On-Line Vibration Monitoring Systems

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On-Line Vibration Monitoring Systems
Presented by Timothy S. Irwin, P.E. Senior
Rotating Machinery Engineer MB Engineered
Solutions, Inc. 13 Aberdeen Way Elgin, SC
29045 Email tsi_at_mbesi.com 17 February, 2006
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On-Line Vibration Monitoring Systems
Some of todays subject items
What kind of monitoring system do we need?
Do we need protection? Or do we need only
monitoring?
What options are available for monitoring systems?
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?
What do we need in a specification to get what we
want?
MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
There are a lot of options available today.
This is only a portion of what is available on
the market.
MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
What kind of different permanent monitoring
systems are available?

• Continuous monitors signals from transducers
  continuously

• Polling Samples signals from transducers on a
  pre-arranged schedule

• Switches or Transmitters Sends a signal to the
  control system

• Permanent transducers with remote connections
  for monitoring/diagnostics

Another differentiating item is whether the
system provides equipment protection or is purely
for monitoring
So to determine what level of monitoring we need,
we need to know what kind of equipment the
system will be installed on.
MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Equipment Classifications

• Is the equipment expensive to repair or replace?

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

• Will equipment failure affect operation/productio
  n of the plant after some time?

• Will equipment failure create an unsafe
  condition (EHS)?

• What is the equipment reliability history?

Answers to the above questions will supply you
with the some of the information that may lead to
an appropriate justification for an appropriate
level of monitoring.
What we need to do is set a goal or target for
the desired system and then use the following
information to develop the specific details, for
anything put a full- blown protection system some
of the following information may not apply.
MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Justification for On-Line Monitoring

• Safety Inaccessible or dangerous area?

• Hazardous Systems Would failure of the machine
  cause a hazardous
• situation?

• Sampling Frequency Would a failure happen too
  fast to catch with
• routine monitoring?

• Manpower Is there just too much too monitor?

• Varying Conditions Do varying conditions make
  route monitoring
• difficult to analyze?

• Monitoring and Analysis Efficiency Would a
  permanent system with
• analysis capabilities significantly improve
• the monitoring and analysis?

• Consistency Repeatability Are there reasons
  that are causing difficulty
• with consistency or repeatability?

MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Continuous vs. Polling
What are the differences and why do we consider
them?
Continuous Monitors the desired parameters on a
continuous basis and can typically be set up to
trip the machine under preset conditions within
milliseconds to several seconds as desired.
Polling Monitors the desired parameters on a
pre-arranged schedule, the polling of the
parameter can typically be set from seconds to
once per day. This type of system is not
typically used for equipment protection but is
used for alert and danger alarms for operations
personnel and machinery monitoring and
diagnostics.
MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Continuous vs. Polling
MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Once the level of monitoring is determined
(continuous or polling), which parameters should
be monitored?
We answer that with another question What kind
of component failures are possible?

• What is in the machine? 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

MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
What parameters do we want?
MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Ron Patricks Jet Powered Beetle
MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
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, lets take
a look at what we want in a monitoring system.
This should be for any system whether it is
Continuous or Polling

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

• Does the monitor/modules have the proper
  transducer options?

• Does the monitor have optional filter settings?

• 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 a buffered output for
  every channel?

• Does the monitor collect multi-channel
  simultaneous data?

MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Monitor details and options continued

• Does the monitor have a local indication for
  verification of the
• remote indication?

• Does the monitor have self-test features?

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

• Can individual channels be turned off when there
  are known problems
• to minimize false indications?

• Does the monitor supply an output to a DCS or
  other remote location?
• Can it also supply trip relays for automated
  protection?

• Is the monitor capable of supplying data to a
  diagnostic software program?

• What is the overall signal output of the monitor
  peak, true-peak, rms?

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

• Does the monitor have process parameter
  capabilities?

MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Software details and options

• Can look at live or historical data

• Has configurable data collection and storage

• Has configurable historical data archive
  capabilities

• Has expansion capability for future needs

• Can store a new data sample at any time

• Has desired plotting capabilities

• Configurable alarm settings

• Demodulated or Enveloped tool is available
• (with multiple bandwidth options)

• Multi-channel simultaneous sampling capability

• Has alarm ability for bad data or channel problem

• Extended Data collection on alarm

MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Are you in an industry or process that requires
or uses any of the standards that are presently
in place?

• American Petroleum Institute (API)

• API 670 Machinery Protection Systems

• International Standards Organization (ISO)

• ISO 29541975 - Mechanical vibration of
  rotating and
• reciprocating machinery -- Requirements for
  instruments for
• measuring vibration severity

• ISO 53481998 - Mechanical vibration and shock
  -- Mechanical
• mounting of accelerometers

• ISO 80421988 - Shock and vibration
  measurements
• Characteristics to be specified for seismic
  pick-ups

MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Standards Continued

• ISO 7919 Mechanical vibration of
  non-reciprocating machines
• Measurements on rotating shafts and evaluation
  criteria
• -- Part 1 General guidelines
• -- Part 2 Land-based steam turbines and
  generators in excess of
• 50 MW with normal operating speeds of 1500
  r/min, 1800 r/min,
• 3000 r/min and 3600 r/min
• -- Part 3 Coupled industrial machines
• -- Part 4 Gas turbine sets
• -- Part 5 Machine sets in hydraulic power
  generating and pumping plants

• ISO 13373-12002 - Condition monitoring and
  diagnostics of machines
• -- Vibration condition monitoring -- Part 1
  General procedures
• ISO 13373-22005 - Condition monitoring and
  diagnostics of machines
• -- Vibration condition monitoring -- Part 2
  Processing, analysis and
• presentation of vibration data

MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Standards Continued

• American Gear Manufacturers Association (AGMA)

• AGMA 6000 B96 Specification for Measurement of
  Linear
• Vibration on Gear Units

What else is there?
The fact is that there are standards on nearly
anything you can think of, do a little digging
and you may find a piece of the puzzle that you
were missing.
MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Now that we have covered

• The type of machinery that we want to monitor

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

• The type of monitoring system that is appropriate

How do we get what we want installed?
It is time to put details into the project

• Will the monitor go into an existing cabinet or
  need a new one?

• Will site personnel install the transducers and
  wiring?

• Someone will have to work with IT to get the
  outputs to the DCS or software

MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
It is time to write a technical specification

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

• You will have the monitoring system that will be
  functional, reliable, and
• with the tools that will make your diagnostic
  efforts more successful

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

What kind of details are we talking about?
Everything that we have discussed
MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
What do you mean I cant do this?!
Without proper monitoring you may end up with
parts that look like this!
MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Technical Specification

• Transducers The specification may include but
  not be limited to

• Temperature range

• Amplitude Range

• Frequency Span

• Linear Range if a proximity probe

• Any size constraints

• Does it need to be a right angle cable connection

• Mounting connections for all transducers

MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Technical Specification

• Monitoring System could include but not be
  limited to

• Desired modules radial vibration, thrust
  position, speed,
• phase reference, etc.

• Equipment protection relays or only monitoring

• Frequency span requirements

• Filtering option requirements

• Do you require local indication for operators

• Do you want any self-test features

• Type of communication requirements to site DCS
  or LAN

• Simultaneous sampling capability

• Short-circuit protected test connections

MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Technical Specification

• Installation

• Generally site/corporate procurement has site
  conditions and contractor
• requirements documentation, but someone still
  has to put together the
• technical requirements for the installation.
  This could include

• Physical description of installation

• Into existing cabinets

• Installation of new cabinets

• Wiring installation

• Transducer installation general locations

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

MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
Technical Specification

• Documentation

• Monitor Operation and User Manuals

• Transducer System Specification Sheets

• Electrical installation drawings

• One line drawings

• Cabinet installation drawings

• Logic drawings

• Transducer installation drawings

• Bill of materials with all replacement part
  numbers

MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
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 everyones job later will be more difficult
and less efficient.
MB ESI Timothy S Irwin February 2007
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On-Line Vibration Monitoring Systems
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
everyones job later will be more difficult and
less efficient.
MB ESI Timothy S Irwin February 2007
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THE END
ANY QUESTIONS?
MB ESI Timothy S Irwin February 2007