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© Meggitt Sensing Systems. This document and the information in
it is proprietary and is the property of Meggitt Sensing Systems. It
may not be copied or disclosed to a third party or used for any
purpose other than that for which it is supplied without the express
written consent of Meggitt Sensing Systems.
Information contained in this document is subject to certain Export
Control regulations, specifically of the (choose as appropriate)
United Kingdom, European Union, other national jurisdiction and /
or the United States International Traffic in Arms Regulations and /
or Export Administration Regulations. Each recipient of this
document is responsible for ensuring that transfer or use of any
information contained in this document complies with all relevant
Export Control Regulations.
Agenda
Machinery Protection 2 Introduction to standards 3
1 Introduction to Meggitt
Condition monitoring 4
Meggitt PLC 1
4
45%
38%
17%
Civil aerospace
Military
Energy and other
Meggitt PLC is a FTSE-100 global engineering company
Strong pedigree in extreme environment engineering
5
Leading technology positions
Meggitt strategic business units
Condition
monitoring
systems
High performance
sensors
Sensing Systems
Thermal
management
Fluid and
pneumatic control
Electromagnetic
control
Seals
Fuel bladders
Fuel systems
Ice protection
Safety systems
Power systems
Defence systems
Specialty
components
Wheels
Brakes
Brake control
Landing gear
control
Nose wheel
steering
Landing systems
monitoring
Equipment Group Polymers &
Composites Control Systems
Aircraft Braking
Systems
Meggitt has been better known in the energy market through its world class product brands:
Meggitt Sensing Systems Energy
Brands
.
. .
.
7
Facilities
3000+ employees
Mainland Europe
Fribourg, Switzerland: condition monitoring
Angoulême, France: ignition systems
Angers and Toulouse, France: electro-mechanical
Archamps, France: position and inertial
Kvistgård, Denmark: piezoceramics
North America
Germantown, MD: industrial accelerometers
Indianapolis, IN: piezoceramics
Tucson, AZ: electronic security, battery
management
Denver, CO: piezoceramics
Portland, OR: electro-magnetic and power
conversion devices
Sunnyvale, CA: MEMS sensor systems
Irvine, CA: condition monitoring
. . .
.
. . .
. MSS factories
. .
Asia and RoW
Xiamen, China: sensor manufacturing/assembly
Dong Nai, Vietnam: electro-mechanical
.
.
UK
Basingstoke: temperature and speed
Rugby: industrial ignition
. .
. .
.
. . .
.
. MSS sales and service offices
. . .
.
Meggitt presentation
About MSS Switzerland
We design and manufacture sensors,
monitoring systems, electronics and
software...
…for demanding, high-tech niche markets
in aerospace, space, power generation, oil
& gas and marine
8
Meggitt SA (Vibro-Meter SA until Sept 2010)
Rte de Moncor 4
PO Box 1616
CH-1701 Fribourg
Switzerland
Tel: +41 26 407 11 11
www.vibro.meter.com
www.meggittsensingsystems.com
Meggitt SA
Over six decades’ expertise in the world’s
most reliable, high performance sensing
solutions
Ensure critical accuracy and reliability within
aerospace, energy, measurement,
automotive and medical markets
Sensors combine with state-of-the-art
electronics and innovative software tools for
the most complete picture of machinery
health available
Product and service offerings tailored to
provide the most flexible and cost-effective
solutions
Capabilities
9
Energy technology
Key applications
Integrated systems monitor thousands of machines
worldwide
− heavy duty gas turbines
− industrial and aero-derivative gas turbines
− steam turbines (nuclear and conventional)
− hydro turbines
− wind turbines
− large generators
− large pumps, compressors and fans
− large electric motors
Installations on the world’s largest, including
− the largest steam turbine at 1800 MW
− the most powerful gas turbine at 530 MW
− the three largest hydro power plant installations
10
Energy technology
Product lines - sensors
11
Sensors
− vibration (acceleration and velocity)
− pressure (dynamic, static)
− proximity probes (eddy current)
− air gap
− displacement (LVDT and RVDT)
− inclinometers
− ice detection systems
− ignition systems
Energy technology
Monitoring solutions
12
VibroSmart®
− module-based distributed monitoring system
− versatile and scalable
− for power generation and auxiliary balance-of-plant
equipment
VM600
− rack-based monitoring system
− powerful and flexible
− for large, heavy-duty rotating machinery
VibroSight®
− common software platform
− for all applications and acquisition devices
− validated by major OEMs
Meggitt is your one source for next-generation monitoring solutions.
Condition monitoring system architecture
13
FFT – spectrum (frequency domain)
Waveform (time domain)
VibroSight
server
Database
Vision
Hardware
Front ends measurements
Meggitt:
Smart Engineering for extreme environment
Mission: New Horizons
Target: Pluto
Lift off: Jan 19, 2006
Contact made: July 14, 2015
Next target: 2014 MU69 (1st Jan 2019)
Monitoring & Protection Systems
− Provides “usable” information about the overall health of the machine/asset
− Shutdown of a plant/machine operation without human intervention
What is Machine Monitoring & Protection System?
Why Monitor your Machines ?
Safety
− Avoid catastrophic failures and unplanned outages
− Protect your personnel and your investment
Return on assets
Help to maximize the overall productivity through :
− higher availability (reduced outages, maintenance optimization)
− Improved Efficiency
− Lower spares, Inventory & Maintenance Costs
Emissions and environment
Help to reduce :
− Fuel consumption
− CO2
− NOx emissions
Which Machine to Monitor & How?
How to decide?
What Machines to Monitor/Protect?
What to Monitor/Protect?
How to Monitor/Protect?
Is this enough for today & next 15 years?
Phase -1:What Machines to Monitor/Protect?
Machine Classification Based on Criticality to Plant Operations & Safety
What if the machine is not available?
Does it effect the safety of the people/plant?
Do I have a standby/Option?
How much does it cost...
Availability
Repair & Maintenance
Downtime
Others...
22
Class-1
Class-II
Class-III
Class-IV
Essential machines (must)
Co
st
of
loss/r
ep
air
Number of Plant Assets
Phase-1...Machine Classification
Critical machinery (limit production capacity)
Serious Machines (impact on maint costs)
Other plant machines
(impact on production
/ maintenance cost)
Phase-2: What to Monitor?
Follow the Best Practice Know your machines very well...
What is the type of machine?
Who is the OEM?
What is the machine speed, what bearings, process etc..?
Machines Failure modes & its effects on the process/plant?
Know the Application & Technology... What is the right sensors system for a given machine?
What is the most Recent & Correct Technology?
What other measurement i need besides vibration?
What are the best Industry standards applicable?
Implement all of the above by... Writing a good system specification
Qualify “Solution Providers” on Technology, Product & support capabilities...
Be “INCHARGE” of your Needs & Specs...
Steam Turbine Applications
Abs. Vibration
Rel. Vibration
Smax
Eccentricity
Phase angle
Position
Displacement
Diff. Expansion
Steam Temperature
Oil Temperature
Dif. Temperature
Steam Pressure
Oil Pressure
Steam flow
What to Monitor?
Gas Turbine Applications
Abs. Vibration
Rel. Vibration
Smax
Eccentricity
Phase Angle
Axial Thrust
Dyn. Pressure
Turbine Outlet Temperature
Oil Temperature
Oil Pressure
Flame on/off
What to Monitor?
Hydro Turbine Applications
Abs. Vibration
Rel. Vibration
Smax
Eccentricity
Phase angle
Axial Position
Turbine clearance
Airgap
Oil Temperature
Oil Pressure
Water flow
Cooling flow
What to Monitor?
Balance Of Plant Applications
Abs. Vibration/ Rel. Vibration
Phase angle
Axial Position
Brg. Temperature
Motor Winding Temperature
Oil Flow, Pressure Temp. Etc.
DCS
iT/TSG Series
What to Monitor?
Phase 3: How to Monitor/Protect?
Execution phase : Critical Machines, Class-1
Online Protection, Condition Monitoring & Diagnostics
Follow International Standards like API670
Plan for redundancies & backups
Ensure to adopt the “Best & Latest Technologies”
Proper Design, Installation & Commissioning very critical...
Essential Machines, Class-2 Online Protection & Condition Monitoring
Follow International Standards like API670
Ensure to adopt “proven technologies”
Proper Design, Installation & Commissioning very critical...
General Purpose Machines, Class-3 Localized/Distributed Online/offline Monitoring & Protection
Online Condition Monitoring (some times...used)
Apply “Simple & easy to Use Technologies”
Other Machines, Class-4 Offline monitoring
Hand held devices
Apply “Simple & easy to Use Technologies”
Analysis & Diagnostics System Server
DCS
iT/TSG Series
Maintain “Same System & Technology”
for Class 1 , 2 “at least”
Definition:
Standard
plural noun: standards
1.a level of quality or attainment.
"their restaurant offers a high standard of
service"
synonyms:quality, level, grade, degree, w
orth, calibre, merit, excellence"the
standard of work is very good"
2.something used as a measure, norm, or
model in comparative evaluations.
"the wages are low by today's standards"
30
As ISO Say it:
What is a standard?
A standard is a document that provides
requirements, specifications, guidelines or
characteristics that can be used consistently
to ensure that materials, products, processes
and services are fit for their purpose.
What are its Benefits?
ISO International Standards ensure that
products and services are safe, reliable and of
good quality. For business, they are strategic
tools that reduce costs by minimizing waste
and errors, and increasing productivity. They
help companies to access new markets, level
the playing field for developing countries and
facilitate free and fair global trade.
31
International Organization for
Standardization (ISO) is an international standard-
setting body composed of representatives from
various national standards organizations.
API
The American Petroleum
Institute (API) is the trade
association for the oil and
natural gas industry. It claims
to represent about 400
corporations involved
in production, refinement, distri
bution, and many other
aspects of the petroleum
industry.
API started during WW1 with
aim of “Advocacy”, “Statistics”,
“Standardization”, “Taxation:..
32
Standards for vibration measurement:
33
ISO − 10816 package (Evaluation of m/c vibration by contact type measurement)
− 5 parts
− 7919 package (Evaluation of m/c vibration by non-contact type measurement)
− 5 parts
− ISO10817 Vibration measuring system
− Related
− ISO 1940 ( Balance quality requirement)
− ISO 13373, 17359 (Condition monitoring and diagnostics of machines)
API : (American Petroleum Institute)
35
API 610
Centrifugal Pumps
API 611
General-Purpose
Steam Turbines
API 612
Special-Purpose
Steam Turbines
API 613
Special-Purpose
Gear Units
API 616
Gas Turbines
API 617
Centrifugal
Compressors
API 618
Reciprocating
Compressors
API 672
Packaged, Integrally
Geared Centrifugal
Compressors
API 671
Special-Purpose
Couplings
API 670
Machinery
Protection Systems
API 614
Lube, Seal, and
Control Oil Systems
and Auxiliaries
API 619
Rotary Positive
Displacement
Compressors
Subcommittee on
Mechanical
Equipment
(SOME)
API670 (5th Edition)
One standard particularly relevant to the monitoring of rotating equipment is the API Standard 670 covering Machinery Protection Systems, which has become heavily adopted by industry.
The standard details the following measuring techniques:-
Casing Vibration
Radial Shaft Vibration
Shaft Axial Position
Shaft Rotational Speed
Piston Rod Drop
Phase Reference
Overspeed
Critical Machinery Temperatures
Surge protection
Condition monitoring
Latest version is 5, Nov 2014
Encrypted, needs a Adobe plug-in to open
Embedded with name of purchaser
API 5th edition Provides:
37
Scope Pertains to
Design and performance
specifications for…
• Transducers..sensitivity
• Monitoring systems
• Displays / Indicators
• Field wiring, conduit, and enclosures
Functional requirements • Response speed
• System maintenance features (bypasses,
alarm suppression, protection, fault
indicators, etc.)
Installation • Transducers
• Monitor racks / systems
• Field Wiring
Documentation • Datasheets
• Test certificates
• Compliance certificates
Condition Monitoring • Data display
• Explanation of faults
Guidelines for Machinery Protection system, Surge protection, Over speed, Condition monitoring.
Typical API-670 Monitor
Peak-to Peak Calc.
Alarm Comparison
Filtering
Unit Conversion
Transducer OK
Isolation
Display
Raw output
Relays
(voting)
Analog
(4-20 mA)
Transducer
Digital
Link
Alarm indication
of
each channel
“Implementation of a CMS should not in any way compromise or
interfere with the functions of machinery protection”
Vibration (all types)
LVDT
Position-axial
4-20 mA
Diff expansion
Phase markers (2 per card)
4 relay outputs
Analog output (4-20 mA)
Raw buffer output
Raw buffer output
Card status
Individual channel
status (API670V5)
RS 232 serial port
Tacho buffer output
ONE CARD DOES IT ALL
Machinery Protection Card (MPC4):
Phase markers (2 per card)
Individual channel trip multiply (factor is user configurable)
..each MPC can get individual contact ..
(multiple machines per rack)
Adaptive Alarm multiplier
..Use Tacho for trip multiplication
External contact
Independently configured
.. CPU not required True Hot insertion …
.. Self configuring
API 670 (V5) Compliant
The machines speak to us
They warn us about their problems
It is just necessary to listen to them
42
44
Machine ENERGY
Supports
Fluid out Fluid In
A typical machine…
Some characteristics:
Driver (electrical/mechanical)
Driven equipment
Bearings
Foundation/Supports
Piping/ducting
Fluid (input/output)
Coupling
Various types of constructions
Lubrication etc..
Various application from turbine to fan
Adjacent to other machines
Part of a process
Losses ..etc
How to assess the condition…. !!!!
What techniques are used for assessing the
condition of the machine:
Condition monitoring techniques:
Vibration monitoring
Lube oil analysis
Acoustics
Current analysis
Temperature monitoring
Thermography
Process parameters etc..,
45
Vibration
Rotor Input
(Energy)
Output
(Work)
How a modern condition monitoring system should look like
48
Essential and critical
machines
VibroSight server
and client
3rd party
remote
capabilities
process
parameters
Digital Control
System
VM600
database
configuration
analysis
multiple data
display
workstations
VibroSight clients
offline
Class-3 machines
Class-4
machines
Other cond
Monitoring
techniques
DATA ANALYTICS
Time
Why condition monitoring: “..Be early in the game..”
Normal operating condition
Hardware TRIP
Hardware ALARM
Usable life extension
Software ALARM
No reaction time
Correction
Correction
MEGGITT – Your condition monitoring partner
50
Total condition monitoring
critical machinery
balance-of-plant assets
VM600
protection, condition and
performance monitoring
Sensors
dynamic pressure
piezoelectric accelerometers
piezoelectric accelerometers
proximity probes
Plant asset management
Reduces the risk of failures and
downtimes, enables maintenance to
be planned, increases global plant
effectiveness
Turbine health management
Safety, return on assets and
environment impact
Blade tip clearance
Efficiency optimisation
Structural damages
Combustion humming, outer segments
Bearing
Defect detection
Turbomachinery operation
Safety, maintenance optimisation,
lower spare parts inventory, improved
efficiency, reduced emissions
Meggitt Sensing Systems Tel: +1 603 657 2535
Email: [email protected] www.vibro-meter.com www.meggittsensingsystems.com
Thank you
The information contained in this document is the property of Meggitt
Sensing Systems and is proprietary and/or copyright material. This
information and this document may not be used or disclosed without
the express authorization of Meggitt Sensing Systems. Any
unauthorized use or disclosure may be unlawful.
The information contained in this document may be subject to the
provisions of the trade compliance regulations (including those
regulations governing transfer to a dual national or third country
national, export and re-export) of various countries; see the first page
for specific requirements. The recipient acknowledges that licences
from the applicable regulatory agency or agencies may be required
before the recipient may further disclose such information to others,
and that such licences may impose restrictions on further disclosure of
such information. The recipient agrees to comply with all applicable
governmental regulations as they relate to the transfer, export and re-
export of information disclosed in this document.