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Vibration Monitoring System

Instrument Unit

PAKARAB FERTILIZERS LIMITED MULTAN

GEN-06 (Rev 0)
Prepared by : M. Junaid
Reviewed by : Ali Raza Soomro
Approved by : Pervaiz Iqbal
Contents

1. Machine Monitoring System

1.1. Brief Introduction


1.2. History

2. Methods Used for Machine Monitoring System

2.1. Contact Method


2.2. Non- Contact Method
2.3. Common Terms
2.4. Units of Measurement

3. Proximity Transducer

3.1. How Probe Works:


3.2. How Proximitter works:
3.3. Why we give negative supply on Proximitter?
3.4. Proximity Probe Used as a Radial Vibration
3.5. Proximity Probe Used as an Axial Position
3.6. Proximity Probe Used as a Keyphasor
3.7. Probe Tip material
3.8. Probe types according to mounting
3.9. Standard length of Transducer system
3.10. How decode the Probe’s / Extension Cable coding:
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3.11. How to check the probe linearity and characteristic?

4. Troubleshooting Sequence

4.1. Check Transducer Supply Voltage


4.2. Check Transducer Field Wiring

4.3. Check Transducer Output Signal


4.4. Test the Probe and Extension Cable
4.5. Troubleshooting a 3500 Rack
4.6. Replacing 3500 Modules
4.7. Hot Swapping Components

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5. BENTLY NEVADA 3500

5.1. 3500 System Monitor Feature


5.2. 3500/15 AC & DC Power Supplies
5.3. 3500/20 Rack Interface Module (RIM)
5.4. 3500/42 Proximitter / Seismic Monitor
5.5. 3500/33 the 16 Channel Relay Module
5.6. 3500/25 Key Phasor Modules
5.7. 3500 Multiple Rack Configurations
5.8. 3500 Software Package
5.9. Rack Configuration Software
5.10. Software Configuration Utility
5.11. Data Acquisition/DDE Server
5.12. Operator Display Software

6. Machine Monitoring System at Pakarab Fertilizer Multan

6.1.Vibration and Thrust monitoring at Line A


6.2.Vibration and Thrust monitoring at Line B
6.3.Vibration and Thrust monitoring at 101 J/JT air compressor
6.4.Vibration and Thrust monitoring at 103 J/JT air compressor
6.5.Vibration and Thrust monitoring at 105 J/JT air compressor
6.6.Vibration and Thrust monitoring at 102 J/JT CO2 compressor

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1. MACHINE MONITORING SYSTEM
Learning objectives:

 To understand purpose of Machine Monitoring System


 To understand importance and usefulness of Machine Monitoring System
 To understand history of Machine Monitoring System

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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.

The first level of machinery management is monitoring and protection, which is


achieved through Machine Monitoring System.

Monitoring is accomplished by using various transducers and sensors, which translates


measurable Machine and process condition parameters into electrical signals. These
signals are accessed and displayed by the Monitoring System modules.

1.2. HISTORY
Earlier of times vibration was Sensing By hand
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Then Vibration Sensing By Rod

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Then Vibration Sensing By Stethoscope

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Meanwhile the problem was Subjective Experience

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Objective Technology
2. METHODS USED FOR MACHINE
MONITORING SYSTEM

Learning objectives:

 To understand different techniques of Machine Monitoring System


 To understand working methodology of Machine Monitoring System
 To understand advantages and limitations of each technique
 To understand different common terms used
 To remember unit of measurement

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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

2. Non contact method

a. Eddy current method

2.1. CONTACT METHOD


Velocity 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
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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

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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

Advantages of Electrodynamics Velocity Transducer

 No external powering

 Powerful signal Output

 Easy to install

 Ability to operate at elevated temperatures

Disadvantages of Electrodynamics Velocity Transducer

 Not useful for very low frequency

 Not useful for very high frequency

 Moving parts wear

 Mounting orientation

Acceleration method

Acceleration is defined as rate of change of the velocity and is measured in g’s of


acceleration relative to the acceleration of gravity.

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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

 No moving Part, No Wear

 Rugged

 Very large dynamic range

 Wide frequency Range

 Can be mounted with any orientation

Disadvantages of Accelerometer:

 Ambient Temperature Effect

2.2. NON-CONTACT METHOD


Eddy current method
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We will discuss in detail eddy current method in Bentley Nevada system.

Here we discuss it advantages and disadvantages.

Advantages of Eddy Current:

 Low frequency response

 Can measure relative displacement

 Useful as a key phasor for dynamic balancing & Analysis

 Reliable if properly installed and maintained

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Disadvantages of Eddy Current:

 Difficult to install

 Practical limits of high frequency displacement measurement

 Calibration dependent on shaft material

 Shaft run out / glitch produce false signals

2.3. COMMON TERMS


Displacement
Displacement is a measure of the total travel of the mass that is, it shows how for the
mass travels back and forth when it vibrates.

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

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In the same direction as the shaft centerline

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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.
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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

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Proximity Probe
A non contacting device which measures the displacement motion and position of an
observed surface relative to the probe mounting location. Typically, proximity probes
used for rotating machinery measurements operate on the eddy current principle and
measurement shaft displacement motion and position relative to the machine bearings
or housing.

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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)
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3. PROXIMITY TRANSDUCER

Learning objectives:

 To understand basic concept of Proximity Transducer


 To understand working methodology
 To understand different measurement applications
 To understand decoding of Transducer system

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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
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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.

Internal construction of Extension Cable:

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

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prevents unwanted grounding of one side of the coil if the cable’s outer Teflon coating
is damaged.

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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.

3.2. How Proximitter works:


Proximity Transducer Systems provide an electrical signal that represents the distance
between a conductive surface and the probe tip of the system. The Proximitter contains
electronics that provide two functions:
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1. Generate a radio frequency (RF) signal using an oscillator circuit.


2. Condition the RF signal to extract usable data using a demodulator circuit.

The supply of the Proximitter is -24Vdc.

It has three terminals

 Supply
 Common
 Output

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Supply and common connect with -24Vdc and the probe output signal is connect
through extension cable on the output terminal of the Proximitter.

3.3. Why we give negative supply on Proximitter


I am glad you benefited from my article. To answer your question is that the first
reliable transistors that were commonly available for use were NPN, which required a
negative supply.
(Mark Snyder, Bentley Nevada)

Proximity transducer systems have many uses in monitoring the behavior of a

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machine's shaft (target). The two most common applications are RADIAL VIBRATION
(radial movement) and THRUST (axial movement).

3.4. Proximity Probe Used as a Radial Vibration


The Proximity Transducer System provides an output voltage directly proportional to
the distance between the probe tip and the observed conductive surface. It is capable of
both static (position) and dynamic (vibration) measurements, and is primarily used for
vibration and position measurement applications on fluid-film bearing machines, as
well as Keyphasor® and speed measurement applications. When conductive material is
present in the RF field, Eddy Currents flow in the surface of that material. The

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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.

2. Amplitude is at a MAXIMUM when distance (Gap) between probe and target


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material is at a MAXIMUM. Minimum eddy current flow occurs.

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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

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Proximitter output is a constant DC voltage, called the gap. If the target is oscillating
(gap changing slowly or rapidly) the Proximitter output is a varying DC voltage (AC)
shown above by a sine wave. If the probe is observing a vibration, the Proximitter will
provide both a DC (gap) and an AC (vibration) component in the output signal. A
typical system frequency response is from 0 Hz (DC) to 10 kHz. Newer transducer
systems, such as the 3300XL proximity system have responses up to 12 kHz.

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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.
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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?

We know that the probe was set at 10.00 volts.


We also know that proximitor characteristics are 8 volt/mm or 200 mv/mil.
So 10.00 – 9.00 = 1.00 volt
8 volt = 1mm (Given), 1.00 volt will be
1.00 / 8 = 0.125 mm. So 0.125 mm will be displacement of the shaft indicated at Monitor
and its direction will be normal side.
Volts are 11.00 and what will be the float (Displacement) and location of the shaft.
1.00 – 10.00 = 1.00
1.00 / 8 = 0.125 mm
The location of the shaft will be at counter side of the monitor.
Voltages at both extreme ends of the shafts are 11.00 and 9.00 volts.

What is the total float of the shaft?

What point we have missed while adjusting the gap voltage of the probe?

Total float of the shaft is 11.00 – 9.00 = 2.00 volt DC.


Float 2.00 / 8 = 0.25 mm

3.6. Proximity Probe Used as a Keyphasor

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Another common use for the proximity transducer system is as a ONCE PER
REVOLUTION marker or KEYPHASOR (Kφ) on a machine shaft. This proximity
transducer system is mounted so that it observes a "notch" or a "projection" on the shaft
and produces a voltage pulse once each revolution. Passage over the notch or projection
causes a much more significant voltage change than expected from normal vibration or
distance measurements. This significant difference in voltage allows the 3500
monitoring system to discriminate between a legitimate ONCE PER REVOLUTION
signal, and background noise or vibration. The Keyphasor timing signal is a very useful
tool when diagnosing machinery problems. At a minimum, the generated pulse can be
used to measure machine speed.

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3.7. Probe Tip material
Probe tip materials commonly used are:

Ryton Tip
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Ceramic Capped Tip

3.8. Probes types according to mounting:

Forward Mounting

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Reverse Mounting

3.9. Standard length of Transducer system


Total length will be written at the Proximitter or it can be noted from the Model No. of
the Proximitter.

For 5 meter System

0.5 m (probe) + 4.5 m (Extension cable) = 5 m


Or
01 m (probe) + 04 m (Extension cable) = 5 m
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For 9 meter System

0.5 m (probe) + 8.5 m (Extension cable) = 9 m


Or
01 m (probe) + 08 m (Extension cable) = 9 m

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3.10. How decode the Probe’s / Extension Cable
Coding:
 How decode the Probe’s Coding

 0.5 M
 1.00 M

Model No. 330101 – 16 – 36 – 10 – 02 – 00

 330101 -----> 8mm Without Armored, Ryton tip


 16 -----> Unthreaded length

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36 -----> Total length
 10 -----> One meter total length
 02 -----> BNC Connector
 00 -----> Agency Approval

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 How decode the extension cable’s coding:

 Model No. 330130 – 040 -00-00


 Model No. 330130 – 045 -00-00
 Model No. 330130 – 080 -00-00
 Model No. 330130 – 085 -00-00
040 -----> 4 METER LENGTH
045 -----> 4.5 METER LENGTH
080 -----> 8 METER LENGTH
085 -----> 8.5 METER LENGTH
00 -----> WITHOUT ARMOURED
01 -----> WITH ARMOURED

3.11. How to check the probe linearity and


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characteristic?
STEPS:

1. Adjust / fix the probe in TK-3.

2. Set and ensure that micro meter is perfectly at its reference/zero position with the
probe tip touching the spindle plate.

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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.

4. Apply following formula to find out the slope of this probe:


{(Voltage at 2mm) – (Voltage at 1mm)} * 25.4 = mV / mil

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).

8. The Permissible limits of resistances of above standardized Probe and Extension


Cable are as under:
 R core = 0.88 ± 0.13 ohms, from center conductor to center conductor
 R jacket = 0.26 ± 0.05 ohms, from /outer conductor to outer conductor
 R probe = 7.59 ± 0.5 ohms, from center conductor to outer conductor

9. Resistance should lie in between these values otherwise replace the component.

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10. Repeat Step no 1 ~ 5 until slope comes within permissible value.

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4. TROUBLESHOOTING SEQUENCE

Learning objectives:
 To understand fault diagnosing procedure
 To understand fault diagnosing techniques
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4. TROUBLESHOOTING SEQUENCE:
This troubleshooting procedure divides a 3500 Monitoring System into three areas:

 Field wiring and Proximitors


 Extension cable and probe
 Rack

4.1. Check Transducer Supply Voltage


Measure the Proximitor supply voltage (-VT) between PWR and COM terminals on the
monitor I/O module. The Proximitor supply voltage (-VT) should be -23.7 ± 0.5 Vdc.

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If -VT is out of tolerance, remove field wire from PWR terminal and measure voltage
between PWR terminal and COM terminal as shown on the next page.
If –VT is within tolerance, the monitor and the I/O module are working correctly.

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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.

4.2. Check Transducer Field Wiring


Measure the voltage between the -VT and COM terminals on the Proximitor system.
The Proximitor supply voltage (-VT) should be -23.7 ± 0.5 Vdc.
If -VT is out of tolerance, the fault is with the field wiring.
If –VT is within tolerance, go to the troubleshooting next step
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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 -VT is out of tolerance, the fault is with the field wiring.


If –VT is within tolerance, replace the Proximitor Sensor with a compatible component.

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4.3. Check Transducer Output Signal
Remove the field wire from the OUT terminal and measure DC gap voltage between
COM terminal and OUT terminal. The voltage should be within the OK Limits for the
Proximitor Sensor.

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

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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.

If the OK voltage is out of limits, replace the field wiring.


If the OK voltage is within the OK limits, reconnect the wire to the SIG /A terminal and
replace the monitor with a compatible item.
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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, preceed the next setup.

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

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outer conductor and the inner conductor of the probe. Normal resistance should be
between 7 and 11 Ω depending on system length.
If resistance is out of limits replace probe with a compatible item.
If resistance is within limits replace extension cable with compatible item.

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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:
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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

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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

4.7. Hot Swapping Components

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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
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5. BENTLY NEVADA 3500

Learning objectives:

 To understand functioning & properties of 3500 Monitoring system


 To understand functioning of different cards
 To understand software application and utilization
 To understand the utilization of different features

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3500 System Monitor

Rack Interface Modules

One or two Any combination of the


Power Supplies following 14 slot positions
•Monitor Module
•Key Phasor Module
•Relay Module
•Temperature Modules
•Communication Gateway
Module
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3500 System Monitor Feature
Microprocessor based system

Modular & Flexible Architecture

Tight integration with DCS using Industry Standards Interfaces

Hot Insertion or Removal of Modules

Provides Enhanced Operator Information

Window based operator Display

Data can be displayed at multiple locations

Improved Reliability due to

Redundant Power supply

Triple Modular Redundant Relay cards

3500/15 AC & DC Power Supplies


Half Height Modules

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Always installed in the left most slot

Upper Module... Primary Supply

Lower Module... Backup Supply

Removing & insertion of one Supply at one time will not disrupt operation

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3500/20 Rack Interface Module (RIM)
Must be located in the 1st Slot

Interface card between the rack & monitoring computer

Works as a communication server

Manages Event List


1
Alarm Event List

System Event List

Rack Interface Module (RIM)


2
1. LEDs GOOD FAULT

– OK

– TX/RX

– TM

– CONFIG OK
3
2. Hardware Switches

– Reset
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– Run & Program Key

– Rack address

3. Configuration Port

– Used to Configure Rack

– Retrieve machinery data

– Using RS-232 Protocol

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3500/42 Proximitor / Seismic Monitor
Four Channel Monitor
1
Accepts input from proximity and seismic transducers

Monitor acceleration, velocity and absolute shaft measurement as well


2
1. Status LEDs

2. Buffered O/Ps

3500/33 The 16 Channel Relay Module

• Full Height Module


1
• Provides sixteen Relay outputs 2

• Provide Alarm on Alert & tripping on Danger situations


3
• Programmable for AND/OR voting of trip Relays

Vibration Monitoring System | GEN-06 (Rev 0)


• LED GOOD FAULT

1. OK

2. TX/RX

3. Channel Al

44
3500/25 Key Phasor Modules
• Half Height module with 2-channels

• Measure RPM of the observed shaft


1
• View either Notch or Projection on the Shaft
2
• Association of key Phasor signal with peak to peak

• vibration is used to determine Vibration spectrum

• Range 1 to 99,999 RPM

• Maximum 4 key Phasor signals are possible in


2
3500 System

• Front View

4. OK and TX/RX

5. Buffered O/P

3500 Rack Configurations


3500 Single Rack Configurations
Vibration Monitoring System | GEN-06 (Rev 0)

3500 Single Rack Configuration

Serial Link

Host Computer 3500 Rack

45
3500 Multiple Rack Configurations

Series of Racks

Host Computer

Plant wide Data Monitoring

3500 Monitor Rack

Vibration Monitoring System | GEN-06 (Rev 0)


Data Acquisition Computer

Plant Wide Ethernet

POperator1 Operator2 Operator3

46
3500 Software Package

Software Package

Rack Data Acquisition Operato


r
Configuration DDE Server
Display
Vibration Monitoring System | GEN-06 (Rev 0)

47
3500 Software Sequence

START

Configure Rack

Using Rack Configuration

Down Load

Rack Configuration

Design Train Diagram

Using Software Configuration Utility

Connect

Data Acquisition/DDE Server

Vibration Monitoring System | GEN-06 (Rev 0)


Monitor Data using

Operator Display Software

48
Rack Configuration Software
• Modules selection

• Define Monitor Types

• Tag Monitor Channels

• Define Set points (Alert/Alarm1 and Danger/ Alarm2) for Monitor Types

• Develop Alarm Drive Logic (And/OR) to trigger trip relays


Vibration Monitoring System | GEN-06 (Rev 0)

49
Software Configuration Utility
• Used to create Machine Train Displays

• Specify Historic trend parameters

– Enabling/Disabling

– Time B/W two consecutive points

– Memory Size

• Generate Report on Machine Train Displays

Vibration Monitoring System | GEN-06 (Rev 0)

50
Data Acquisition/DDE Server

• Collect Machinery monitoring Data, Alarm, and System Events data


Vibration Monitoring System | GEN-06 (Rev 0)

• Provide Data to Operator Display Software

• Store historical and real-time trend data

• Act as Dynamic Data Exchanger (DDE)

with other systems using industry standard protocols

51
Operator Display Software
• Display Machine monitoring Data using

– Current values

– Bargraphs

– Trends (Historical/Real)

– Machine Train Diagrams

• Used to View

– System Event List

– Alarm Event List

Current Values

Vibration Monitoring System | GEN-06 (Rev 0)

52
Vibration Monitoring System | GEN-06 (Rev 0)

53
Bar graphs
Trends

Vibration Monitoring System | GEN-06 (Rev 0)

54
Vibration Monitoring System | GEN-06 (Rev 0)

55
Machine Train Diagram
System Event List

Vibration Monitoring System | GEN-06 (Rev 0)

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

 To remember tagging scheme used at PFL

 Area owners must remember probe installation & logic scheme

Vibration Monitoring System | GEN-06 (Rev 0)

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

1 XIA-02730 H VT-02130 A Steam Turbine VIBRATION 50 µm 100 µm YES

2 XIA-02730 V VT-02130 B Steam Turbine VIBRATION 50 µm 100 µm YES

3 XIA-02731 H VT-02131 A Steam Turbine VIBRATION 50 µm 100 µm YES

4 XIA-02731 V VT-02131 B Steam Turbine VIBRATION 50 µm 100 µm YES

5 YIA-02752-1 XT-02152 A Steam Turbine THRUST 0.2 mm 0.4 mm


YES
( 2oo2 )
6 YIA-02752-2 XT-02152 B Steam Turbine THRUST 0.2 mm 0.4 mm

7 XIA-02732 H VT-02132 A Air Compressor VIBRATION 75 µm 125 µm YES

8 XIA-02732 V VT-02132 B Air Compressor VIBRATION 75 µm 125 µm YES

9 XIA-02733 H VT-02133 A Air Compressor VIBRATION 75 µm 125 µm YES

10 XIA-02733 V VT-02133 B Air Compressor VIBRATION 75 µm 125 µm YES

11 YIA-02750-1 XT-02150 A Air Compressor THRUST 0.2 mm 0.4 mm


YES
( 2oo2 )
12 YIA-02750-2 XT-02150 B Air Compressor THRUST 0.2 mm 0.4 mm

13 XIA-02734 H VT-02134 A Tail Gas Turbine VIBRATION 50 µm 100 µm YES

Vibration Monitoring System | GEN-06 (Rev 0)


14 XIA-02734 V VT-02134 B Tail Gas Turbine VIBRATION 50 µm 100 µm YES

15 XIA-02735 H VT-02135 A Tail Gas Turbine VIBRATION 50 µm 100 µm YES

16 XIA-02735 V VT-02135 B Tail Gas Turbine VIBRATION 50 µm 100 µm YES

17 YIA-02751-1 XT-02151 A Tail Gas Turbine THRUST 0.2 mm 0.4 mm


YES
( 2oo2 )
18 YIA-02751-2 XT-02151 B Tail Gas Turbine THRUST 0.2 mm 0.4 mm

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

1 XIA-02730 H VT-02230 A Steam Turbine VIBRATION 50 µm 100 µm YES

2 XIA-02730 V VT-02230 B Steam Turbine VIBRATION 50 µm 100 µm YES

3 XIA-02731 H VT-02231 A Steam Turbine VIBRATION 50 µm 100 µm YES

4 XIA-02731 V VT-02231 B Steam Turbine VIBRATION 50 µm 100 µm YES

5 YIA-02752-1 XT-02252 A Steam Turbine THRUST 0.2 mm 0.4 mm


YES
( 2oo2 )
6 YIA-02752-2 XT-02252 B Steam Turbine THRUST 0.2 mm 0.4 mm

7 XIA-02732 H VT-02232 A Air Compressor VIBRATION 75 µm 125 µm YES

8 XIA-02732 V VT-02232 B Air Compressor VIBRATION 75 µm 125 µm YES

9 XIA-02733 H VT-02233 A Air Compressor VIBRATION 75 µm 125 µm YES

10 XIA-02733 V VT-02233 B Air Compressor VIBRATION 75 µm 125 µm YES

11 YIA-02750-1 XT-02250 A Air Compressor THRUST 0.2 mm 0.4 mm


YES
( 2oo2 )
12 YIA-02750-2 XT-02250 B Air Compressor THRUST 0.2 mm 0.4 mm

13 XIA-02734 H VT-02234 A Tail Gas Turbine VIBRATION 50 µm 100 µm YES

Vibration Monitoring System | GEN-06 (Rev 0)


14 XIA-02734 V VT-02234 B Tail Gas Turbine VIBRATION 50 µm 100 µm YES

15 XIA-02735 H VT-02235 A Tail Gas Turbine VIBRATION 50 µm 100 µm YES

16 XIA-02735 V VT-02235 B Tail Gas Turbine VIBRATION 50 µm 100 µm YES

17 YIA-02751-1 XT-02251 A Tail Gas Turbine THRUST 0.2 mm 0.4 mm


YES
( 2oo2 )
18 YIA-02751-2 XT-02251 B Tail Gas Turbine THRUST 0.2 mm 0.4 mm

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

1 A - POINT VT-130 A Steam Turbine VIBRATION 75 µm 100 µm YES

2 A - POINT VT-130 B Steam Turbine VIBRATION 75 µm 100 µm YES

3 B - POINT VT-131 A Steam Turbine VIBRATION 75 µm 100 µm YES

4 B - POINT VT-131 B Steam Turbine VIBRATION 75 µm 100 µm YES

5 HXA-153 A XT-150 A Steam Turbine THRUST 0.35mm 0.45 mm


YES
6 HXA-153 B XT-150 B Steam Turbine THRUST 0.35mm 0.45 mm

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

Vibration Monitoring System | GEN-06 (Rev 0)


13 F- POINT VT-134 A GEAR BOX VIBRATION 75 µm 100 µm NO

14 F - POINT VT-134 B GEAR BOX VIBRATION 75 µm 100 µm NO

15 H - POINT VT-137 A GEAR BOX VIBRATION 75 µm 100 µm NO

16 - POINT VT-137 B GEAR BOX VIBRATION 75 µm 100 µm NO

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 KEY101J-1 N.A N.A N.A
COMPRESSOR Reference
HP Speed /
24 KEY Phasor KEY101J-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

Vibration Monitoring System | GEN-06 (Rev 0)

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

1 VT-311 A VT-330 A LP Steam Turbine VIBRATION 50 µm 75 µm NO

2 VT-311 B VT-330 B LP Steam Turbine VIBRATION 50 µm 75 µm NO

3 VT-312 A VT-331 A LP Steam Turbine VIBRATION

4 VT-312 B VT-331 B LP Steam Turbine VIBRATION

5 HXA-304 A XT-350 A LP Steam Turbine THRUST 0..3 mm 0.4 mm


YES
6 HXA-304 B XT-350 B LP Steam Turbine THRUST 0..3 mm 0.4 mm

7 VT-313 A VT-332 A HP Steam Turbine VIBRATION 75 µm 100 µm NO

8 VT-313 B VT-332 B HP Steam Turbine VIBRATION 75 µm 100 µm NO

9 VT-314 A VT-333 A HP Steam Turbine VIBRATION 75 µm 100 µm NO

10 VT-314 B VT-333 B HP Steam Turbine VIBRATION 75 µm 100 µm NO

11 HXA-303 A XT-351 A HP Steam Turbine THRUST 0.3 mm 0.4 mm


YES
12 HXA-303 B XT-351 B HP Steam Turbine THRUST 0.3 mm 0.4 mm

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 KEY103J-1 N.A N.A N.A
COMPRESSOR Reference

Vibration Monitoring System | GEN-06 (Rev 0)

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

1 VT-530 A Steam Turbine VIBRATION

2 VT-530 B Steam Turbine VIBRATION

3 VT-531 A Steam Turbine VIBRATION

4 VT-531 B Steam Turbine VIBRATION

5 HXA-503 A XT-550 A Steam Turbine THRUST 0.3 mm 0.4 mm


YES
6 HXA-503 B XT-550 B Steam Turbine THRUST 0.3mm 0.4 mm

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

Vibration Monitoring System | GEN-06 (Rev 0)


HP
15 VT-535 A VIBRATION
COMPRESSOR
HP
16 VT-535 B VIBRATION
COMPRESSOR
HP
17 HXA-501 A XT-552 A THRUST 0.3 mm 0.4 mm
COMPRESSOR YES
HP
18 HXA-501 B XT-552 B THRUST 0.3 mm 0.4 mm
COMPRESSOR

HP Speed /
19 KEY phasor KEY105J-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

5 HXA-202 A XT-551 A GEAR BOX THRUST 0.3 mm 0.4 mm YES


6 HXA-202 B XT-551 B GEAR BOX THRUST 0.3mm 0.4 mm

13 VT-230 A COMPRESSOR VIBRATION

14 VT-230 B COMPRESSOR VIBRATION

15 VT-231 A COMPRESSOR VIBRATION

16 VT-231 B COMPRESSOR VIBRATION

17 HXA-201 A XT-250 A COMPRESSOR THRUST 0.3 mm 0.4 mm


YES
18 HXA-201 B XT-552 B COMPRESSOR THRUST 0.3 mm 0.4 mm

Vibration Monitoring System | GEN-06 (Rev 0)

72

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