Online monitoring systems VI 02 2007

On-Line Vibration Monitoring Systems 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 On-Line Vibration Monitoring Systems Some of today s subject items: What kind of monitoring system we need? Do we need protection? Or we need only monitoring? What options are available for monitoring systems? What kind of failure modes 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? What we need in a specification to get what we want? M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems There are a lot of options available today This is only a portion of what is available on the market M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems What kind of different permanent monitoring systems are available? Continuous Polling monitors signals from transducers continuously 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 M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems Equipment Classifications: Is the equipment expensive to repair or replace? Will equipment failure immediately affect operation/production of the plant? Will equipment failure affect operation/production of the plant after some time? Will equipment failure create an unsafe condition (EHS)? What is the equipment reliability history? 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 M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems Justification for On-Line Monitoring: Safety Inaccessible or dangerous area? Hazardous Systems Would failure of the machine cause a hazardous situation? Sampling Frequency Would a failure happen too fast to catch with routine monitoring? Manpower Is there just too much too monitor? 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? M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems Continuous vs Polling: What are the differences and why 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 M&B ESI Timothy S Irwin February 2007 AM AM AM AM AM AM AM AM AM AM AM AM AM AM AM AM AM AM AM AM AM AM AM Time 10:04:02 AM 10:03:40 AM 10:03:51 AM 10:03:30 AM 10:03:08 AM 10:03:19 AM 10:02:46 AM 10:02:57 AM 10:02:35 AM 10:02:13 AM 10:02:24 AM Continuous 10:02:02 AM 10:01:40 AM 10:01:51 AM 0.5 10:01:29 AM 10:01:07 AM 10:01:18 AM Continuous 10:00:45 AM 10:00:56 AM 1.5 10:00:34 AM 2.5 10:00:12 AM 10:00:23 AM Am plitude (Mils) 10:00:01 AM 10:00:01 10:00:12 10:00:23 10:00:34 10:00:45 10:00:56 10:01:07 10:01:18 10:01:29 10:01:40 10:01:51 10:02:02 10:02:13 10:02:24 10:02:35 10:02:46 10:02:57 10:03:08 10:03:19 10:03:30 10:03:40 10:03:51 10:04:02 Amplitude (Mils) On-Line Vibration Monitoring Systems Continuous vs Polling: Polling 2.5 1.5 seconds 10 seconds minute 0.5 Time M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems 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? high-speed, etc sleeve bearings, REBs, gears, pumps, low-speed, The answers to the above question will determine the appropriate transducers Non-Contact proximity probes Accelerometers Low, high, standard frequencies Velocity Coils Speed Reference Phase Reference Some process parameters may also be appropriate M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems What parameters we want? M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems Monitor details and options continued: Does the monitor have a local indication for verification of the remote indication? 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? Are there any system or alarm log capabilities in the monitoring system? Does the monitor have process parameter capabilities? M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems Software details and options: Can look at live or historical data Has configurable data collection and storage Has configurable historical data archive capabilities Has expansion capability for future needs Can store a new data sample at any time 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 M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems 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 M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems Standards Continued: 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 M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems 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, a little digging and you may find a piece of the puzzle that you were missing M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems Now that we have covered: 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 How we get what we want installed? 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 software M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems 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 M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems What you mean I can t this?! Without proper monitoring you may end up with parts that look like this! M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems Technical Specification Transducers The specification may include but not be limited to: Temperature range Amplitude Range Frequency Span Linear Range if a proximity probe Any size constraints Does it need to be a right angle cable connection Mounting connections for all transducers M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems Technical Specification Monitoring System could include but not be limited to: Desired modules radial vibration, thrust position, speed, phase reference, etc Equipment protection relays or only monitoring Frequency span requirements Filtering option requirements Do you require local indication for operators Do you want any self-test features Type of communication requirements to site DCS or LAN Simultaneous sampling capability Short-circuit protected test connections M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems 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 M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems Technical Specification Documentation 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 M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems Without proper documentation at installation how 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 M&B ESI Timothy S Irwin February 2007 THE END ANY QUESTIONS? M&B ESI Timothy S Irwin February 2007 ... 10:01:40 10:01:51 10 :02: 02 10 :02: 13 10 :02: 24 10 :02: 35 10 :02: 46 10 :02: 57 10:03:08 10:03:19 10:03:30 10:03:40 10:03:51 10:04 :02 Amplitude (Mils) On-Line Vibration Monitoring Systems Continuous vs... ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems What parameters we want? M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems Ron Patrick s Jet Powered... on alarm M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems M&B ESI Timothy S Irwin February 2007 On-Line Vibration Monitoring Systems Are you in an industry or process