Instrument Unit
GEN-06 (Rev 0)
Prepared by : M. Junaid
Reviewed by : Ali Raza Soomro
Approved by : Pervaiz Iqbal
Contents
3. Proximity Transducer
4. Troubleshooting Sequence
1
5. BENTLY NEVADA 3500
2
Vibration Monitoring System | GEN-06 (Rev 0)
3
1. MACHINE MONITORING SYSTEM
Learning objectives:
4
1.1 BRIEF INTRODUCTION
For optimum performance of the machine & to avoid damage it is necessary to
continuously and accurately monitor parameters like<
Radial Vibration,
Axial or thrust
Speed (Keyphasor).
Machine Monitoring System is used to protect the machine from the Imbalance,
Misalignment Shaft crack and Bearing Failures, and it also helps to diagnose and
anticipate other machinery problems.
1.2. HISTORY
Earlier of times vibration was Sensing By hand
Vibration Monitoring System | GEN-06 (Rev 0)
5
Then Vibration Sensing By Stethoscope
6
Vibration Monitoring System | GEN-06 (Rev 0)
7
Objective Technology
2. METHODS USED FOR MACHINE
MONITORING SYSTEM
Learning objectives:
8
2. METHODS USED FOR MACHINE
MONITORING SYSTEM
There are two types of method used for MMS
1. Contact method
a. Velocity Method
b. Acceleration method
Vibration velocity is a measure of the speed at which the mass is moving or vibrating
during its oscillations. Technically, velocity measures how much the displacement is
changing over a period of time. The units of measure are inches per second or
millimeters per second.
Velocity Sensor
Vibration Monitoring System | GEN-06 (Rev 0)
The system operates on the inertial mass-moving case principle. The transducer
contains a magnet which is fixed to the transducer case. Surrounding the magnet is an
inertial mass coil
9
mounted to the case on springs. Since the transducer is rigidly mounted to the machine,
the magnet vibrates in harmony with the machine case. The magnet moving within the
coil which is proportional to the machine housing velocity
No external powering
Easy to install
Mounting orientation
Acceleration method
10
Piezoelectric Accelerometer
At sea level, 1.0 g equals 32.2 ft/sec2 which equals 386.087 in/sec/sec or 9806.65
mm/sec/sec. Acceleration is greatest where velocity is at a minimum. Piezoelectric
material (sensing element) is placed under load using a mass. As machine vibrates,
crystal is squeezed or released. Charge output is proportional to the force (acceleration)
Electronics convert charge output into voltage output.
Advantages of Accelerometer:
Self generating
Rugged
Disadvantages of Accelerometer:
11
Disadvantages of Eddy Current:
Difficult to install
Vibration
OSCILLATION OF A MACHINE OR ITS COMPONENT FROM A MEAN POSITION
Radial Vibration
A direction on a machine which is perpendicular to the shaft centerline in the xy plane
Radial Displacement
Shaft dynamic motion or casing vibration which measured in a direction perpendicular
to the shaft axial
Axial
12
Axial Displacement
Displacement of shaft in the axial direction with respect to some fixed reference is called
axial displacement or Thrust
Key Phasor
Transducer which produces once per shaft turn voltage, called the Keyphasor.
The occurrence can be a key way, hole or slot, a projection.
This signal is used primarily to measure shaft rotative speed and as reference for
measure vibration phase lag angle .It is essential element in measure slow roll bow/ run
out.
Vibration Monitoring System | GEN-06 (Rev 0)
13
Eddy Current
Electrical current which is generated in a conductive material when such material
intercepts the electromagnetic field of a proximity probe
Cross Talk
Interference or noise in a transducer signal or channel which originates in another
transducer or channel, when using proximity probes, cross talk can occur when the tips
of two (or more) probes are too close together.
Scale Factor
The change in output per change input (sensitivity) of a transducer, Also, the factor by
which a signal must be increased or decreased to meet the input requirements of an
instrument
Critical Speed
In general, any shaft relative speed which is associated with high (dangerous level
vibration amplitude. Often, critical speed is used to describe a shaft relative speed equal
to rotor system natural frequency .This is more correctly called a balance resonance
speed
Proximitter
A Bentley Nevada signal condition device which sends radio frequency signal to an
eddy current proximity probe, demodulation the probe output, and provide out signals
proportional to both the average and dynamic probe gap distance. Also called an
oscillator - demodulator
14
2.4. Units are used in MMS
MIL = .001 inch (displacement)
pp = peak-to-peak amplitude
In/s = inches per second velocity
G = acceleration due to earth gravity
m/s2 = meter per second squared (acceleration)
Hz = cycle per second (frequency)
Cpm = cycle per minute
rpm = revolution per minute (shaft rotation speed)
µm = micrometer 10-6(displacement)
Vibration Monitoring System | GEN-06 (Rev 0)
15
3. PROXIMITY TRANSDUCER
Learning objectives:
16
3. PROXIMITY TRANSDUCER:
The transducer system has three individual components.
PROBE,
EXTENSION CABLE and
PROXIMITOR
A typical Bentley Nevada PROBE has a tip assembly, made of a generic version of
polyphenylene sulfide (PPS) that thread into a stainless steel case. The tip assembly can
be various sizes in diameter and contain a coil that terminates to the center conductor
and inner screen of a 75 ohm miniature triaxial cable that exits the stainless steel casing
Vibration Monitoring System | GEN-06 (Rev 0)
17
3.1. How Probe Works:
Coil inside probe tip serves as an antenna and radiates high frequency energy into free
space. Any conductive material within the field absorbs energy and causes output of
probe to decrease proportional to air gap distance.
Basically the extension cable is Triaxial Cable. The triaxial cable has a center conductor
and two screens. The inner screen and center conductor are connections from the coil in
the tip to the miniature connector at the probe cable end. The outer screen is not
connected to the coil or the connector, so it is not part of the electrical properties of the
system. This outer screen provides a mechanical protection for the inner screen. This
18
The 3300 XL probe cable and extension cable use the Click Loc connector which
Reduces concerns about under or over tightening connectors. This connector is
Corrosion-resistant and gold-plated and requires only finger-tight torque (connectors
Will "click"). This specially engineered locking mechanism prevents the connectors from
loosening. They do not require any special tools for installation or removal.
Supply
Common
Output
19
Supply and common connect with -24Vdc and the probe output signal is connect
through extension cable on the output terminal of the Proximitter.
20
penetration depth of the eddy currents depends on the material’s conductivity and
permeability. 4140 steel penetration is around 0.003 inches (3 mils).
Once the probe is close enough to cause eddy currents to flow in a conductive material
the RF signal is affected in two ways:
1. Amplitude is at a MINIMUM when distance (Gap) between probe and target material
(Target) is at a MINIMUM. Maximum eddy current flow occurs.
21
If the target is moving SLOWLY within the RF field, the signal amplitude INCREASES
or DECREASES SLOWLY. If the target is moving RAPIDLY within the RF field, the
signal amplitude INCREASES or DECREASES RAPIDLY. Oscillatory movement of the
target causes the RF signal to modulate.
The demodulator circuit deals with slowly or rapidly changing signal amplitude in the
same way. If the target is not oscillating, as might be the case with a thrust probe, the
22
3.5. Proximity Probe Used as an Axial Position
Thrust Position is the average position, or change in position, of a rotor in the axial
direction with respect to some fixed reference. Typically, the reference is the thrust
bearing support structure or other casing member to which the probe is mounted.
Thrust position measurements are valuable because they let you track the axial position
of the shaft and avoid destructive events like axial rubs. The thrust position probe may
observe the thrust collar directly or some other integral, axial shaft surface, as long as it
is within about 305 mm (12 inches) of the thrust bearing.
Vibration Monitoring System | GEN-06 (Rev 0)
23
Installation Method of Axial probe
Suppose the Gap voltages during running the machine at XT is 9.00 Volts. What will be
the float and in which direction?
What point we have missed while adjusting the gap voltage of the probe?
24
3.7. Probe Tip material
Probe tip materials commonly used are:
Ryton Tip
Vibration Monitoring System | GEN-06 (Rev 0)
25
Ceramic Capped Tip
Forward Mounting
26
Reverse Mounting
27
3.10. How decode the Probe’s / Extension Cable
Coding:
How decode the Probe’s Coding
0.5 M
1.00 M
28
How decode the extension cable’s coding:
characteristic?
STEPS:
2. Set and ensure that micro meter is perfectly at its reference/zero position with the
probe tip touching the spindle plate.
29
3. Now start varying the distance between the probe tip and the spindle plate in the
fixed increments of 0.2mm and note down the corresponding output voltage
from Proximitter till the time distance reaches 2mm.
5. Ideally the above value should be 200 mV / mil but following deviation limits
have been deemed acceptable / permissible:
Axial Vibration Probe = 200 mV / mil ± 2.5 %
Radial Vibration Probe = 200 mV / mil ± 5 %
6. If slope does not lie in these constraints, try alternatively changing different
components i.e. probe, extension cable & Proximitter – one at a time.
7. Also check the Core and Jacket Resistance (R core & R jacket) of Extension Cable
and Probe Resistance, R probe. (5m Proximitter system for Bentley Nevada has
been standardized in Pakarab fixing length of Extension Cable at 4.0 meter while
1.0 meter for Probe).
9. Resistance should lie in between these values otherwise replace the component.
30
4. TROUBLESHOOTING SEQUENCE
Learning objectives:
To understand fault diagnosing procedure
To understand fault diagnosing techniques
Vibration Monitoring System | GEN-06 (Rev 0)
31
4. TROUBLESHOOTING SEQUENCE:
This troubleshooting procedure divides a 3500 Monitoring System into three areas:
32
Check the voltage at the Proximitor sensor as shown in figer
Remove the field wire from the PWR terminal and measure voltage between the PWR
terminal and COM terminal. The Proximitor supply voltage (-VT) should be -23.7 ± 0.5
Vdc.
If -VT is out of tolerance, the problem is in the monitor or I/O module because voltage
regulation of -VT occurs in both of these units. Replace the monitor with a compatible
item and measure the voltage between PWR and COM terminals.
If –VT is within tolerance, the monitor and I/O module are working correctly. Remove
the field wire from the PWR terminal and measure voltage between the PWR terminal
and COM terminal. The Proximitor supply voltage (-VT) should be -23.7 ± 0.5 Vdc.
If -VT is out of tolerance, the problem is in the monitor or I/O module because voltage
regulation of -VT occurs in both of these units. Replace the monitor with a compatible
item and measure the voltage between PWR and COM terminals.
If –VT is within tolerance, the monitor and I/O module are working correctly.
33
Disconnect the VT wire on the Proximitor Sensor and measure the voltage at the end of
the wire. VT should be –23.7 ± 0.5 Vdc.
If the OK voltage is out of limits, check the transducer extension cable as described
below
If the OK voltage is within the OK limits, reconnect the wire to the OUT terminal
34
Remove the field wire from the SIG /A terminal on the I/O module and measure DC gap
voltage between COM terminal and SIG / A terminal. The voltage should be within the
OK Limits for the Proximitor Sensor.
35
4.4. Test the Probe and Extension Cable
Re-connect the field wiring to the OUT terminal of the Proximitor and remove the
miniature co-axial extension cable connector from the Proximitor. Ensure that the
female connector on the Proximitor and the male connector on the extension cable are
clean. Measure the resistance between the outer (not the armor braid if fitted) conductor
and the inner conductor of the extension cable. Normal resistance should be between 7
and 11 Ω depending on system length.
If the resistance is within limits, the probe and extension cable are okay.
If the resistance is out of limits, break the miniature co-axial connection between the
probe and the extension cable. Ensure that the female connector on the extension cable
and the male connector on the probe are clean. Measure the resistance between the
36
4.5. Troubleshooting a 3500 Rack
The 3500 Monitioring System continously checks the condition of the transducer and
field wiring by detecting the upper and lower input voltage limit set of each monitor
(OK limits).
If either of these limits is exceeded, the OK LED will go off and the BYPASS LED will
come on. The first step for troubleshooting a 3500 rack is to check the status LEDs on the
front panel of the monitors. The LEDs indicate the condition of the monitor as follows:
Vibration Monitoring System | GEN-06 (Rev 0)
OK: Indicates that the Proximitor / Seismic Monitor and the I/O Module are operating
correctly.
TX/RX: Flashes at the rate that messages are received and transmitted.
Bypass: Indicates that some of the monitor functions are temporarily suppressed
37
4.6. Replacing 3500 Modules
Disabling (Bypassing) Monitor
Monitors and power supplies are designed to be removed from the monitor rack while
the monitoring system is on (“Hot Swappable”); the monitor will place itself in bypass
when it is reinstalled while it goes through a self-test process
38
While monitors and power supplies (one at a time) can be removed with the power on,
the following should not be “hot swapped”: the Rack Interface Module (RIM) or
Transient Data Interface (TDI); communications to outside devices and monitor
management will be lost causing unreliable results changing some I/O modules may
create safety hazards for the technician, damage the I/O and/or the associated monitor,
and could cause machine trips due to their disconnection
Vibration Monitoring System | GEN-06 (Rev 0)
39
5. BENTLY NEVADA 3500
Learning objectives:
40
3500 System Monitor
41
3500 System Monitor Feature
Microprocessor based system
Removing & insertion of one Supply at one time will not disrupt operation
42
3500/20 Rack Interface Module (RIM)
Must be located in the 1st Slot
– OK
– TX/RX
– TM
– CONFIG OK
3
2. Hardware Switches
– Reset
Vibration Monitoring System | GEN-06 (Rev 0)
– Rack address
3. Configuration Port
43
3500/42 Proximitor / Seismic Monitor
Four Channel Monitor
1
Accepts input from proximity and seismic transducers
2. Buffered O/Ps
1. OK
2. TX/RX
3. Channel Al
44
3500/25 Key Phasor Modules
• Half Height module with 2-channels
• Front View
4. OK and TX/RX
5. Buffered O/P
Serial Link
45
3500 Multiple Rack Configurations
Series of Racks
Host Computer
46
3500 Software Package
Software Package
47
3500 Software Sequence
START
Configure Rack
Down Load
Rack Configuration
Connect
48
Rack Configuration Software
• Modules selection
• Define Set points (Alert/Alarm1 and Danger/ Alarm2) for Monitor Types
49
Software Configuration Utility
• Used to create Machine Train Displays
– Enabling/Disabling
– Memory Size
50
Data Acquisition/DDE Server
51
Operator Display Software
• Display Machine monitoring Data using
– Current values
– Bargraphs
– Trends (Historical/Real)
• Used to View
Current Values
52
Vibration Monitoring System | GEN-06 (Rev 0)
53
Bar graphs
Trends
54
Vibration Monitoring System | GEN-06 (Rev 0)
55
Machine Train Diagram
System Event List
56
Vibration Monitoring System | GEN-06 (Rev 0)
57
Alarm Event List
6. MACHINE MONITORING SYSTEM AT
PAKARAB FERTILIZERS
Learning objectives:
To remember architecture of Compressor trains in the vicinity of PFL
58
Vibration / Thrust Monitoring at Line A
Key Phasor
Vibration Monitoring System | GEN-06 (Rev 0)
59
VIBRATION MONITORING SYSTEM
NITRIC ACID PLANT LINE A
SET POINTS OF AIR COMPRESSOR TRAIN
Sr TRIP AT
OLD TAG # NEW TAG # LOCATION SERVICE ALERT DANGER
# DANGER
Speed/
19 KEY phasor Tail Gas Turbine N.A N.A N.A
Reference
60
Vibration / Thrust Monitoring at Line B
Key Phasor
Vibration Monitoring System | GEN-06 (Rev 0)
61
VIBRATION MONITORING SYSTEM
NITRIC ACID PLANT LINE B
SET POINTS OF AIR COMPRESSOR TRAIN
Sr TRIP AT
OLD TAG # NEW TAG # LOCATION SERVICE ALERT DANGER
# DANGER
Speed /
19 KEY phasor Tail Gas Turbine N.A N.A N.A
Reference
62
Vibration / Thrust Monitoring at 101-J/JT Air Compressor
Vibration Monitoring System | GEN-06 (Rev 0)
63
VIBRATION MONITORING SYSTEM
AMMONIA PLANT
SET POINTS OF AIR COMPRESSOR(101-J/JT)
Sr TRIP AT
OLD TAG # NEW TAG # LOCATION SERVICE ALERT DANGER
# DANGER
LP
7 C - POINT VT-132 A VIBRATION 75 µm 100 µm YES
COMPRESSOR
LP
8 C - POINT VT-132 B COMPRESSOR VIBRATION 75 µm 100 µm YES
LP
9 D - POINT VT-133 A COMPRESSOR VIBRATION 75 µm 100 µm YES
LP
10 D - POINT VT-133 B COMPRESSOR VIBRATION 75 µm 100 µm YES
LP
11 HXA-151 A XT-151 A COMPRESSOR THRUST 0.35mm 0.45 mm
YES
LP
12 HXA-151 B XT-151 B THRUST 0.35mm 0.45 mm
COMPRESSOR
64
HP
17 J - POINT VT-138 A VIBRATION 50 µm 100 µm YES
COMPRESSOR
HP
18 J - POINT VT-138 B COMPRESSOR VIBRATION 50 µm 100 µm YES
HP
19 K - POINT VT-139 A COMPRESSOR VIBRATION 50 µm 100 µm YES
HP
20 K - POINT VT-139 B COMPRESSOR VIBRATION 50 µm 100 µm YES
HP
21 HXA-152 A XT-154 A COMPRESSOR THRUST 0.35mm 0.45 mm
YES
HP
22 HXA-152 B XT-154 B COMPRESSOR THRUST 0.35mm 0.45 mm
LP Speed /
23 KEY Phasor KEY101J-1 N.A N.A N.A
COMPRESSOR Reference
HP Speed /
24 KEY Phasor KEY101J-2 N.A N.A N.A
COMPRESSOR Reference
Vibration Monitoring System | GEN-06 (Rev 0)
65
Vibration / Thrust Monitoring at 103-J/JT Air Compressor
66
VIBRATION MONITORING SYSTEM
AMMONIA PLANT
SET POINTS OF SYN COMPRESSOR(103-J/JT)
Sr TRIP AT
OLD TAG # NEW TAG # LOCATION SERVICE ALERT DANGER
# DANGER
LP
13 VT-315 A VT-334 A VIBRATION 50 µm 100 µm NO
COMPRESSOR
Vibration Monitoring System | GEN-06 (Rev 0)
LP
14 VT-315 B VT-334 B VIBRATION 50 µm 100 µm NO
COMPRESSOR
LP
15 VT-316 A VT-335 A VIBRATION 75 µm 100 µm NO
COMPRESSOR
LP
16 VT-316 B VT-335 B VIBRATION 75 µm 100 µm NO
COMPRESSOR
LP
17 HXA-302 A XT-352 A THRUST 0.3mm 0.5 mm
COMPRESSOR YES
LP
18 HXA-302 B XT-352 B THRUST 0.3 mm 0.5 mm
COMPRESSOR
67
HP
19 VT-317 A VT-336 A VIBRATION 75 µm 100 µm NO
COMPRESSOR
HP
20 VT-317 B VT-336 B COMPRESSOR VIBRATION 75 µm 100 µm NO
HP
21 VT-318 A VT-337 A COMPRESSOR VIBRATION 75 µm 100 µm NO
HP
22 VT-318 B VT-337 B COMPRESSOR VIBRATION 75 µm 100 µm NO
HP
23 HXA-301 A XT-353 A COMPRESSOR THRUST 0.3mm 0.6 mm
YES
HP
24 HXA-301 B XT-353 B COMPRESSOR THRUST 0.3mm 0.6 mm
HP Speed /
25 KEY Phasor KEY103J-1 N.A N.A N.A
COMPRESSOR Reference
68
Vibration / Thrust Monito ring at 105-J/JT Ammonia Compressor
Vibration Monitoring System | GEN-06 (Rev 0)
69
VIBRATION MONITORING SYSTEM
AMMONIA PLANT
SET POINTS OF AMMONIA COMPRESSOR(105-J/JT)
Sr TRIP AT
OLD TAG # NEW TAG # LOCATION SERVICE ALERT DANGER
# DANGER
LP
7 VT-532 A VIBRATION
COMPRESSOR
LP
8 VT-532 B VIBRATION
COMPRESSOR
LP
9 VT-533 A VIBRATION
COMPRESSOR
LP
10 VT-533 B VIBRATION
COMPRESSOR
LP
11 HXA-502 A XT-551 A THRUST 0.3 mm 0.5 mm
COMPRESSOR YES
LP
12 HXA-502 B XT-551 B THRUST 0.3 mm 0.5 mm
COMPRESSOR
HP
13 VT-534 A VIBRATION
COMPRESSOR
HP
14 VT-534 B VIBRATION
COMPRESSOR
HP Speed /
19 KEY phasor KEY105J-1 N.A N.A N.A
COMPRESSOR Reference
70
Vibration / Thrust Monitoring at 120-J/JT CO2 Compressor
Vibration Monitoring System | GEN-06 (Rev 0)
71
VIBRATION MONITORING SYSTEM
AMMONIA PLANT
SET POINTS OF CO2 COMPRESSOR(120-J/JT)
Sr TRIP AT
OLD TAG # NEW TAG # LOCATION SERVICE ALERT DANGER
# DANGER
72