Condition Monitoring and Maintenance Systems. Condition Monitoring for Industrial Applications

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1 Condition Monitoring and Maintenance Systems Condition Monitoring for Industrial Applications

2 A Complete Solution

3 Condition Monitoring and Maintenance Systems Presentation Objectives Overview of CMMS Commitment of CMMS in on-line Applications Solutions for all Monitoring and Data Acquisition Requirements Integrated Monitoring Service Support-Machinery Testing, Startup, Installation, Commissioning, Analysis and Training

4 Condition Monitoring and Maintenance Systems Factory in Prague Czech Rep. Kosice, Slovakia Sales and Service Center in:prague, Budapest TLW

5 Integrated Condition Monitoring Range of Products Integration Plantwide Monitoring

6 Condition Monitoring and Maintenance Systems Vision To be recognized as the worldwide supplier of condition monitoring, offering the quality products and support services which enable our customers to operate the most effective programs in their industries.

7 Condition Monitoring and Maintenance Systems CMMS is a supplier of products and services to many customers: Shell VW SKODA ABB FLUOR DANIEL DURR CM PCB REK CEZ SD

8 Integrated Condition Monitoring Multi-Data Device Interface Single, Distributed Database Standard High Speed Network Multi-User Operation Basic monitoring to Protection Systems Ethernet File Server

9 CMMS CHECKER/EXPERT Tools and Technology To Keep Machinery Up and Running Operator's Tool No more clipboards! Operators and PdM/Vibration Analysis/ Reliability Departments work cooperatively User defined coded notes for analyst review; User notes for additional operator comments Easy To Use Alerts operator to changes- Alert or Danger Signal Saves Time Collect Vibration, Process Data and Visual Inspection info at one-time Once alarm is recognized, no need for analyst to return to field for additional data.

10 CMMS EXPERT

11 CMCP Programmable Machinery Monitoring and Protection System A machinery protection system which brings flexibility, reliability and the economy of digital electronics to large scale plant machinery. The CMCP places useable machinery information and instantaneous diagnostics at your fingertips, providing continuous on-line protection monitoringmeeting and exceeding API 670 Third Edition guidelines. Protection Monitoring Reliability Multi-Parameter Monitoring Monitors vibration, position, speed, temperature, and process inputs.

12 CMMS PROACTINANCE Management and Analysis Software A high quality, modular approach to managing an integrated condition monitoring program. CMMS PROACTINANCE is the core component of the Software package, offering an exceptional feature set to greatly simplify machinery analysis while enhancing the analyst's. diagnostic capabilities Graphical User Interface Drag and Drop Editing Multi-Tasking Enhanced Data Display

13 CMMS DAQ /CMMS PROACTINANCE The CMMS DAQ /CMMS PROACTINANCE provides round the clock automated data collection, and offers a powerful array of analysis tools to optimize your condition monitoring efforts. A Logical Solution for Cost Effective Plantwide Monitoring Automated Data Collection Reduces maintenance and labor costs.

14 CMMS DAQ and Proactinance A Logical Solution for Cost-Effective Plantwide Monitoring Tools for Bearing and Machinery Fault Detection, Analysis and Diagnosis Acceleration Enveloping HF Technology Permanently Mounted Sensors and Distributed Hardware Easy Installation Monitor dangerous and difficult to reach locations safely and efficiently. Consistent and secure sensor locations for reliable assessment of machine condition. Low start-up costs, quicker return on investment. Fast and accurate detection of bearing and gearbox problems. Detect ineffective lubrication before faults occur.

15 CMMS DAQ and Proactinance Enhances the functionality of machinery protection systems by enabling the acquisition of data into Proactinance on-line. The DAQ offers users an additional value to any currently installed protection system, providing high resolution predictive analysis capabilities for identification and correction of problems in critical machinery.

16 Two Major Components: DAQ Hardware 10 rack mount 4 to 256 channels 4 channel portable Proactinance Software MS SQL database Normal network server configuration Open data architecture Internet Access Prepared Multiple users Full network integration User friendly Data analysis and control functions WinXP/7

17 CMMS DAQ Hardware Overview Components Input Card DSP Card CPU Card CMMS DAQ Configuration HDD MMS- ROACTINANCE W 8-Channel Input/Protection Card 8-Channel 8-Channel Filter Card 8-Channel Filter Card 24-Channel Filter Card MUX ONLY IN MUXED SYSTEMS Power Supply Units 16-Channel 4-Channel ADC Card DSP Card Pentium II 500 MHz CPU Card Network Card

18 Typical System Overview SQL DB XP Server SQL Server analysis Dedicated Ethernet Link CMMS DAQ Display Network Printer CMMS DAQ

19 Transient Database ODBC Steady State Database ODBC Process CBM Database ODBC Transient Data FFT Acquisition Steady State Data FFT Acquisition DCS Process Data Acquisition ESD API-670 DSP Protection Monitor Modbus/FieldBus Digital Trip Single Point API-670 Monitors Single Point Transmitter Transducer Base Transducer Base Transducer Base Critical Machines Semi Critical Machines Balance of Plant Machines

20 CMMS DAQ and Proactinance High Speed Data Acquisition Analysis Collects and analyzes machinery vibration data unde both transient and steady state conditions. Comprise of a high speed data acquisition device which capture and processes machinery data, and a software packa that is easy to use, DAQ provides the most sophisticated analysis tools and widest range of display options available in such a system. Flexible Options for Data Acquisition Transient and Steady State Data Collection Collect data during transient and/or steady state conditions: One unit performs both. Analysis tool for all types of critical machinery (Turbine generators, steam, gas, generator sets, fans, blowers and other rotating machinery).

21 CMMS DAQ Multiple Displays Live Displays Normal and Fast Transient Data Collection On-Line Critical Shaft Monitoring Allows continuous monitoring of the dynamic equilibrium of the machine as it operates. Extensive variety of data display formats. Analyst sees events occur in a live mode.

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24 The Compresor Project... An Integrated Solution Three primary levels of machinery requirements: Balance of Plant - CMMS CHECKER Cooling Tower Gearboxes - CMMS DAQ's Compresors CMCP/CMMS DAQ

25 The Compresor Project... An Integrated Solution Associated Product Qty 1 CMMS CHECKER...8,000 points 12 CMMS DAQ's points 32 CMCP's points

26 CMMS Surveillence System Rack Room CMMS PROACTINANCE RS485 Multi-Drop CMMS DAQ #1 12 Surveillence Systems Alarm Relay CMMS DAQ #12 Yokogawa, Fisher, Foxboro, Bailey, Honeywell, etc. RS485 Multi-Drop

27 CMMS Protection System Rack Room CMMS PROACTINANCE RS485 Multi-Drop RS485 CMPC #1 Protection System CMPC #12 Yokogawa, Fisher, Foxboro, Bailey, Honeywell, etc. RS485 Multi-Drop

28 The Compresor Project... An Integrated Solution CMMS supplied the complete Network 1 WinXP file server 2 WinXP DAQ workstations 1 workstation running all CMMS PROACTINANCE applications All configured identically running WinXP

29 The Compresor Project... An Integrated Solution All information is available at any networked location in the plant: live data historical data Monitor Mode Transient Mode

30 Integrated Condition Monitoring at Compresor DAQ PC DAQ PC Work Station 1 Work Station 2 Work Station 3 CMMS DAQ Data Acquisition Systems Field Work Station 4 CMMS DAQ MUX Data Acquisition s Rack Room RS232 10Mbit/s Ethernet CMMS CHECKER Sensor interface Machine Type Gear boxes Blowers Monitored Equipment Buffered Outputs Buffered Outputs CMCP/BN3000 Data Acquisition Systems Rack Room Sensor interface Monitored Equipment Cooling tower Equipment Monitored Equipment K501 MAC REC Modbus Windows XP DCS

31 The Compresor Project... An Integrated Solution Condition Monitoring and Maintenance Systems Can provide Data Acquisition on the critical machines. This provided baseline data to be compared with the site startup activities Baseline data integrated into site database

32 The Compresor Project... An Integrated Solution CMMS provide the cabinet integration for all vibration monitoring, data acquisition CMMS integral as part of the plant commissioning team and activities Integrated solutions help provide for one of the shortest plant commissionings

33 CMMS System solution BOP Equipment SemiCritical Equipment Critical Equipment Critical Equipment Critical Equipment Analytical Analytical Analytical Analytical Protection (shutdown) CMMS CHECKER/EXPERT Hand held analyser CMMS DAQ MULTIPLEXED Data Acquisition Systems CMMS DAQ High Speed Data Acquisition Systems CMMS DAQ Data Acquisition Paralell Systems CMCP Data Acquisition Systems Main Function Periodic overall vibration monitoring of Balance Of Plant (BOP) equipment. Field balancing. Periodic overall vibration monitoring of equipment Fast, parallel monitoring of critical equipment with startup and coastdown capture capabilities. Periodic overall vibration monitoring of Critical equipment. Fast, continuous overall vibration monitoring of critical equipment with shutdown capability. Data Collection Based on routes 5 minute for each section of 24 channels. Storage is decimated. 1 minute for each section of 32 channels. Continuous storage of short and long term trends upto 2 months. Periodic overall vibration monitoring of Critical equipment. Calculates an Overall value in 30 milli-seconds and compares the result to Alert and Danger values. Data Storage Types Overall Value Spectrum Time waveform Phase. Overall Value Spectrum Time waveform Phase Overall Value Spectrum Time waveform Phase Overall Value Spectrum Time waveform Phase Overall Value Spectrum Time waveform Phase Display Types Live bar Spectrum Time waveform Live bar Spectrum Time waveform Bar, Bode Polar, Orbit Spectrum,Trend Acceptance Region Waterfall, Cascade Live bar Spectrum Time waveform Orbit Bargraph Value (overall, gap) Status (safe, alert, danger) RPM vs Time Software Package CMMSPROACTI- NANCE CMMSPROACTI- NANCE CMMSPROACTI- NANCE CMMSPROACTI- NANCE CMMSPROACTI- NANCE

34 Typical Compressor Instrumentation

35 MMSDAQ/PROACTINANCE System chematic Compressor K501 Compressor MAC Compressor REC Sensors 8 triax. Accel proximity Sensors (New 8 triax. Accel. or existing) Sensors (New 8 triax. Accel. or existing) uffered Analog Signals 12+1 CMCP Existing BN3300 Protection Monitor Existing BN3300 Protection Monitor CMMSDAQ 25 Channel Trip Circuit CMMSDAQ 36 Channel Trip Circuit CMMSDAQ 44 Channel Trip Circuit Relay Contact Signal USB 2.0 or TCP/IP Network RS-422/485 Modbus Link TDC3000 DCS Plant Information Network Ethernet Windows XP/7 CMMSPROACTINANCE ANALYSIS SERVER OPC Server System WIN XP Server

36 Service and Training Initial Product Support Services Ensured Success Programs Application and Machinery Consulting Program Optimization Training

37 CMMS Service Initial Product Support Portable system setup and installation, with hardware and software products configured specifically for your facility On-Line system setup, installation and commissioning, including accelerometer sensors Network setup, configuration, and installation Local protection unit installation and commissioning Software installation, configuration, and Training. Optimize predictive maintenance objectives

38 CMMS Service Application and Machinery Consulting Machinery condition assessment services/audits Predictive maintenance programs Machinery data acquisition, analysis and Balancing and alignment services Lube oil/fluid analysis programs and report

39 Condition Monitoring and Maintenance Systems A Partnership For Achieving Maximum Machine Uptime

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