On-Line Vibration Monitoring Systems

On-Line Vibration Monitoring SystemsOn-Line Vibration Monitoring Systems

Presented by:

Timothy S. Irwin, P.E.Senior Rotating Machinery Engineer

M&B Engineered Solutions, Inc.13 Aberdeen WayElgin, SC 29045

Email: [email protected]

17 February, 2006

M&B ESITimothy S IrwinFebruary 2007


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 onlya portion of what is availableon the market.



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 protectionor 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 informationthat may lead to an appropriate justification for an appropriate level of monitoring.

• What is the equipment reliability history?

What we need to do is set a goal or target for the desired system and then usethe following information to develop the specific details, for anything put a full-blown protection system some of the following information may not apply.



Justification for On-Line Monitoring:

• Safety – Inaccessible or dangerous area?

• Hazardous Systems – Would failure of the machine cause a hazardoussituation?

• 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 withanalysis capabilities significantly improve the monitoring and analysis?

• Consistency & Repeatability – Are there reasons that are causing difficultywith 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 secondsto once per day. This type of system is not typically used forequipment protection but is used for alert and danger alarmsfor operations personnel and machinery monitoring and diagnostics.



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Polling

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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

• Velocity Coils

• Speed Reference

• Phase Reference

• Some process parameters may also be appropriate



What parameters do we want?



Ron Patrick’s Jet Powered Beetle



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 wantin 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?



Monitor details and options continued:

• 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?



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





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

Standards Continued:

• 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



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 canthink of, do a little digging and you may find a piece of the puzzlethat you were missing.



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

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

How do we get what we want installed?



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



What do you mean I can’t do this?!

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



Technical Specification

• Transducers – The specification may include but not be limited to:

• Temperature range

• Amplitude Range

• Frequency Span

• 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




• 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

• Depending on how the project is broken down the Owner, Contractor, and Vendor will all have different responsibilitieswithin the project.




• 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



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.



What about the vendor support of their product?

• What kind of warranty are you getting? Are there extension options?

• What kind of hardware/firmware/software updates are available to you?

• Does the vendor have any kind of field service available?

• Does the vendor work with your desired Contractor?

Without the proper documentation up front everyone’s job later will be more difficult and less efficient.


THE END

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On-Line Vibration Monitoring Systems