Samples signals from transducers on a pre-arr

Presented by:

Timothy S Irwin, P.E.

Senior Rotating Machinery Engineer M&B Engineered Solutions, Inc.

13 Aberdeen Way Elgin, SC 29045 Email: tsi@mbesi.com

17 February, 2006

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What kind of monitoring system do we need?

What options are available for monitoring systems?

Do we need protection? Or do we need only monitoring?

What kind of failure modes do we need to monitor?

Would it be appropriate to reference any industry standards?

What type of monitoring/diagnostic software are we

or would we be using?

Some of today s subject items:

What do we need in a specification to get what we want?

There are a lot of options available today This is only

a portion of what is available

on the market

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What kind of different permanent monitoring systems are available?

Continuous monitors signals from transducers continuously

Polling Samples signals from transducers on a pre-arranged schedule

Switches or Transmitters Sends a signal to the control system

Permanent transducers with remote connections for monitoring/diagnostics

Another differentiating item is whether the system provides equipment protection

or is purely for monitoring

So to determine what level of monitoring we need, we need to know

what kind of equipment the system will be installed on.

Equipment Classifications:

Is the equipment expensive to repair or replace?

Will equipment failure immediately affect operation/production of the plant?

Will equipment failure create an unsafe condition (EHS)?

Will equipment failure affect operation/production of the plant after some time?

Answers to the above questions will supply you with the some of the information

that may lead to an appropriate justification for an appropriate level of monitoring.

What is the equipment reliability history?

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Justification for On-Line Monitoring:

Safety Inaccessible or dangerous area?

Hazardous Systems Would failure of the machine cause a hazardous

situation?

Manpower Is there just too much too monitor?

Sampling Frequency Would a failure happen too fast to catch with

routine monitoring?

Varying Conditions Do varying conditions make route monitoring

difficult to analyze?

Monitoring and Analysis Efficiency Would a permanent system with

analysis capabilities significantly improve the monitoring and analysis?

Consistency & Repeatability Are there reasons that are causing difficulty

with consistency or repeatability?

Continuous vs Polling:

What are the differences and why do we consider them?

Continuous:

Monitors the desired parameters on a continuous basis and can

typically be set up to trip the machine under preset conditions

within milliseconds to several seconds as desired

Polling:

Monitors the desired parameters on a pre-arranged schedule,

the polling of the parameter can typically be set from seconds

to once per day This type of system is not typically used for

equipment protection but is used for alert and danger alarms

for operations personnel and machinery monitoring and diagnostics

Once the level of monitoring is determined (continuous or polling),

which parameters should be monitored?

We answer that with another question:

What kind of component failures are possible?

What is in the machine? sleeve bearings, REBs, gears, pumps, low-speed,

high-speed, etc.

The answers to the above question will determine the appropriate transducers.

Non-Contact proximity probes

Accelerometers Low, high, standard frequencies

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What parameters do we want?

Ron Patrick s Jet Powered Beetle

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Once the monitoring parameter details (i.e transducer types and numbers)

are determined the actual monitor details can be developed

Various monitor details and options:

As a diagnostic oriented professional, let s take a look at what we want

in a monitoring system This should be for any system whether it is

Continuous or Polling

Does the monitor have a buffered output for every channel?

Does the monitor have a buffered output for connecting portable instruments?(i.e this is a short circuit protected test connection)

Does the monitor have optional filter settings?

Does the monitor have the necessary frequency span/amplitude range?

Does the monitor/modules have the proper transducer options?

Does the monitor collect multi-channel simultaneous data?

Does the monitor have self-test features?

Can modules be replaced or removed from the monitor while powered?

Can individual channels be turned off when there are known problems

to minimize false indications?

Does the monitor supply an output to a DCS or other remote location?

Can it also supply trip relays for automated protection?

Is the monitor capable of supplying data to a diagnostic software program?What is the overall signal output of the monitor peak, true-peak, rms?

Does the monitor have a local indication for verification of the

remote indication?

Are there any system or alarm log capabilities in the monitoring system?

Does the monitor have process parameter capabilities?

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Software details and options:

Can look at live or historical data

Has configurable historical data archive capabilities

Has expansion capability for future needs

Can store a new data sample at any time

Has configurable data collection and storage

Has desired plotting capabilities

Configurable alarm settings

Demodulated or Enveloped tool is available

(with multiple bandwidth options)

Multi-channel simultaneous sampling capability

Has alarm ability for bad data or channel problem

Extended Data collection on alarm

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Are you in an industry or process that requires or uses any of the

standards that are presently in place?

American Petroleum Institute (API):

API 670 Machinery Protection Systems

International Standards Organization (ISO):

ISO 2954:1975 - Mechanical vibration of rotating and

reciprocating machinery Requirements for instruments for

measuring vibration severity

ISO 5348:1998 - Mechanical vibration and shock Mechanical

mounting of accelerometers

ISO 8042:1988 - Shock and vibration measurements

Characteristics to be specified for seismic pick-ups

ISO 7919 Mechanical vibration of non-reciprocating machines

Measurements on rotating shafts and evaluation criteria

Part 1: General guidelines

Part 2: Land-based steam turbines and generators in excess of

50 MW with normal operating speeds of 1500 r/min, 1800 r/min,

3000 r/min and 3600 r/min Part 3: Coupled industrial machines

Part 4: Gas turbine sets

Part 5: Machine sets in hydraulic power generating and pumping plants

ISO 13373-1:2002 - Condition monitoring and diagnostics of machines Vibration condition monitoring Part 1: General procedures

ISO 13373-2:2005 - Condition monitoring and diagnostics of machines Vibration condition monitoring Part 2: Processing, analysis and

presentation of vibration data

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Standards Continued:

American Gear Manufacturers Association (AGMA):

AGMA 6000 B96 Specification for Measurement of Linear

Vibration on Gear Units

What else is there?

The fact is that there are standards on nearly anything you can

think of, do a little digging and you may find a piece of the puzzle

that you were missing

The type of machinery that we want to monitor

The type of monitoring (i.e transducers) that is appropriate

The type of monitoring system that is appropriate

It is time to put details into the project Will the monitor go into an existing cabinet or need a new one?

Will site personnel install the transducers and wiring?

Someone will have to work with IT to get the outputs to the DCS or softwareHow do we get what we want installed?

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It is time to write a technical specification

The more detailed the technical specification, the more likely it is that:

You will have the monitoring system that will be functional, reliable, and

with the tools that will make your diagnostic efforts more successful

The installation of the system will be successful and completed in a

timely manner

What kind of details are we talking about?

Everything that we have discussed

Without proper monitoring you may end up with parts that look like this!

Any size constraints

Does it need to be a right angle cable connection

Linear Range if a proximity probe

Mounting connections for all transducers

Monitoring System could include but not be limited to:

Desired modules radial vibration, thrust position, speed,

phase reference, etc

Frequency span requirements

Filtering option requirements

Do you require local indication for operators

Do you want any self-test features

Equipment protection relays or only monitoring

Type of communication requirements to site DCS or LAN

Simultaneous sampling capability

Short-circuit protected test connections

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Technical Specification

Installation

Generally site/corporate procurement has site conditions and contractor

requirements documentation, but someone still has to put together the

technical requirements for the installation This could include:

Physical description of installation:

Into existing cabinets

Installation of new cabinets

Wiring installation

Transducer installation general locations

Owner and Contractor responsibilities

Monitor Operation and User Manuals

Transducer System Specification Sheets

Electrical installation drawings

One line drawings

Cabinet installation drawings

Logic drawings

Transducer installation drawings

Bill of materials with all replacement part numbers

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Without proper documentation at installation how do you

accomplish the following?

Verify installation locations of the transducers

Verify calibration of the transducer systems

Verify calibration of the monitors

Troubleshoot any identified problems

Without the proper documentation and

materials up front everyone s job later will

be more difficult and less efficient

ANY QUESTIONS?