Prognost Nt En

7232019 Prognost Nt En

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PROGNOSTreg-NT Safety Protection and Online Condition Monitoring

for Rotating Equipment

Automated Diagnosesand Messaging

Scalability PerformanceOptimization

Operating Condition Recognitionand Threshold Adjustment





Contents

Introduction 4

Proven by experience 5

PROGNOSTreg-NT system overview and capabilities 6Asset Performance Management 6

PROGNOSTreg-NT 6

PROGNOSTreg-NT modules profiles 7

System scalability 8

Diagnostic capabilities 9

PROGNOSTreg-SILver 10

Machine Condition Visualization (VISU) 11

Safety Analyses 12

Early Failure Detection 13

Wear Monitoring 14

Performance Optimization 14

Lubrication Monitoring 14

Process Data Analyses 15

Component Tracking 15

Tech Corner ndash Advanced technologies 16

Why vibration monitoring 16

Automated p-V diagnoses 17

Monitoring of compressor components 18

Piston rod and Plunger 19

Crosshead 20

Cylinder and Packing lubrication 20

Crankshaft bearings 20

Crankshaft 20

Process problems 21

Discharge and Suction valves 21

Rider rings and Piston sealing rings 21

Packing 22

Cylinder liner and Compression chamber 22

Monitoring of centrifugal equipment 23System scalability 24

Data acquisition and SIL 2-certified safety protection 24

Signal Plausibility Check 24

Ringbuffer 24

Sensor positions 25

Sensor types and uses 25

Sensor signals and positions 25

Signal analyses and display 26

Conclusion 26

3



PROGNOST Systems started monitoring reciprocating

compressors more than 25 years ago The first commercial

installation was realized in 1990 Today PROGNOSTreg-NT is

monitoring all kinds of rotating machines all over the world

Over the years PROGNOST Systems has developed an exces-

sive customer orientation that is re1047298ected in our continuous

dialog with our customers and their in1047298uence in our RampD

process Our Customer Support repeatedly gets very good

Introduction

marks for compentence responsiveness and supportiveness

within our annually conducted Customer Satisfaction Survey

according to our ISO 9001 certification

We will continue to strengthen our market position and

maintain our brand to be the No 1 supplier for Asset Perfor-

mance Management systems for all rotating equipment

4



A reliable full-featured monitoring system requires a solid

number of installations and many years of field experience

No amount of ldquolaboratoryrdquo testing can re1047298ect the condi-

tions of the actual operating environment ndash much less the

characteristics of many different operating environments

over extended periods of time What assurance do you have

that your monitoring system will perform as promised How

much confidence do you have in the accuracy of the diag-

noses your system generates

Insist that your vendor documents the amount of time their

system has been in actual use in operating locations Deter-

Proven by experience

mine the amount of time in which the vendor has resolved

problems and implemented user suggestions from the field

in order to refine the performance of their monitoring sys-

tem Ask for references Contact as many of them as possible

Better still visit user sites whose environments most closely

match your own Input from vendor representatives is useful

However uncensored comments from genuine users are

invaluable in deciding whether a prospective system will

meet your expectations

Just ask us We look forward to bring you in contact with the

PROGNOST User community

5



PROGNOSTreg-NT System overview and capabilities

PROGNOSTreg-NT

PROGNOSTreg-NT is an automated machinery diagnostic

system incorporating safety protection and online condi-

tion monitoring It is developed specifically for reciprocating

machinery but is also used for different kinds of rotating

equipment It detects impending failures at an early stage

and assigns the affected components Operation-critical

damages are avoided and maintenance measures can be

performed effi ciently

A full Asset Performance Management system owns a total

approach in terms of machine condition monitoring with

emphasis on safety protection and early failure detection

Precise detection of irregularity is accomplished by captur-

ing a complex combination of signals and analyzing them in

a way that allows even minor changes to be recognized By

detecting slight changes and understanding their con-

sequences early failures are detected ndash and false alarms

are avoided This type of in-depth intelligence demands a

monitoring system that has been perfected through 25 years

of field experience

Additional features like permanent monitoring of wearparts such as piston rider rings or the integration of DCS

values eg temperatures help to maximize machinery up-

time and minimize maintenance efforts

Asset Performance Management

6



PROGNOSTreg-NT modules profiles

Data Acquisition amp Safety Protection PROGNOSTreg-SILver ndash SIL 2-certified protection hardware

Safety Analyses Transient data recording for alarms or user events and visualization

of online signals and trends

Early Failure Detection Monitoring of critical components automatic pattern recognition

Wear Monitoring Trend based monitoring of wear parts

Performance Optimization Automated p-V diagram analyses for optimizing compressor effi ciency

and detection of leakages

Lubrication Monitoring Continuous monitoring of cylinder and packing lubrication

Process Data Analyses DCS data analyses and trending visualization with PampI diagram

Component Tracking Maintenance planning tool component lifetime registry

Visualization Signal visualization machine status online and trend data logbook

7



System scalability

As your needs change and your experience with this system

grows it is likely that you wish to extend coverage to other

machines

Think Big ndash Start Small

PROGNOSTreg-NT is scalable in two ways First it is function-

ally scalable allowing new or additional capabilities such

as measuring loops or diagnostic modules to be added

to an installed system without inordinate cost or diffi culty

Second PROGNOSTreg-NT is scalable in magnitude In other

words this system offers the expansion of monitoring to

additional machines This allows a simple cost-sensitive

pathway for growth

Turn key PROGNOSTreg-NT system ndash completely assembled

configured tested and ready for shipping

8



Diagnostic capabilities

PROGNOSTreg-NT does not solely indicate problems but also

provides an accurate diagnosis with specific component

identification location and indication of the extent of dam-

age Equipped with this information you can make well-

founded decisions about the maintenance procedures you

need to take and the time you need to take them

PROGNOSTreg-NT Swift for temporary and periodical monitoringapplications eg initial machine start-up or after compressor

overhauls or regular short-term measurements eg every 3 month

9



Signal Plausibility Check ndashAvoiding alarms caused by instrumental

PROGNOSTreg uses specialized signal processing to avoid false

alarms caused by electrical or hardware failures such as bro-

ken or loose wires short circuits or broken terminals Even

out-of-range signals are identified and indicated as ldquoUNSAFEldquo

Users are informed about any ldquoUNSAFErdquo loop immediately

Data acquisition and SIL 2-certified safety protection The vital role of a protection system to reduce the risk of

serious damages is covered by PROGNOSTreg-SILver This

hardware has proven its effectiveness and reliability on a

daily basis worldwide and in different process environ-

ments PROGNOSTreg-SILver is the only machinery protection

system for reciprocating machinery with a SIL 2 certificate

(IEC 615082010) for all shutdown loops connected (max 68

loops) The intelligent combination of vibration dynamic rod

position dynamic cylinder pressure and temperatures analy-

ses provides the most reliable shutdown parameters in the

industry The PROGNOST Systems invention of ldquoSegmented

Vibration Analysisrdquo and a unique algorithm ensure fast reli-

able machine shutdown and no false alarms

PROGNOSTreg-SILver gives you a stand-alone safety protec-

tion system but also convenient wiring options for the data

acquisition of PROGNOSTreg-NT

PROGNOSTreg-SILver

PROGNOSTreg-SILver 19rdquo hardware for various installation options

eg cabinet frame mounting wall mounting housings

PROGNOSTreg-SILver in Ex-housing for field installation (Ex-zone)

optional without cooling

10



Signal visualization machine status online and trenddata logbook

PROGNOSTreg-NT Visualization is much more than a ldquodata

displayrdquo software It allows active access to all kinds of signals

analyses and logbook entries User-friendly design of func-

tions views and data access enables even untrained users

to receive status information of the machine with just a few

clicks All of our customers enjoy the logical and easy way

to investigate waterfall diagrams alarm logbooks and trend

views Supported with audio replay functions for vibration

measurement and easy data export to standard Offi ce soft-

ware you find the most comprehensive tool set for diagnosis

Machine Condition Visualization (VISU)

Vibration signal segmentation

3D trend p-V diagram with automated effi ciency analysis

Machine status view in the ldquoOneClick Cockpitrdquo

Logbook with all alarms machine starts and stops

11



Visualizes the Safety Protection analyses performed

by PROGNOSTreg-SILver eg online signals trends and

safety limit violations

Reliable safety protection hardware is only one side of the

story Answers as to ldquowhyrdquo a safety incident occured is the

next step further PROGNOSTreg-NT Safety Analyses is a mod-

ule to visualize and save online and trend data to provide all

information required for precise root cause analysis

Ringbuffer

Transient data recording allows to replay all monitored

signals as time waveform during a safety shutdown alert or

machine start-up by examining a gapless recording in an

uncompressed format ndash revolution by revolution The ring-

buffer offers this possibility of subsequent analyses the time

frame of seven minutes before and three minutes after the

ALERT SHUTDOWN or UNSAFE alarm can be closely evalu-

ated using all recorded time signals from all dynamic sensors

and process values in the PROGNOSTreg-NT system

Safety Analyses

Peak-to-Peak analysis of the piston rod position (operational run out)

Monitoring the following components(Legend see page 19 and following)

0

15

30

45

60

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

TDC

BDC

TDC

0

10

20

30

40

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

1 2 3 4 5 6 7 8

RD Stage 1 Peak-Peak over 8 Seg 45 degrees

degree crank angle

degree crank angle

12



bull Avoidance of costly damages through identification of

mechanical defects at an early stage

bull Information instead of data clear text messages with

local and functional clarity

With its dedicated analyses PROGNOSTreg-NT detects de-

veloping damages at an early stage providing users with

valuable lead time for proactive machine operation manage-

ment and effi cient maintenance planning

Automatic detection of operating conditions

PROGNOSTreg-NT recognizes changing machine operating

conditions and automatically switches to corresponding

pre-defined threshold sets to avoid false warnings caused by

changing load conditions

Automated threshold setting

Using the automated threshold setting the system can easily

be configured for new operating conditions to guarantee

high quality of warnings

Early Failure Detection

Pattern recognition with fully integrateddiagnostic database

All PROGNOSTreg-NT users benefit from experiences of more

than 425 million recip operating hours annually and more

than 25 years of diagnostic experience All major failure

modes are integrated within a failure pattern database

and can be diagnosed automatically providing clear text

messages including failure type and location of the failing

component The diagnostic capabilities are a blend of the

most reliable and useful soft computing disciplines ndash from

Fuzzy Logic to Rule Based

Online vibration signal and segmented analysis for one crank revolution

-40

-30

-20

-10

0

10

20

30

40

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

0

05

10

15

20

25

30

35

40

45

50

55

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 15 16 17 18 19 20 21 2 2 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36

TDC BDC TDC

CHS 1 RMS valuesvia 36 Seg 10 degrees

Monitoring the following components

13



bull Quantified and exact display of wear development

bull Accurate planning of maintenance activities is

supported and eased

PROGNOSTreg-NT Wear Monitoring provides wear trend plots

of critical components Thus development from normal wear

to threatening damage becomes recognizable The operator

is advised by threshold violations and therefore wear-based

damages become predictable and avoidable As a result the

number of machine stops decreases as well as the number

of replaced components because components can be oper-

ated over their full wear potential

Machine outages to perform periodic manual inspections

can be avoided when an accurate means to quantify remai-ning rider band potential is continuously available

Reliable and meaningful piston rod position

PROGNOSTreg-NT uses the full revolution of the piston rod

position signal to provide a precise piston rider ring wear

calculation The dynamic rod position signal is also used to

monitor the mechanical condition of the piston rod and its

connections Used as a protection parameter for automatic

shutdown it is the only method to detect cracked piston

rods before they fail

Wear Monitoring

bull Continuous measurement of lubricant volume

based on 1047298ow rate

bull Long-term and short-term trend analysis of individual

measuring pointsbull Passive measuring sensors usable in hazardous areas

With this application any number of lubrication lines can

be equipped with PROGNOSTreg-NT Lubrication Monitoring

sensors to monitor the 1047298ow rate These sensors are ideally lo-

cated near the injector to get information about lubrication

quantities The 1047298ow rate of the individual lubrication points

is monitored by trend analysis and changes become visible

at an early stage Blockages or leakages are identified before

they cause component failures

Lubrication Monitoring



bull Improving operative effi ciency and reducing

energy consumption

bull p-V diagram analysis for performance and

condition monitoring

Measuring dynamic cylinder pressures PROGNOSTreg-NT

evaluates the effi ciency and condition of a compressor and

its sealing elements The continuous and automated p-V dia-

gram analyses detects impending valve failures most reliably

Apart from p-V diagram analyses the following additional key

values are calculated monitored and recorded in the logbook

Performance Optimization


bull Analyses of the compression cycle

bull Piston rod load

bull Piston rod load reversal

These data analyses provides operators and maintenance

personnel with all information that is required for an opti-

mized operation of reciprocating machinery

See also page 17

14



bull Communication through use of standard interfaces

for data exchange

bull Display and threshold monitoring of defined

DCS values as trendsbull Definition of operating conditions with

DCS parameters avoiding false warnings

This module establishes a direct communication between

DCS and PROGNOSTreg-NT When operating conditions of

the compressor are changing eg speed or pressure these

changes are re1047298ected within the PROGNOSTreg-NT analyses to

avoid false warnings Conversely status messages from Safety

Protection or Early Failure Detection modules are forwarded

to the control room personnel for further actions Information

exchange is realized with standard interfaces Modbus RTU

OPC or Profibus The module also offers the possibility of dis-

playing DCS data as graphic trends and continuously compar-

ing these trends with warning threshold values

Process Data Analyses

bull Demand-based planning and tracking

of all maintenance activities

bull Logging of component real-time running hours

for a comparison of spare part lifetimes

This module supports predictive maintenance strategies

with an effi cient tool for planning and tracking mainte-

nance activities along with real-time component lifetime

information Users receive all information required running

time of individual components (based on actual machine

run-time not on installation date) and a timeline displaying

all planned and realized maintenance activities Further-

more expected dates for replacement of wear parts can be

configured

Component Tracking

Component history installation date and operating hours


15



The most important and well established technique for

machine monitoring is vibration analyses However not all

vibration analyses are the same Seemingly minor differ-

ences in data acquisition and evaluation strategies have

dramatic impact on the quality of signal diagnoses Choos-

ing the proper mathematical evaluation method is the key

to reliable Early Failure Detection and Safety Protection Re-

ciprocating machinery has specific vibration characteristics

eg vibration peaks during valve opening and closing which

must be taken into consideration to avoid false alarms

Segmentation

Monitoring systems should continuously acquire and

diagnose machine vibrations for each revolution and then

segment signals into crank angle-related portions This al-

lows harmless but sometimes erratic machine behavior to

be rightly identified as a ldquogood conditionrdquo ndash thereby avoiding

false alarms

PROGNOST Systems invented the ldquoSegmented Vibration

Analysisldquo and thus determined that it is the best approach

to subdivide the 360deg of one revolution into 36 segments of

10deg crank angle each This is the most accurate proportion of

an average impact width related to one revolution Vibration

signals must be evaluated using the most accurate mathe-

matical analysis For reciprocating machinery only RMS (Root

Mean Square) analysis has proven reliable RMS analysis is

superior because it considers not only amplitude but also

the energy content of an impact

Why vibration monitoring

Tech CornerAdvanced technologies

-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

crosshead guide Cyl1 RM S valu es via 36 Seg 1 0 degr ees

degree crank angle

degree crank angle

Crosshead vibration signal and segmented analysis

16



The benefits of optimal equipment performance are clear

reduced energy consumption and increased productivity

Tracking performance can also provide other benefits such

as early warning of impending gas leakages Unfortunately

Automated p-V diagnoses

losses in effi ciency often go undetected by many monitor-

ing systems that focus on vibration piston position and tem-

perature only Machine effi ciency ndash like other key parameters

ndash should be monitored continuously

PROGNOSTreg-NT checks machine effi ciency and provides

comprehensive analyses that identify how to restore opti-

mum operation Analyses begin by detecting any changes

in dynamic pressure during operation and performing

automated specialized p-V analyses to identify components

causing effi ciency reductions They also incorporate in1047298u-ences resulting from todayrsquos compressor regulations Finally

they analyze other key values such as compression cycle

piston rod load and piston rod reversal Monitoring systems

should compile all this information to give a comprehensive

view of machine effi ciency

Pressure curve with piston rod load

17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5

Flow control caused problems 4

Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20

Monitoring of compressor components

18



As for double-acting compressors alternating tensile and

compressive forces on the piston rod are the result of gas

compression on the crank end side (CE) or head end side

(HE) of the compression chamber These forces from two op-

posing directions act alternately upon the piston rod

Loosened connections

The integrity of motion works is ensured via vibration analy-

ses and rod position monitoring Accelerations on the cross-

head slide gaplessly record vibration arising as the result of

increasing clearances Subsequent diagnosis identifies actual

deviations in the vibration pattern

Piston rod position analyses reveal connections that are in

the process of detaching at an early stage eg cracks By

permanent rod position measurement even weakened con-

nections (eg low contact pressure between piston nut and

piston) are detectable

Overloadexcessive piston rod load

(compressive and tensile forces)

The compressive and tensile forces affecting the piston

rod can be calculated continuously

Plunger monitoring (Hyper compressor)

For Hyper compressors orbit monitoring (horizontalvertical

displacement of the plunger ldquoplunger run-outrdquo) is recom-

mended to detect excessive wear of the packing Increased

vibration is detected at an early stage to prevent damaging

of the brittle hard metal plunger An automatic shutdown is

crucial to avoid costly consequential damages Additionally

gap protection can also be used for safety shutdown

PROGNOSTreg-NT monitoring modules recommended

bull Safety Protection

bull Safety Analyses

bull Early Failure Detection

bull Wear Monitoring

bull Performance Optimization

Piston rod and Plunger

19



Crosshead

Cylinder and Packing lubrication

Crankshaft bearings

Crankshaft

Segmented vibration analysis (see page 16) allows the earlydetection of mechanical damages within motion works

from the connecting rod to the piston Loosened con-

nections eg between connecting rod and crosshead are

detectable at an early stage as they create characteristic

vibration peaks at rod load reversal points

Wrist pin

Wrist pin failures are usually consequential damages caused

by loss of lubrication Using p-V monitoring dynamic rod

load changes periods can be calculated If these periods are

too short a loss of lubrication of the wrist pin is creating a

critical situation






Vibration analysis assists in the early detection of mechani-cal damages within motion works eg the connecting rod

Due to the low operating speed of most piston compressors

temperature monitoring of bearings is not always distinct

The friction heat generated by a damaged bearing often

is insuffi cient to produce a significant rise in temperature

In contrast vibration allows sleeve bearing damages to be

recognized immediately Unlike temperature instrumenta-

tion vibration measurement can be installed even if no

borehole at the bearing cap is designed for the sensor by

the manufacturer





Measurement of lubrication 1047298ow quantities takes place

through special 1047298ow transmitters Clogged lines and leak-

ages often are not recognized by the customary method of

line pressure monitoring because back1047298ow is distributed

evenly in the remaining oil channels Flow quantity sensors

installed at each lube oil line precisely record lubrication

quantity and trigger an alarm in case of excessive or insuffi -

cient lubrication As a result lubrication undergoes complete

measurements making the reading of sight glasses obsolete

and thus reducing the time spent by maintenance person-

nel in hazardous areas at the machine


bull Lubrication Monitoring

During compressor operation the crankshaft is exposed

to continuous torsional vibration When the machine was

designed a definite vibration behaviour was calculated and

the shaft was sized correspondingly However the use of

load controls such as stepless valve unloaders generates

operating conditions which may not have been taken into

consideration during the design phase As a consequence

resonances can be excited which result in unplanned

loads for the crankshaft and its drive connection To enable

damage-free operation despite changing 1047298owrates conti-

nuous monitoring of torsional vibration is recommended



20



Process problems

Discharge and Suction valves

Rider rings and Pistonsealing rings

Liquids in the compression chamber cause a short term riseof the piston It can be detected with a peak-to-peak analysis

of piston rod position using a displacement sensor Another

way to detect liquid carryover is provided by a crosshead

slide acceleration sensor when incompressible liquid is

pressed through discharge valves This often results in high

vibration around TDC and BDC

Both analyses are highly recommended as shutdown signals

to prevent severe consequential damages such as piston rod

failures or broken cylinder head




Automated p-V diagram analysis is one of the most impor-tant methods for evaluating the condition of piston sealing

rings For the detection of leaking piston sealing rings on

a double acting cylinder the two opposite compression

chambers are analyzed in parallel If changes appear in both

compression chambers it can be considered as an indica-

tion of leaking piston sealing rings

The vertical position of a piston is an important indicator for

wear of piston rider rings The measured vertical position of

a piston rod can be converted into a lowering in the piston

centre which corresponds to the wear of the rider rings To

receive accurate rider ring wear values only the segmented

monitoring of each complete revolution gives reliable

results




Automated p-V diagram analysis (pressurevolume diagram)

is one of the most important methods to determine the

condition of valves Valve leakages cause characteristic

changes in the measured pressure curve which can be

recognized with p-V analyses The dynamic pressure curve

measured is converted to a p-V diagram for which particu-

lar characteristic values are calculated These values eg

discharge losses polytropic exponents or the crank angle of

the suction valve opening are assigned warning thresholds

which result in warning messages when exceeded

Acquisition and analysis of the vibration on cylinders assists

the early detection of mechanical damages eg cracks in the

valve body or valve plates Flow noise of damaged valves as

well as shifted valve opening or closing events are detect-able through high resolution measurement with accelera-

tion sensors

Measurement of valve temperature is the traditional method

here Using a temperature sensor gas temperature in the

valve chamber is measured If the temperature at a valve

is clearly increased a damage eg leak can be assumed

However if there are several valves on the cylinder costs

have to be taken into consideration as a temperature sensor

is required for each valve




bull Process Data Analyses

21



PackingCylinder liner andCompression chamber

Automated p-V diagram analysis Increased leakages causecharacteristic changes in the indicated pressure curve Ap-

propriate analyses are capable to differentiate between valve

piston ring and packing leakage The results are compared

with the pattern recognition database and displayed as clear

text




The cylinder liner can be damaged by worn-out rider ringsand solid residue in the compression chamber eg caused

by gas impurities These types of damages are detected

with a peak-to-peak evaluation of piston rod position using

a displacement sensor as well as crosshead vibration Both

analyses are recommended as shutdown signals






22



Monitoring of centrifugal equipment



System scalability

PROGNOSTreg-NT is scalable in two ways Functional scalabil-ity allowing new or additional capabilities such as diag-

nostic modules to be added to an installed system without

inordinate cost or diffi culty Scope scalability in other


additional machines

Data acquisition andSIL 2-certified safety protection

The vital role of a protection system to mitigate the risk ofserious damages is covered by PROGNOSTreg-SILver This hard-

ware has proven its effectiveness and reliability on a daily ba-

sis worldwide and in many different process environments

PROGNOSTreg-SILver holds a SIL 2 certificate (IEC615062010)

for all shutdown loops connected (max 68 loops) by design

Signal Plausibility Check

PROGNOSTreg uses specialized signal processing to avoid falsealarms caused by electrical or hardware failures Even out-of-

range signals are identified and indicated as ldquoUNSAFErdquo Users

are informed about any ldquoUNSAFErdquo loop immediately

Ringbuffer

Transient data recording allows users to replay a safety

shutdown alert or machine start-up by examining a gapless

recording of all signals in an uncompressed format ndash even

revolution by revolution The ringbuffer offers the possibilityof subsequent root cause analyses the time frame of seven

minutes before and three minutes after the ALERT SHUT-

DOWN or UNSAFE alarm can be closely evaluated using all

recorded time signals from all dynamic sensors and process

values in the PROGNOSTreg-NT system

24



Sensor positions

Sensor types and uses

Accelerometer

This commonly used sensor has a high frequency range and

can be easily integrated into Velocity values The sensor can

be mounted for x y and z-axis measurements and should be

mounted as close to energy source as possible (ie bearing

cap gear etc) The accelerometer probe is used to detect

bearing defects (sleeve and rolling element) gear defects

electrical anomalies belt defects etc

ProximityEddy Current Probe

The first choice to detect impending failures on sleeve

bearings They must be drilled or tapped into the bearing

cap with proper gap voltage set To allow Orbit or alignment

analyses it is recommended to install one sensor in X- and

one in Y-direction The z-axis measurement is desired if an

axial thrust bearing is to be monitored

Sensor signals and positions

Signal Position

Displacement

Radial shaft position

Axial shaft position

Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration

Roller bearing housing

Casing

Velocity

Shaft vibration

Sleeve bearing housing

Casing

Temperature Bearing

Motor winding

Speed Coupling

Bearing vibration Speed

Axial shaft position Radial shaft position

Bearing temperature Radial shaft position

25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N

Signal analyses and display

Online shaft orbit plots

bull For 2-dimensional shaft monitoring

bull Screenshot of the PROGNOSTreg-NT VISU user interface

software showing the online orbit of 1 shaft revolution

The slider allows to display consecutive revolutions

Trended bearing vibration monitoring

bull Peak vibration

bull RMS vibration

bull Amplitude of 1234 10 harmonic of rotary frequency

3D waterfall Long time trend to detect

impending failures

3D orbit trend Long time trend to detect

impending failures

AmplitudeTime

Harmonics 05x 10x 10xplus Subsynchronous

plus Non-Synchronous

Conclusion

PROGNOSTreg-NT is a fully capable and effective tool to monitor centrifugal and reciprocating machinery

26





PROGNOST Systems GmbH

Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom

PROGNOST Systems Inc

1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom





Contents

Introduction 4



PROGNOSTreg-NT 6






Safety Analyses 12


Wear Monitoring 14










Crosshead 20



Crankshaft 20

Process problems 21



Packing 22





Ringbuffer 24

Sensor positions 25




Conclusion 26

3











Introduction







4


























5




PROGNOSTreg-NT



















of field experience





6















7



System scalability



machines









pathway for growth



8












9

























PROGNOSTreg-SILver





10



















11











Ringbuffer










Safety Analyses



0

15

30

45

60

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

TDC

BDC

TDC

0

10

20

30

40

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

1 2 3 4 5 6 7 8


degree crank angle

degree crank angle

12
































-40

-30

-20

-10

0

10

20

30

40

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

0

05

10

15

20

25

30

35

40

45

50

55

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 15 16 17 18 19 20 21 2 2 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36

TDC BDC TDC



13





supported and eased



















Wear Monitoring

















energy consumption

















See also page 17

14




for data exchange




























configured

Component Tracking



15













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom



Contents

Introduction 4



PROGNOSTreg-NT 6






Safety Analyses 12


Wear Monitoring 14










Crosshead 20



Crankshaft 20

Process problems 21



Packing 22





Ringbuffer 24

Sensor positions 25




Conclusion 26

3











Introduction







4


























5




PROGNOSTreg-NT



















of field experience





6















7



System scalability



machines









pathway for growth



8












9

























PROGNOSTreg-SILver





10



















11











Ringbuffer










Safety Analyses



0

15

30

45

60

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

TDC

BDC

TDC

0

10

20

30

40

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

1 2 3 4 5 6 7 8


degree crank angle

degree crank angle

12
































-40

-30

-20

-10

0

10

20

30

40

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

0

05

10

15

20

25

30

35

40

45

50

55

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 15 16 17 18 19 20 21 2 2 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36

TDC BDC TDC



13





supported and eased



















Wear Monitoring

















energy consumption

















See also page 17

14




for data exchange




























configured

Component Tracking



15













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom











Introduction







4


























5




PROGNOSTreg-NT



















of field experience





6















7



System scalability



machines









pathway for growth



8












9

























PROGNOSTreg-SILver





10



















11











Ringbuffer










Safety Analyses



0

15

30

45

60

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

TDC

BDC

TDC

0

10

20

30

40

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

1 2 3 4 5 6 7 8


degree crank angle

degree crank angle

12
































-40

-30

-20

-10

0

10

20

30

40

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

0

05

10

15

20

25

30

35

40

45

50

55

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 15 16 17 18 19 20 21 2 2 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36

TDC BDC TDC



13





supported and eased



















Wear Monitoring

















energy consumption

















See also page 17

14




for data exchange




























configured

Component Tracking



15













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom


























5




PROGNOSTreg-NT



















of field experience





6















7



System scalability



machines









pathway for growth



8












9

























PROGNOSTreg-SILver





10



















11











Ringbuffer










Safety Analyses



0

15

30

45

60

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

TDC

BDC

TDC

0

10

20

30

40

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

1 2 3 4 5 6 7 8


degree crank angle

degree crank angle

12
































-40

-30

-20

-10

0

10

20

30

40

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

0

05

10

15

20

25

30

35

40

45

50

55

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 15 16 17 18 19 20 21 2 2 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36

TDC BDC TDC



13





supported and eased



















Wear Monitoring

















energy consumption

















See also page 17

14




for data exchange




























configured

Component Tracking



15













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom




PROGNOSTreg-NT



















of field experience





6















7



System scalability



machines









pathway for growth



8












9

























PROGNOSTreg-SILver





10



















11











Ringbuffer










Safety Analyses



0

15

30

45

60

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

TDC

BDC

TDC

0

10

20

30

40

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

1 2 3 4 5 6 7 8


degree crank angle

degree crank angle

12
































-40

-30

-20

-10

0

10

20

30

40

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

0

05

10

15

20

25

30

35

40

45

50

55

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 15 16 17 18 19 20 21 2 2 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36

TDC BDC TDC



13





supported and eased



















Wear Monitoring

















energy consumption

















See also page 17

14




for data exchange




























configured

Component Tracking



15













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom















7



System scalability



machines









pathway for growth



8












9

























PROGNOSTreg-SILver





10



















11











Ringbuffer










Safety Analyses



0

15

30

45

60

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

TDC

BDC

TDC

0

10

20

30

40

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

1 2 3 4 5 6 7 8


degree crank angle

degree crank angle

12
































-40

-30

-20

-10

0

10

20

30

40

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

0

05

10

15

20

25

30

35

40

45

50

55

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 15 16 17 18 19 20 21 2 2 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36

TDC BDC TDC



13





supported and eased



















Wear Monitoring

















energy consumption

















See also page 17

14




for data exchange




























configured

Component Tracking



15













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom



System scalability



machines









pathway for growth



8












9

























PROGNOSTreg-SILver





10



















11











Ringbuffer










Safety Analyses



0

15

30

45

60

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

TDC

BDC

TDC

0

10

20

30

40

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

1 2 3 4 5 6 7 8


degree crank angle

degree crank angle

12
































-40

-30

-20

-10

0

10

20

30

40

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

0

05

10

15

20

25

30

35

40

45

50

55

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 15 16 17 18 19 20 21 2 2 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36

TDC BDC TDC



13





supported and eased



















Wear Monitoring

















energy consumption

















See also page 17

14




for data exchange




























configured

Component Tracking



15













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom












9

























PROGNOSTreg-SILver





10



















11











Ringbuffer










Safety Analyses



0

15

30

45

60

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

TDC

BDC

TDC

0

10

20

30

40

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

1 2 3 4 5 6 7 8


degree crank angle

degree crank angle

12
































-40

-30

-20

-10

0

10

20

30

40

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

0

05

10

15

20

25

30

35

40

45

50

55

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 15 16 17 18 19 20 21 2 2 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36

TDC BDC TDC



13





supported and eased



















Wear Monitoring

















energy consumption

















See also page 17

14




for data exchange




























configured

Component Tracking



15













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom

























PROGNOSTreg-SILver





10



















11











Ringbuffer










Safety Analyses



0

15

30

45

60

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

TDC

BDC

TDC

0

10

20

30

40

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

1 2 3 4 5 6 7 8


degree crank angle

degree crank angle

12
































-40

-30

-20

-10

0

10

20

30

40

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

0

05

10

15

20

25

30

35

40

45

50

55

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 15 16 17 18 19 20 21 2 2 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36

TDC BDC TDC



13





supported and eased



















Wear Monitoring

















energy consumption

















See also page 17

14




for data exchange




























configured

Component Tracking



15













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom



















11











Ringbuffer










Safety Analyses



0

15

30

45

60

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

TDC

BDC

TDC

0

10

20

30

40

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

1 2 3 4 5 6 7 8


degree crank angle

degree crank angle

12
































-40

-30

-20

-10

0

10

20

30

40

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

0

05

10

15

20

25

30

35

40

45

50

55

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 15 16 17 18 19 20 21 2 2 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36

TDC BDC TDC



13





supported and eased



















Wear Monitoring

















energy consumption

















See also page 17

14




for data exchange




























configured

Component Tracking



15













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom











Ringbuffer










Safety Analyses



0

15

30

45

60

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

TDC

BDC

TDC

0

10

20

30

40

mil

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360

1 2 3 4 5 6 7 8


degree crank angle

degree crank angle

12
































-40

-30

-20

-10

0

10

20

30

40

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

0

05

10

15

20

25

30

35

40

45

50

55

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 15 16 17 18 19 20 21 2 2 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36

TDC BDC TDC



13





supported and eased



















Wear Monitoring

















energy consumption

















See also page 17

14




for data exchange




























configured

Component Tracking



15













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom
































-40

-30

-20

-10

0

10

20

30

40

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

0

05

10

15

20

25

30

35

40

45

50

55

g

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360deg CA

1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 15 16 17 18 19 20 21 2 2 23 24 25 26 27 28 29 3 0 31 32 33 34 35 36

TDC BDC TDC



13





supported and eased



















Wear Monitoring

















energy consumption

















See also page 17

14




for data exchange




























configured

Component Tracking



15













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom





supported and eased



















Wear Monitoring

















energy consumption

















See also page 17

14




for data exchange




























configured

Component Tracking



15













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom




for data exchange




























configured

Component Tracking



15













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom













Segmentation






false alarms













-20

-10

0

10

20

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 28 5 30 0 31 5 33 0 34 5 36 0

TD C BD C TD C

0

5

10

15

g

0 15 30 45 60 75 90 10 5 12 0 13 5 15 0 16 5 18 0 19 5 21 0 22 5 24 0 25 5 27 0 285 30 0 31 5 33 0 34 5 36 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36


degree crank angle

degree crank angle


16























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom























17



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom



Valve Failures 29

Piston Rod 7

Misc 7

Sensor Failure 6

Crosshead 5


Piston Rings 3

Plunger 3

Rider Rings 3

Piston 2

Bearing 2

Leackage 2

Liquid slug 2

Process 2

Pulsations 2

Packing 1

Cylinder 1

5 10 15 20


18






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom






































19



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom



Crosshead


Crankshaft bearings

Crankshaft






Wrist pin





critical situation















the manufacturer































20



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom



Process problems



























results


















tion sensors












21








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom








text














22






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom






System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom



System scalability





additional machines











Ringbuffer









24



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom



Sensor positions


Accelerometer
















Signal Position

Displacement



Shaft

Bearing

Shaft end

Shaft collar

Acceleration

Shaft vibration


Casing

Velocity

Shaft vibration


Casing

Temperature Bearing

Motor winding

Speed Coupling




25



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom



-05

00

05

10

15

20

25

30

35

40

45

05122003

180000

07122003

180000

09122003

180000

11122003

180000

13122003

180000

15122003

180000

17122003

180000

T I_ P N T_

2 0 1 5_

0 1_

E N








bull Peak vibration

bull RMS vibration



impending failures


impending failures

AmplitudeTime



Conclusion


26






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom






Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom




Daimlerstr 10

48432 Rheine

Germany

+49 (0)59 71 - 8 08 19 0

+49 (0)59 71 - 8 08 19 42

infoprognostcom


1018 Hercules

Houston TX 77058

USA

+1 - 281 - 480 - 9300

+1 - 281 - 480 - 9302

infousaprognostcom

wwwprognostcom

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