Condition Monitoring Systems BERAN INSTRUMENTS

Transcription

1 Condition Monitoring Systems BERAN INSTRUMENTS

2 On-line Condition Monitoring In today's increasingly competitive market, the need to reduce costs while maximising output is paramount. In many industries, the introduction of a preventative maintenance strategy has proved highly beneficial in both reducing operating costs and increasing plant availability. Condition monitoring of rotating machinery is widely acknowledged as a valuable tool for implementing such a strategy, helping to identify faults as they develop, and allowing appropriate remedial action to be carried out before a costly breakdown occurs. Investment in a comprehensive continuous data monitoring system is often realised within months through: Optimised plant usage; Avoidance of costly penalties; Minimising unnecessary stoppages; Reduced spares holding. Beran Instruments have been providing on-line monitoring systems for over 15 years into the power generation, steel and petrochemical industries, and to a wide variety of plant manufacturers. The systems offer cost-effective, adaptible, and flexible monitoring for all rotating plant. Now in its fifth generation, the On-line Condition Monitoring System harnesses Beran Instruments unrivalled experience to provide state-of-the-art solutions that meet the needs of today's condition-based maintenance strategies. Nuclear Hydroelectric Fossil CCGT Combined Cycle Petrochem 2

3 Beran Condition Monitoring Systems Beran Condition Monitoring Systems provide comprehensive functionality, flexible data handling, and efficient communications in a highly intuitive and easy to use package which can be configured to meet every need. The Beran Condition Monitoring System features parallel dynamic acquisition for both steady-state (on-load, barring) and variable speed (run-up, run-down) plant modes, with simultaneous acquisition of vibration and process parameters. The system performs all functions simultaneously so there are no restrictions on graph plotting and real-time analysis they operate concurrently with data recording. Multiple users access real-time and historic data displays utilising a Windows-based user front end running on a standard PC connected to the Beran system via an Ethernet connection, enabling remote communication via a LAN or WAN. Control and interrogation of the system may also be carried out remotely, via a modem on a standard telephone line. The system is highly flexible, and can be configured to monitor virtually all types of rotating plant including, for example, any of the following: Turbines Pumps Fans Compressors Combustion cans Industrialised gas turbines Gas circulators User Interface Easy both to configure and use Windows front end LAN, WAN or dial-up compatible Data handling Fast data capture Comparison of real-time data with historic Open communications standards enable remote access to real-time and historic data wherever it is required locally or on the other side of the world. Functionality Powerful condition-based alarm functions Automatic plant-state detection Modular and expandable, ensuring that the system can be extended and adapted to meet your future needs. 3

4 System Architecture The building blocks for the Beran Condition Monitoring System are the 766/768 Data Acquisition Units (DAUs), which are networked together via an Ethernet LAN and to a PC workstation in the Control Room. Using the appropriate DAUs, systems can be configured to monitor permanent installations ranging from a single machine to a complete facility, including multiple turbines and auxiliary machines with multiple tacho/ synchroniser and analyser combinations. More DAUs can be installed later to monitor additional plant as required. Robust and fault tolerant Each DAU contains integral data acquisition, processing and file storage for dynamic and static channels, and can function independently of the rest of the network. The acquisition and storage functions of a DAU are unaffected by any failures in the network, central PC or display terminal, or another DAU, ensuring a highly reliable and fault tolerant system. All data is processed and stored on an onboard hard disk in each Beran DAU. The data is accessed and displayed using Windows client PCs, which are located wherever they are needed, providing any number of users with simultaneous access to condition data across the plant. Remote users can also gain access to the data via corporate WAN or modem links. A modem link is available to allow remotely based Vibration Analysts to access any monitored plant item and view identical condition displays to those at the plant - even in real-time. Additionally, data values may be exported into an optional spreadsheet-style workbook in CSV format, mathematically processed via userentered formulae, and the result returned into the Beran System as a new process parameter. This capability provides the user with the flexibility to add performance monitoring, absolute vibration, efficiency, thermal stress calculations, etc. Continuous or routine automatic monitoring Monitoring conditions of each plant item are individually configured. Thus key plant items can be monitored continuously, while auxiliary plant items are monitored every few hours. The system can be set to react to vibration or process parameter changes. For example to: increase the monitoring rate; close a set of relay contacts (to provide alarm status information to other systems); automatically store the immediately preceeding high resolution data for diagnostic purposes. This approach ensures the minimum of information is stored when a plant item is operating normally and the maximum is stored before and after an incident, therefore optimising the Beran System storage capability. 4

5 Flexible measurement options BERAN 766 The Beran 766 DAU is a 19" rack-mount unit providing modular acquisition/analysis of up to 64 parallel channels from acceleration, velocity, proximity and pressure sensors. This ensures high-speed condition information is acquired during both steady-state and variable speed modes vital for accurate diagnosis of many fault conditions. Process (DC) parameters may be acquired directly by each Beran unit using either voltage or optional 4-20mA and thermocouple signals with full galvanic isolation capability. Alternatively, a connection to the plant DCS or process computer may be utilised to acquire these parameters via an electronic data link, including, for example, MODBUS, PI or Alstom s AMODIS. BERAN 768 The Beran 768 Condition Monitoring System is an optimised solution for smaller turbines such as those used in hydroelectric and gas pumping installations. In addition, an alternative configuration utilising a multiplexed input option is ideal for auxiliary plant applications. The Beran 768 DAU can monitor up to 4 Tacho signals, 8 AC signals (32 Multiplexed), 16 local DC channels (up to 256 remote), 8 digital channels and has 8 alarm relay outputs. The multiplexed variant allows up to 4 non-critical plant items to be monitored cost effectively. Dynamic Channels Parallel: Multiplexed: Number of Inputs Beran 766 Beran to 32 in multiples of 2, up to 64 with slave unit 4x8 to 4x32 in multiples of 8, up to 256 with slave unit 2, 4, 6 or 8 8, 16, 24 or 32 Tacho Channels 1, 2, 3 or 4 1, 2, 3 or 4 Static (DC) Inputs Digital Inputs Alarm Outputs 0, 16, 32 or 48 (hardwired) up to 256 (total) via ext. computer link 0 or 8 (TTL) 4 normally open 4 normally closed 1 system failure 1 alert + 1 alarm triggered by any channel/ alarm condition 0 or 16 (hardwired) up to 256 (total) via ext. computer link 0 or 8 (TTL) 4 normally open 4 normally closed 1 system failure 1 alert + 1 alarm triggered by any channel/ alarm condition Type Acceleration, Velocity, Displacement, and Non-Vibration ICP current drive available Differential Voltage TTL or displacement ±1V DC, 0-1 V DC, 4-20 ma, 0-10 ma Thermocouple Voltage free Voltage free User-configurable 5

6 767 - portable condition monitoring To complement the permanent installations provided by the 768/766-based condition monitoring systems, Beran Instruments also have the perfect solution for temporary monitoring installations. The 767 Portable Condition Monitoring System is ideal for on-site commissioning, balancing, return-to-service and fault finding applications. It offers unparalleled facilities in a compact, rugged and easily portable unit weighing less than 12.5 kg. Full control of measurement, analysis and alarm configuration is achieved via a local Ethernetcapable PC. Alternatively, it can function as a standalone or remote system for longer-term monitoring or analysing of intermittent faults and problems. Using the latest data compression technology, full real-time graphical capability is available over a modem link or via Ethernet WAN. This allows a 767 Portable to be left on-site, but monitored by vibration analysts at a remote location - anywhere in the world! For unattended operation no PC is required, giving greater security and eliminating the possibility of the PC being removed without authorisation. Time and RPM based logging may be enabled ensuring run-up, run-down and on-line plant operational modes are automatically stored. Beran s 767 can be configured with up to 32 parallel dynamic channels, 16 additional static (dc), 8 digital and 4 tacho inputs, and can accept inputs from most dynamic sensors; ICP supply and hi- and lo-pass filters are integral. The unit is equipped with comprehensive alarm detection and alarm-initiated actions, including configurable storage, acquisition rate increase and contact closure. A comprehensive range of real-time and historic data displays are available, and data can be exported in CSV format for balancing programs, Excel, etc. The unit has a high capacity solid-state disk for data storage. Signal conditioning capability Beran Instruments manufactures signal isolation modules to interface to the wide variety of instrumentation signals found on industrial sites. Signal isolation of process parameters, vibration channels and tacho signals helps to protect sensitive equipment and maintain signal integrity. Beran will advise on the optimum solution for your plant, and can supply the equipment needed for your condition monitoring project. 6

7 Display formats Beran on-line condition monitoring systems provide a wide variety of configurable and user-defined data displays to optimise the analysis and interpretation of static and dynamic plant data. Concurrent system users can select whichever display formats suit their needs, without affecting data acquisition or other users. Plant condition displays include Bode (stacked and multi-plot), Polar, FFT, Orbit, Time-Domain, Histogram, Waterfall, Shaft Centreline, Real-Time Text and Trend. Both real-time and historic data may be simultaneously displayed, including the ability to view a current run-up or coast-down overlaid onto a reference or historic file. A Graph Wizard utility guides the user through the process of configuring a graphic display. Mimic A mimic, customised to suit the plant monitored, provides an overview pictorial view that delivers an easy-to-use summary of the current vibration levels and process parameters, allowing the operator to determine precisely which area to investigate further. Colour changes inform the operator if any vibration channel or process parameter moves from a normal operating condition into alert or alarm status. The operator can then access either a real-time display or view the alarm log to assist in determining plant condition. Histogram This plot provides an at-a-glance view of overall vibration levels or other key plant parameters. The colour of the bar gives an immediate indication of alert and alarm status. Bode Single bearing bode showing overall vibration level, order 1 vibration and phase information. This example shows several run-up data files overlaid in different colours to rapidly determine a visual indication of changing conditions. Real time data may also be overlaid against historic base line data. 7

8 Display formats Multiplots Mulitplots allow different parameters to be displayed against a common x-axis. This display shows vibration data from four bearings over time, with the individual full scale Y- axes differentiated by colour. Trends A trend display shows long-term variations in vibration over time, enabling slowly increasing vibration levels to be detected. This user-created plot shows the trend of vibration magnitude for a single channel (overall and orders 1-4) on a 500MW generation unit over a period of four days. To ensure that long-term data is only trended from stable conditions, and to improve clarity, the plot has been configured to exclude data points below 80% of machine load. This quickly allows the user to spot increasing vibration. Orbit Orbit display showing overall orbit and filtered orbit for a Gas Turbine run-up. The graph may be configured to show individual bearings or a combination of positions along the machine. The tracking cursor along top of the display is used to display the orbit data at a selected time/speed. The user may display four separate bearings or alternatively, a single bearing offset by X acquisition points. This allows the progression on the orbit shape to be viewed at the current and three previous shaft speeds. Shaft Centreline Shaft centreline display of a gas turbine, showing the change in shaft centreline position as the machine runs up to full speed. Colour is used to indicate the shaft speed and auto annotation of speeds is also added, to assist the user. 8

9 Display formats Colour waterfall Single bearing FFT waterfall displayed with speed as the trace color change parameter and order tracking lines enabled. The colour parameter may be selected from RPM, time, static parameter, etc. Here the colour is related to valve position, and the plot shows clearly the sudden increase in subsynchronous energy in the 30Hz region as the valve position changes from 100% to 80%. X-Y plots Single bearing (order 1 mag and phase) plus generator load displayed with respect to time. A cross-hair cursor provides a simultaneous value display of all traces. File statistics may also be displayed with the cursor including the max, min and mean data values. Polar plots Polar plot showing vector change of dynamic data during a run up. Enabling colour trace and automatic annotation every 300 rpm assists with the interpretation of the data. Vector difference The lower trace shows the vector difference between two run-ups on the same channel as the speed increases allowing rapid data screening of changing plant conditions. 9

10 Alarm management and display A powerful and comprehensive suite of alarms is integral to the Beran On-line Condition Monitoring System, providing complete protection for the monitored plant. Alerts and alarms with hysteresis are available for both dynamic, static and process channels. Separate vector alarms are provided for all monitored harmonics on both amplitude and phase, including step changes. The system offers intelligent functionality, enabling different levels to be configured for specified combinations of machine state and other key plant parameters. Unique conditions for each plant item to be entered, to minimise the occurrence of false alarms. For example, an individual alarm may be set to function only when the shaft speed is greater than 1100 RPM. Different alarm thresholds can be set for different plant load settings, and for hot, cold or warm start-ups. The boundaries of ellipse alarms may be automatically calculated with respect to the plant historical running condition. For example, the user may request an automatic calculation of the position and size of an ellipse alarm setting based on the last three months' normal steady-state running. The prediction may be accepted and enabled and manually enlarged or reduced by means of a scaling factor. A variety of user-defined actions can be initiated when an alert or alarm occurs, including: storing the rolling buffer data (one hour before, or 30 minutes before and after); storing spectral data relay contact closure. Unrivalled ease of use The Beran System makes use of the familiar Windows user interface, including full contextsensitive help, enabling users to use the system with minimum training. Each display PC con be configured for unique displays that reflect the level of plant diagnostic knowledge demanded of each type of user. Data display windows may be tiled or cascaded. Historic data and real-time data can be viewed simultaneously. Zoom cursors allow expansion of user-selected data display areas. The Beran user interface fully integrates with Microsoft Office applications, allowing easy report generation. Real-time and historic graphical data can be copied via the Windows clipboard to word processors or data can be exported in 'csv' format for import into a spreadsheet, thus allowing output to be ed or electronically transferred. 10

11 Total capability, full support TransCal TM To complement our range of condition monitoring systems, Beran Instruments manufactures a comprehensive range of transducer calibration systems, including the Beran 445 Portable suitable for localised verification of transducers in situ. Optimised for condition monitoring, the Beran TransCal 455 system combines high precision stimulation and measurement facilities for calibrating both magnitude and phase in vibration sensors up to 1 kg. The transportable unit is ideal for use in the laboratory or out in the field. A laboratory based system, the TransCal 475 provides high precision, fully automatic calibration and reporting of vibration transducers and microphones, traceable to national standards. These systems are widely used throughout the world within the power, automobile, aerospace and transducer manufacturing industries. Beran Instruments also provides an on-site calibration service for all types of vibration sensors, along with verification of site-installed TSE and On-line Vibration Monitoring Systems. Project Management During the initial stages of a project Beran Instruments experts will attend the site to understand fully the requirements of the condition monitoring system and advise on the optimum system configuration to maximise the benefits of installing the system. Beran Instruments provide project management during installation: Installation and Commissioning of the Beran systems Signal cabling and termination Network cabling and termination Installation of vibration sensors System training at operator and system manager level Service and After-sales support In the event that a fault is suspected, Beran engineers can access the installation via the modem link to perform comprehensive diagnostic tests and recommend remedial action. The modular configuration of the Beran unit, which utilises plug-in cards for all functions, including process (DC) and vibration (AC) acquisition, tachos and Ethernet communications, allows a faulty card to be replaced quickly in the unusual event of a hardware failure. These two features ensure that system downtime is minimised. All of our customers are offered extended maintenance cover after the initial warranty period, providing complete peace of mind and protecting the capital investment made. 11

12 Since the formation of Beran Instruments in 1984, three fundamental issues have dominated the Company's direction - Quality, Innovation and Service. Success in these areas has led to expansion and growth. Beran Instruments supply and service the international market from purpose built headquarters in the UK, supported by direct sales and service subdivisions in the USA and Germany, and distributors around the world. Beran Instruments' product range includes:- Condition Monitoring Systems for rotating machinery Automated Calibration Systems for vibration and microphone transducers Signal Conditioning Amplifiers for transducer interfacing Frequency Response Analysers Beran Condition Monitoring Systems are in use around the globe within numerous power generation companies including coal, oil, gas-fired, nuclear and hydro. The plant monitored includes steam, gas and water turbines, pumps, fans, compressors and coolant circulators. Our Transducer Calibration Systems are in service with many European and USA automotive, aerospace and power generation companies, along with Certified Calibration Houses, meeting the ISO 9000 requirement for calibration integrity. Beran Frequency Response Analysers are employed in the verification of many aircraft and missile control systems. Beran Instruments has been awarded ISO UKAS system approval. Helitune is an associate company and world leader in aircraft Rotor Track and Balance (RTB) technology. Helitune products include an innovative range of vibration analysis and diagnostic systems, specialising in the dynamic balance of helicopter rotors and aircraft propellers. More details can be found at USA PO Box 5129, 4965 Cox Road, Glen Allen, VA Tel: Fax: sales@beraninstruments.com Head Office Hatchmoor Industrial Estate Torrington Devon, EX38 7HP United Kingdom Tel: +44(0) Fax: +44(0) sales@beran.co.uk Germany BERAN INSTRUMENTS Sonderflughafen Oberpfaffenhofen Geb. 309, Rm Wessling Germany Tel: +49 (0) Fax: +49 (0) sales@beran.co.uk