Download Document

Advancements in Transmitter-Based Monitoring
Systems
AM2005
San Diego, California
Wednesday, May 11 from 3:00 - 4:00 PM
Frank Howard
President
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Transmitter Strategy
• Enable users to make use of their existing PLC and DCS
Systems for Machinery Condition Monitoring
• Offer Wonderware HMI systems where the users DCS or PLC is
inadequate or will be upgraded in the future
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Transmitter Based Systems
•
Advantages:
•
•
•
•
•
•
•
•
•
•
Disadvantages:
•
www.stiweb.com
Low Cost (1/2 Legacy Systems)
Simple to Install
Can make use of existing sensors
Distributive Architecture
4-20 mA noise free
Digital to save wiring costs
Choice of Protocol
Easy repair and replacement
Local Dynamic Signal w/BNC
No Remote Dynamic or Transient Data
Vibration Monitoring & Machine Protection Systems
Legacy Systems
• Large centralized “Rack” based systems
•
•
•
•
•
•
Control Room mounted
Originally Capital Projects
OEM supplied sensors
All sensors wired to “Rack”
Requires lots of instrument wire and conduit (2x cost)
Large Racks do nothing that a PLC or DCS system cannot do
• Overall Values
• Time Delay
• Power up inhibit
• OK Circuit
• 99% not wired to “Shutdown”
• Many are ‘Obsolete”
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
What’s Changed ?
• Hardware
• PLC and DCS Systems are faster, cheaper and more common.
• Many Plants are upgrading to New DCS and PLC Systems.
• HMI Systems like Wonderware are available.
• People
•
•
•
•
•
•
•
•
Vibration and machinery specialists are retiring, or spread out.
A lot of specialty work is contracted.
Engineers and Technicians are forced to be “Jack of All Trades”.
Operators are being assigned more tasks “OCM”.
Users want smarter, simpler and easier to maintain systems.
Users are more budget conscious.
Engineers and Technicians are more computer oriented.
Major machine flaws have been fixed.
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Distributive Systems
• Hard or Soft Alarms (Hardware or Software)
• Transmitters or Monitors are local to machine
• Analog to Digital Converters (ADC) new or existing
• Communications in users preferred protocol
• Modbus RS-485
• Modbus TCP/IP
• Hundreds of others
• Make use of existing networks
• Make use of existing Historians
• Keeps overhead and bandwidth requirement low
• Make use of Operators existing CRT’s !
• Instrumentation people understand 4-20 mA !
• No proprietary protocols
• Use all available hardware like Industrial Radio Modems
• Easy repair or replacement
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Types of Transmitter Based Systems
• Transmitters
•
•
•
OK Circuit
BNC Output
4-20 mA Output
• Transmitters with Analog to Digital Converter
•
•
•
Same as above +
Digital Output (Choice of Protocol)
Choice of Protocol
• Transmitters w/ADC and Wonderware HMI
•
•
•
Same as above +
Wonderware license
Custom Wonderware runtime
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Why 4-20 mA
•
•
•
Extremely accurate
Low voltages (typically 24 VDC)
Long distances can be handled
•
•
•
•
•
www.stiweb.com
Voltage has resistance losses
4-20 mA Current constant anywhere on loop
Noise immunity
Very common in process measurements
Instrument Technicians understand
Vibration Monitoring & Machine Protection Systems
3-Wire Transmitter
CMCP500 Series Transmitter
PLC, DCS OR ADC.
4-20 mA
R LOAD
100 to 250 OHM TYP.
4-20 mA Return / Common (600 Ohms Max.)
+24 VDC
Power Supply
+24 VDC
+
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
25 Channel System +24 VDC
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
Red
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
CMCP
T1F-16AD-1
CMCP
T1F-16AD-1
Red
Black
CMCP
CMCP
T1K-01AC T1H-EBC100
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Black
Red
Black
Red
Black
Black
Red
-V
+V
CMCP515-2100
Power Supply
L
www.stiweb.com
N
G
Vibration Monitoring & Machine Protection Systems
25 Channel System 4-20 mA
www.stiweb.com
3
4
CMCP
CMCP
T1K-01AC T1H-EBC100
5
6
7
CMCP
T1F-16AD-1
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
CMCP
T1F-16AD-1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
2
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
All White +
1
Vibration Monitoring & Machine Protection Systems
4-20 mA Compliance
• Compliance – “The total amount of resistance in the circuit that
the 4-20 mA Transmitter is able to power”.
• Calculate by adding together:
• Shunt Resistor
• 100 Ω (.4 TO 2.00 Volts DC)
• 250 Ω (1 to 5 Volts DC)
• Wire Resistance (at 68° F)
• 18 AWG 6.385 Ω per 1,000’
• 20 AWG 10.15 Ω per 1,000’
• 22 AWG 16.14 Ω per 1,000’
• Power Protection Resistor (If used)
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Protocols
System
Developer
Year
Nodes
Media
Distance
Speed
Modbus RTU
Modicon
1978
250
Twisted Pair
350 m
38.5 Kbps
Modbus TCP
Schneider
1998
1,024
Cat5
Fiber
100 m
50 km
10, 100, 1000
Mbps
ControlNet
Allen Bradley
1996
99
Coaxial
Fiber
250 m
400 m
5 Mbps
DeviceNet
Allen Bradley
1994
64
Twisted Pair
500 m
500 Kbps
Profibus
German Gov.
1991
126
Twisted Pair
1200 m
31.25 Kbps
Foundation
Fieldbus
Fieldbus
Foundation
2000

Twisted Pair
Fiber
100 m
2000 m
100 Mps
Hart
Rosemount
1989
240
Twisted Pair
3000 m
4 Updates Sec.
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Ethernet TCP/IP
• TCP - Transmission Control Protocol, provides a reliable stream
delivery and virtual connection service to applications through
the use of sequenced acknowledgement with retransmission of
packets when necessary (TCP/IP).
• Ethernet - is a widely used data communications network
standard developed by DEC, Intel, and Xerox. It uses a bus
topology and CMSA/CD access method. The terms Ethernet
and the IEEE 802.3 standard are often used interchangeably.
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
CMCP500 Series Transmitters
•
•
•
•
•
•
•
•
CMCP525 Acceleration (Accelerometer)
CMCP530 Velocity (Accelerometer)
CMCP535 Displacement (Velocity)
CMCP540 Radial Vibration (Eddy Probe)
CMCP545 Thrust Position (Eddy Probe)
CMCP547 Differential Expansion
CMCP548 Case/Shell Expansion
CMCP549 Valve Position
www.stiweb.com
•
•
•
•
•
•
CMCP560 RTD Temperature
CMCP565 Thermocouple
CMCP570 Solid State Temperature
CMCP575 Speed
CMCP580 Process Variable
CMCP585 Eccentricity
Vibration Monitoring & Machine Protection Systems
CMCP500 and CMSS500 Transmitter Features
•
•
•
•
•
•
•
•
•
•
Compact Size
Din Rail Mountable
OK Circuit (<2 mA)
Optional Filters
ISO Standards
CE Approved
BNC Buffered Output
Terminal Buffered Output (CMU)
24 VDC Powered (NEC Low Voltage)
Selectable Range
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
CMCP500 and CMSS 500 Monitor Features
•
•
•
•
•
•
•
•
•
OK, Alert and Danger Relays
Selectable as Latching or Non-Latching
Trip Multiply
Reset terminal
Bypass terminal
Selectable Time Delay
Connector for optional display
BNC w/switch to set alarm levels
Can be added later
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #1
Customer:
Dynegy
System Type:
Coal Crushers
Location:
2 Locations, Illinois, USA
Salesperson:
Gary Gbur
Value:
$40,000.00
Year Installed:
2004 / 2005
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #1
• Problem
•
•
•
•
•
Coal Crushers with embedded accelerometers needed monitoring
User wanted to use existing DCS system
Existing system was not working properly
User unwilling to pay for conduit and instrument wire
Low Speed Bearings needed Enveloping
• Solution
•
•
•
•
•
Velocity and Enveloping Transmitters Used (some slow speed)
16 Channel ADC using Modbus TCP/IP Ethernet used
Industrial Ethernet Radio Modem used
No lost packets. Very robust.
Both Modbus RS-485 and TCP used
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #1
Master Radio
www.stiweb.com
Slave Radio
Vibration Monitoring & Machine Protection Systems
Case History #2
Customer:
Xcel Energy
System Type:
TSI System
Location:
Saint Paul, Minnesota, USA
Salesperson:
Frank Howard
Value:
$60,000.00
Year Installed:
2004
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #2
• Problem:
•
•
•
•
TSI System for GE Turbine Generator Set.
Customer wanted to use existing New DCS System.
Wanted local display for operators.
Intermediate terminals to save installation time.
• Solution:
•
•
•
•
CMCP500 Series Transmitters.
Pre-wired Integrated Custom Panel.
4-20 mA Loop to DCS.
Custom Mimic Panel w/Displays.
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #2
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #2
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #3
Customer:
WDC
System Type:
Critical Fans
Location:
Pine Bluff, Arkansas, USA
Salesperson:
David Gallagher
Value:
$160,000.00
Year Installed:
2004
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #3
• Problem:
•
•
•
•
•
•
6 IRD/Entek 5815 Monitors mounted in outdoor cabinets.
Critical service on high temperature furnace fans.
IRD/Entek no longer supported.
Primary competition: BNC
1 Vibration Channel.
8 Temperature Channels.
• Solution:
•
•
•
•
CMCP530 Transmitter.
ADC with direct RTD input.
15” Industrial Touch Screen Rack Mount Computers.
Custom Wonderware HMI w/Bargraphs.
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #3
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #3
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #3
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #3
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #3
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #3
Main Screen
Alarm List
Historical Trend
Real Time Trend
Real Time Trend
Setup
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #4
Customer:
Satcon / Magmotor
System Type:
Kinetic UPS 2.1 mW
Location:
Various
Salesperson:
Mike Bussing
Value:
$80,000.00 each
Year Installed:
2003 / 2004
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #4
• Problem:
•
•
•
Large Kinetic UPS System Monitoring.
Vibration, Enveloping, Temperatures, Speed, Pressures.
Flywheel Diameter Calculation.
• Solution:
•
•
•
•
CMSS530, CMSS590, CMCP540 and CMCP545 Transmitters.
Process Variables direct to ADC.
12.1” Touch Screen Rack Mount Industrial Computer.
Custom Wonderware HMI.
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #4
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #4
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Case History #4
Main Screen
Alarm List
Historical Trend
Real Time Trend
Real Time Trend
Setup
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Other Transmitter Based Systems
User
Location
Machine
System
Enterprise Products
Louisiana
Refrigeration Compressor
T, ADC, WW
Xcel Energy
Black Dog
TSI
T
Xcel Energy
Denver, CO
TSI
T, ADC, WW
Aramco
Saudi Arabia
Reciprocating Compressor
T, ADC, WW
Ameren Corp.
Newton, IL
2 Units, ID, FD and PA Fans
T, ADC
Pacific Gas and Electric
Pittsburg, CA
2 TSI Systems and CT’s
T, ADC, WW
Andritz
OEM
Refiner Monitoring
T
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Transmitter Tips
• Be sure to program in Time Delays. (3 second standard).
•
•
•
•
•
•
•
•
OK Circuits should be designed into transmitter (<2 mA).
BNC Buffered Output.
Peak or RMS.
True RMS (is it really, pseudo, quasi, ?).
Optional Filters (Low Pass, High Pass).
24 VDC (NEC low voltage).
Optional Displays.
ISO Standards are available.
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Go Wireless !
Industrial Radios
Features Include:
 Class I, Div II, Group’s A,B,C,D.
 Superior noise immunity - advanced frequency
hopping spread spectrum technology.
 Worldwide Unlicensed 2.4 GHz.
 Ethernet (TCP/IP, Ethernet/IP, Modbus/TCP, etc.)
 MODBUS RTU RS-485, RS-422, RS-232.
 32 Frequency Channels.
 Up to 16 mile range w/ Hi Gain Antennas.
 Can be extended with Repeaters.
 250 Kbps RF Data Rate.
 Configurable to Master/Repeater/Remote with
Windows setup / diagnostics software.
Ethernet Model
www.stiweb.com
Vibration Monitoring & Machine Protection Systems
Thank You
Questions ?
www.stiweb.com
Vibration Monitoring & Machine Protection Systems