The

Solution

Vibration & Condition Monitoring Product Line

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Condition Monitoring - Applications

 Alarm & Monitoring (Protection)  Surveillance  Predictive Maintenance

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Condition Monitoring - Methodology

 Establish Base Line Trend  Compare Current Trend to Base Line Trend  Identify Deviation and Cause

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Condition Monitoring - Benefits

 Protection  Fault Indication  Knowledge Based Maintenance

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Market Needs
 Maximum Production  Maximum Runtime  Condition Based Maintenance  Asset Management

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Market Concerns
 Aging Equipment  Personnel Reduction  Expertise Disappearing

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Condition Monitoring Product Line

CMM

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Condition Monitoring Module (CMM)

  

4 Measurement channels per module A Universal module Each channel configurable to measure:  Vibration: (Relative, Seismic or Absolute)  Eccentricity  Thrust Position  Case Expansion  Differential Expansion including Complementary and Ramp Accepts any combination of Proximity Probes, Seismic Probes and DC LVDT inputs Self calibrating to achieve accuracy of +.25% of full scale 2 relay outputs on board

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Condition Monitoring Module (CMM)

 

Ethernet connection to analysis computers Vibration analysis outputs include:  Time wave forms  Overall vibration  Gap  1x, 2x & 3x amplitude and phase  Not1x  Smax Synchronous and asynchronous sampling Buffered outputs of all transducer and event marker inputs

 

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Function Code 247


CMM
  

13 Block Inputs per Channel

10 Analog 2 Digital 1 Module Status

Each Channel Independently Configured  Vibration  Eccentricity  Thrust Position  Differential Expansion  Case Expansion  Dual Probe 13 Block Outputs
   

3 Analog 6 Measurement 2 Alarm Indicators 1 Module Status

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Complete Machinery Management

Graphing Tool for Condition Monitoring Analysis Plots Machinery Process Data from Data Server Bode XY Polar Orbit Spectrum. . .
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Analyst
 Graphical Presentation of Historical Data  Assists in Recognizing Patterns and Trends  Plots Machinery and Process Data from Data Server

Supports 10 Plot Types

    

X versus Y Bode Polar Polar + Trend Orbit

    

Shaft Centerline Time Waveforms Spectrum Cascade Waterfall

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Analyst


Flexible, Easy to Learn and Use

(Orbit Plots)

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Analyst


(Polar+Trend & XY Plots)

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Complete Machinery Management

Automated Diagnostic Program Predictive Maintenance Prioritizes Reporting Details Repair Action Problem Description Vibration Details

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Expert
 A Screening Tool

 Up to 96% accuracy compared to human 

Reports problems long before Alert and Danger levels are reached
 Notifies by pager and email  Detailed information posted to a web page

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Expert - How We Implement

 ABB teamed with Partner to incorporate their Expert System

software
 Partner- Established provider of Expert Systems  Modular Software which is imbedded into ABB system  Retrieves time waveforms from data server  Utilizes a proven empirical, rule based diagnostic engine

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Expert & Analyst Together

 Expert and Analyst are Complementary Tools

Expert to Detect
 Scans frequency spectra tirelessly, 24 hours/day  Reports subtle problems early

then Analyst to Confirm

 A person plots machinery and process data looking

for confirmation

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Data Server
 Stores Time Waveforms  Stores Data periodically at (4) four

different rates for each measurement

 Event Driven
 Alarm  Run-up  Run-down  Trip

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Complete Condition Monitoring System

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Advantages

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User Advantages
 Cost effective - uses the existing DCS infrastructure  No Foreign Device Interface - Condition Monitoring is

integrated directly with the plant control and information system

 Tight integration with the DCS has many benefits
 Common operator interface  Consistent time stamps for all alarms  Allows correlation of vibration data with process parameters

such as:
 Bearing metal and oil drain temperatures  Steam flow, megawatts, vars  Valve positions
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User Advantages
 Flexible DCS logic provides sophisticated alarming for

improved protection

 Interfaces to most existing field devices such as:

 Bently Nevada  Brel Kjr  CEC  CSI  General Electric  Metrix  PCB/IMI  Schenk  SKF (Dymac)  Shinkawa  Vibrometer  Wilcoxon  Entek IRD (CML)

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User Advantages
 Single supplier for parts and service  Minimum training & expense - use existing tools to

program and maintain

 Universal module - just 1 part to stock

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How to Implement
 Add on to Existing Hardware  Include in New Project

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Condition Monitoring - Summary

 Complete Vibration & Condition Monitoring

Totally Integrated into the DCS

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Power Generation

Questions?

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