ppp esbjerg copy - emerson...revised 17-feb-06, slide 2 emerson overview emerson confidential...

Askalon ABMachine monitoring

ProtectionPredictionPerformance

Thomas Thor Sales Manager

Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 2

Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #2

Since 197363 Employees16 mill Euro 2013

ValvesEngineeringAsset ManagementService

Education

Process industry Sweden, Finland, Denmark

Askalon ABAskalon AB



1. Products / Valves1. Products / Valves• Fisher Controls

• Globe valves• Rotary valves• Fieldvue positioner• Self acting regulators• Tank blanketing

• Virgo• On-Off Valves

• Enardo• Hatches• Flame arrestor

• TopWorx• Valve Top• GO Switch



2. ENGINEERING2. ENGINEERING

Design Engineering CAD drawing Welding Pressure test Assembly PID Instrument PED / CE mark Testing Documentation



Gas turbine fuel valve and Flow labGas turbine fuel valve and Flow labPilot valve DN40Main valve DN50

Standard and ATEX

Very quick: 200 mSec full strokeVery accurate: 5/15000= 0,03%

Profibus control



EducationEducation Approx. 80-100 students and 20-25 classes

on a yearly basis Courses

– MHM– Fisher Valves– FIELDVUE– AMS/Valvelink

Emerson Process Management

Reliability Solutions



Share HolderValue

SafetyIncidents

Availability

MaintenanceCost

…

Results

Reliability is a Business StrategyReliability is a Business StrategyLinks required to createand sustain reliabilityperformance

Annual Report

…

DATA

CONDITION

WORK

RELIABILITY

ReliabilityStrategy

Reliability Value Chain



Reactive maintenance costs are 50% higher than planned maintenance costs

Source: 2010 NPRA Reliability and Maintenance Conference

Reliability

Mai

nten

ance

Cos

t Run-to-failure Preventive

Maintenance PredictiveMaintenance Automated

Monitoring

Correlation Between Reliability and Total Maintenance CostCorrelation Between Reliability and Total Maintenance Cost


Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #10CRITICAL MACHINES

Overspeed Protection

MODBUS

AMS:MachineryHealth Manager

…PREDICTION

PlantHistorian PERFORMANCE

PROTECTIONAPI /TSI

BALANCE OF PLANT (Monitoring)ESSENTIAL IMPORTANT SECONDARY

AMS: Asset Performance Management

CMMS

Existing Protection Sys

SMARTWIRELESSGATEWAY

AMS: Performance Advisor

OPCOPC

WorkOrders

MAINT. Actions

AMS:IntelligentDevice Manager

Instrument,Valves &Drives

PROCESSCONTROL

Emerson Plant-Wide Reliability Solutions



Machinery Health SolutionsMachinery Health Solutions



Criticality of Machinery AssetsCriticality of Machinery Assets

Heat Exchangers

Pumps

Cooling Towers

Blowers / Fans

Air Cooled Heat Exchangers

Turbines

Generators

Generators

Motors

Fans

Gears



Online Machinery MonitoringProtection, Prediction, Performance MonitoringOnline Machinery MonitoringProtection, Prediction, Performance Monitoring

Operations Maintenance

Machinery Protection• Avoid catastrophic failures• Increase safety• Satisfy insurers

Performance Monitoring• Maximize production• Reduce energy used• Minimize emissions

Predictive Diagnostics• Maximize availability• Increase dependability• Reduce maintenance costs



Criticality of Machinery AssetsCriticality of Machinery Assets

Heat Exchangers

Pumps

Cooling Towers

Blowers / Fans

Air Cooled Heat Exchangers

Turbines

Generators

Generators

Motors

Fans

Gears

[File Name or Event]Emerson Confidential27-Jun-01, Slide 15

Machinery Protection SystemsMachinery Protection Systems Critical rotating assets require protection systems

– Internal company requirements, best practice– Insurance, safety

API-670 was formed to provide recommended guidelines– Sensor configurations and installation recommendations– Minimum requirements for monitoring systems– End users adopt the API-670 recommendations as their best

practice standards

Machinery Protection


Machinery Prediction SystemsMachinery Prediction Systems Uses the data provided by the Machine Protection

System Prediction Systems considerably enhance the utility of a

Machine Protection system by providing actionable information to operators and engineers which can prevent a sudden plant trip or requirement for emergency shutdown of the machine or process

Predictive Diagnostics


Why Prediction? For Start-up, Coast-Down and Production State MonitoringWhy Prediction? For Start-up, Coast-Down and Production State Monitoring

Shaft cracks Coupling degradation Bearing condition and lubrication

changes Alignment Foundation, piping resonance

changes Imbalance changes Bump in the night capture and

replay Predictive planning for next

outage See inside the turbine, make

decisions fast and early

Prediction serves as protection for your bottom

line



Performance Monitoring What Do We Mean?Performance Monitoring What Do We Mean? Basically – “How Well Is An Asset Doing Its Job” Thermodynamic Analysis

How much of the ENERGY IN….. Electrical PowerSteamWaste GasHeat Fuel

….. is converted to USEFUL ENERGY OUT! Power FlowHeat Etc.

Compared to what we expect the unit to achieve

Performance Monitoring



Turbomachinery InstrumentationTurbomachinery Instrumentation

Green = measurements are monitored by operators to optimize turbine ramp rateBlue = machinery shutdown on high vibrationThrust and Overspeed are most critical shutdown parameters

Bearing Vibration

6110

Bearing Vibration

6110

Bearing Vibration

6110

Bearing Vibration

6110

Dual Thrust Position6210

Temperature 6220 Case Expansion

6410

Eccentricity6220

Speed/Phase 6312

Differential Expansion 6210

Valve Position

6410



Machinery Events:Controllable, Predictable or UnpredictableMachinery Events:Controllable, Predictable or Unpredictable

Equi

pmen

t Hea

lth

0%

100%

Time

Predictive Diagnostics and Performance Monitoring provide the advanced warning necessary for business decisions

Effective online machinery monitoring addresses all three situations

Controllable Predictable Unpredictable

Machinery Protection


Performance Monitoring



21

Am

plitu

d

Frekvenz

Spectrum

Protection vs PredictionProtection vs Prediction

Protection Total Vibration

Prediction System utilize frequency bandUnbalance

Coupling

degradation

Pea

k-P

eak



Unpredictable EventsUnpredictable Events

User BenefitsSudden Events Can Occur Without Warning • Prevent catastrophic machine

damage• Protect human safety• Avoid environmental releases• Meet insurance requirements

• Operations induced• Metal fatigue cracks• Component failure• Process upsets

PlantWeb AdvantageThe Solution

• Integration with process automation systems enables orderly shutdown of complete unit while protecting the asset

• Integrates protection capabilities with predictive diagnostics and performance monitoring



Predictable EventsPredictable Events

• Imbalance• Misalignment• Rubs• Rotor bow

• Bearings faults• Oil instabilities• Cracked shaft• Coupling issues

• Improve plant uptime• Plan labor and parts• Prioritize maintenance activities • Extend mean time between repair• Aide process control decisions

with real-time asset information

Early Fault Detection

• Most comprehensive predictive diagnostics for turbomachinery and other rotating equipment

• Diagnostics extend to field devices

• Performance monitoring provides insights

User Benefits




Controllable EventsControllable Events

• 40-50%* of equipment breakdowns due to poor operating practices

• Take action to avoid downtime / machine damage

• Optimize operation to extend equipment life

• Ramp rate• Load / speed changes• Lube oil temperature, pressure,

flow• Steam temperature

* Ron Moore, Making Common Sense Common Practice

Take Action Before Affecting Machine Health

• Integration with process automation systems provide real-time actionable feedback to operators

• Operators receive machinery information alongside process data and field device diagnostics

User Benefits




CSI 6500 Machinery Health MonitorCSI 6500 Machinery Health Monitor

Transient Analysis


ProtectionAPI 670



Protection & Prediction diagnostic system, CSI 6500Protection & Prediction diagnostic system, CSI 6500

CSI 6500 Machinary Health Monitor

Junction Box

Server

Plant LAN

Ethernet

Wireless LAN

Multi cable

Sensor cable



Dual, Redundant 24 VDC PowerDual, Redundant 24 VDC Power

CSI 6500 Machinery Health Monitorfor Critical MachinesCSI 6500 Machinery Health Monitorfor Critical Machines

API 670 Compliant ProtectionFull turbine supervisory instrumentation

API 670 compliant

Hardware• 19” rack mount• Hot swappable protection cards

Relay Module• 2-out-of-3 Voting• Flexible Voting Logic• Alert, Danger, OK and System relays• Time Delay• Trip Multiply

Buffered Outputs• Raw vibration waveform• Connectivity with any data collector for balancing, recording or machine diagnostics

4-20mA Outputs• Provides analog input to PLC’s or process control proportional to vibration

2-Ch, Micro-processor based Monitors• Independent monitors• Extensive self-checking• Self-temperature monitoring

Rack Interface Communication Module• Modbus• Dual-path Serial • Ethernet

TSI = Turbine Supervisory Instrumentation

Full TSI• Case Expansion• Differential Expansion• Eccentricity• Thrust position• Relative Vibration• Temperature• Speed• Zero speed• Absolute Vibration

Full TSI• Case Expansion• Differential Expansion• Eccentricity• Thrust position• Relative Vibration• Temperature• Speed• Zero speed• Absolute Vibration




Control system style field-based predictive processor

Control system style field-based predictive processor

PeakVue for rolling element and gearboxes

PeakVue for rolling element and gearboxes

Predictive MonitoringField based intelligence

API 670 Compliant Protection Full turbine supervisory instrumentation

Full integration to the AMS SuiteFull integration to the AMS Suite



Trend ofBalance

Trend of Bearings

Alarm

Am

plitu

deSub-

Harmonic 1X 2X Bearing Bearing Gears Bearing

1x 2x 50x

5mm/sec

1mm/secTime

(Days)Time(Days)

Prediction, Narrow Bands with trendPrediction, Narrow Bands with trend



Data Collection SetDifferent alert levels at different operating conditions.Data Collection SetDifferent alert levels at different operating conditions.

Unique alarm limits at :– Startup– Run out– If RPM<500 alert set 1 – If RPM>500 Alert set 2– If RPM>1000 Alert set 3– If RPM<1400 Alert set 4…




Transient Analysis For Turbomachinery

Transient analysis for turbomachineryTransient analysis for turbomachinery

Predictive MonitoringField based intelligence

API 670 Compliant Protection Full turbine supervisory instrumentation

100+ hour transient data recording100+ hour transient data recording

Live View ModeLive View Mode

Replay Mode of recorded data Replay Mode of recorded data



Transient / Live ModeTransient / Live Mode

1. Data extraction of all diagnostic data from each CSI 6500 for the past 100 hours with 6400 lines (up to 5X per second sampling rate)

Real-time plotsPolarBodeSpectrumOrbitWaveformCascadeShaft Centerline



SensorsSensorsSensors• Accelerometers

• Industrial• Test & Measurement

• Velocity Sensors• Displacement Sensors• 4-20 mA Output Sensors

Cables/Connectors• Twisted, Shielded Pair • Drain Wire• Heavy Gauge, Twisted Stand Wire• Kevlar Strength Member• Heavy Duty Jacket

Mounting Hardware• Magnets• Quick connect• Pads• Mounting tools• Zerk Adapters• Adaper studs & Screws

Junction Boxes• Switch Boxes• Signal Management Boxes• Cable Termination Boxes• Cable Reduction Boxes• MAXX Boxes



AMS Suite : Asset Graphics Graphic package to visualize machines and

machine condition

Trend capability to view history and live trends

Open connectivity integrating multiple data sources

– Vibration

– Process parameters

Notification package

– Alarms and events screen

– Notification (email)

- OPC and Modbus compliant -



Performance tabPerformance tab

Asset Graphics start ViewAsset Graphics start View



Protection tabProtection tab



Prediction tabPrediction tab



Performance tabPerformance tab

Fjärrövervakning - Diagnostik• Reglerventiler

• Turbiner

• Kompressorer

• Pumpar


Questions?Questions?

Our global customer knowledge sharing event and technology exhibition.

300+ papers and work shops.



Asset Performance Management- User Focused Home PageAsset Performance Management- User Focused Home PageUser Focused Home Page



Rank Data for Analysis and Action



Bad Actors-Work Cost by Equipment GroupBad Actors-Work Cost by Equipment GroupRank Data for Analysis and Action

ppp esbjerg copy - emerson...revised 17-feb-06, slide 2 emerson overview emerson confidential...

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