Rockwell Automation Integrated Condition Monitoring

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Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 1

Sensor SolutionsRockwell Automation Integrated Condition Monitoring

Patrick CarleGlobal Product ManagerMarch 2017

Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 2PUBLIC

ICM PortfolioDynamix™ 1444 Monitors: • Integrated condition monitoring• API-670 capable machinery protection• Smart machine monitoring…o Automated fault detection and identification

within the Integrated Architecture®• Secure configuration in Logix Designer

Dynamix™ 2500 Portables:• Data collector for predictive maintenance and

machinery vibration diagnostics. o Part of a comprehensive CbM programo Download your measurements to Emonitor® CMS

• A real-time, multi-channel signal analyzero A standalone instrument for use in balancing, run up / coastdown

analysis, bump testing and more.

Sensors:• 1442 Series Eddy Current Probeso API-670 compliant sensors, extension

cables and drivers for all common size and range requirements

• 1443 Series Sensorso Industrial accelerometers, cables and mounting solutions

Emonitor® CMS Software:• Proven, comprehensive tools for executing any size condition

based monitoring program • Online and offline analysis and

data collection• Automated diagnosticso Fault frequency identificationo Built-in and user editable rule sets


Agenda

1443 Series Sensors

Measuring Vibration

1442 Series Eddy Current Probes


Vibration MeasurementsWhy bearing type mattersThe vast majority of bearings are one of two types: Rolling Element, or “Anti-Friction” Bearings and Fluid Film Bearings

bearing

bearing housing

bearing

bearing housing

Oil Wedge (load zone)Soft Metal

(Babbitt)

Eddy Current ProbeMounted in hole drilled through the bearing housing so that the tip is very near (but does not touch) the shaft.

AccelerometerMounted on bearing housing. Ideally screwed on but may be glued or mounted with a magnet.

Fluid Film: Capable of supporting very high loads, high temperatures, high speed. Expensive and associated rotor dynamics are very complex.

Rolling Element: Low cost, simple to apply, but are capable of only moderate speeds and relatively light loads. Rotor dynamics aren’t bad, but diagnostics can be complex due to all those spinning balls.


Vibration MeasurementsThree ways to conduct measurements

5

bearing

bearing housing

bearing

bearing housing

Shaft Relative: The measurement is the relative vibration between the shaft and the bearing, which is the structure that the sensor is mounted on.

This is what a typical ECP installation measures.

Case Absolute: The measurement is the absolute vibration of the casing relative to free space.

This is what an accelerometer or velocity sensor that is mounted on the bearing housing measures.

Shaft Absolute: The measurement is of shaft vibration relative to free space.

This is (usually) measured by adding the vibration of an ECP and an accelerometer that are mounted at the same location and in the same orientation.


Agenda

1443 Series Sensors

Measuring Vibration



SensorsDefinition

Accelerometer and Velocity Sensors and Accessories

Per API-6705.2 Seismic Transducers5.2.1 Accelerometer Sensors5.2.1.1 The standard accelerometer system shall be an electrically isolated transducer consisting of a case, a piezoelectric crystal, an integral amplifier, and a connector.…5.2.3 Velocity Sensors5.2.3.1 The standard velocity sensor shall be an electrically isolated, internally integrating accelerometer consisting of a case, a piezoelectric crystal, an integral amplifier and integrator, and a connector. 5.2.3.2 If specified, a velocity sensor utilizing a moving coil (electromechanical design) may be used instead of an internally integrating accelerometer…


1443 Series SensorsQuality Accelerometers and Accessories

Top Exit Sensors General-purpose Low Frequency High Frequency Hazardous Area Velocity Output Dual Output (Acceleration & Temperature)

Side Exit Sensors General-purpose Velocity Output Hazardous Area Dual Output (Acceleration & Temperature)

Sensors with Integral Cables General-purpose 5 m/16 ft. 10 m/32 ft. Shield case grounded Shield case isolated


1443 Series SensorsBetter Sensors at Lower Prices!

Easier Selection Smart Catalog Numbers Parts easily identified by their catalog number No “decoder ring” necessary

Fewer Catalogs 14 - 1443 Sensors replace over 23 EK Sensors

Lower Cost 1443 Sensors average 33% less

expensive than their EK equivalents

Improved Performance Higher rated temperature for standard

sensors Wider frequency range, more

consistent across sensors


Small machines (<500 HP) can usually be monitored with one radial sensor per bearing. Large machines may require two. Add an axial sensor when misalignment is a significant concern, or when thrust forces are expected.

Permanent sensors should always be mounted using drill-and-tap.

Sensors on a pillow-block bearingGlue-mounted sensors on small motors

1443 Series SensorsAcceleration & Velocity Sensor Installation

Vertical, horizontal and axial sensors on a large motor


1443 Series SensorsAdditional Materials

Materials available on the Literature Library

Data Sheet 1443-TD001User Manual 1443-UM001Application Guide 1444-AT001


Agenda

1443 Series Sensors

Measuring Vibration



Eddy Current ProbeDefinition

Eddy Current Probes are also called Proximity Probes

Per API-6705.1.1 Proximity Probes5.1.1.1 A proximity probe consists of a tip, a probe body, an integralcoaxial cable or triaxial cable, and a connector…5.1.1.2 Unless otherwise specified, the standard probe shall have a tip diameter of 7.6 mm to 8.3 mm (0.300 in. to 0.327 in.), with a reverse mount, integral hex nut probe body approximately 25 mm (1 in.) in length and 3/8-24-UNF-2A threads. 5.1.1.3 If specified, the standard options may consist of one or more ofthe following forward mount probe configurations…


1442 Series Eddy Current ProbesFor Precision Displacement Measurements

API-670 Compliant System fully satisfies API-670 Accuracy Requirements –

Even when probes, extension cables and drivers are switched out!

Isolated Driver No special enclosure required Less chance of introducing signal noise Easier installation

Color-coded Connectors Reduces likelihood of installation and maintenance errors

Injection Molded Probe Design Improved quality and reliability

Narrow Profile DIN Mount Driver Less space Easier Installation


1442 Series Eddy Current ProbesVibration Measurements

Fluid Film Bearing Vibration Measure vibration of shafts fitted with fluid film bearings Measurement is “relative,” between the shaft surface and the

structure that the sensor is mounted on - usually the bearing housing

Also provides the displacement input to an Absolute Shaft vibration monitor


TSI Vibration MeasurementsShaft Relative Measurements

XY Radial Vibration NCPU mounted through the bearing cap using probe holders


1442 Series Eddy Current ProbesSpeed, Overspeed & Phase Measurements

Speed and Phase Measure speed using a once-per-revolution pulse to support phase measurements Measure speed using a high number of pulses per revolution to:

Provide a highly accurate speed measurement to support machine control

Provide rapid, reliable speed measures as input to an overspeed protection system


Phase measurements require monitoring a once-per-revolution indicator. Speed measurements usually monitor a multi-tooth wheel.

Notch machined into shaft to provide a target for the phase measurement

Phase transducer and bracket located at the exciter on a turbine generator

TSI Vibration MeasurementsPhase Measurement Installation

A magnetic speed sensor mounted facing a toothed wheel


1442 Series Eddy Current ProbesPosition Measurements

Position & Expansion Linear position, distance to target measurements, such as thrust or some valve position Differential measurements calculate the difference between two sensors


Each of these is a critical measurement necessary to startup or operate a steam turbine, other turbomachinery, and (for thrust) any other machine with a thrust bearing

Differential Expansion bracket (for an eddy current probe) viewing a

concave ramp on the rotorDual (redundant) thrust

sensors (ECP’s)

TSI Vibration MeasurementsThrust, Eccentricity & Differential Expansion

An eddy current probe (ECP) speed sensor

mounted facing a toothed wheel.

Eccentricity ECP sensor. The wheel is

also used for eccentricity.


1442 Series Eddy Current ProbesAdditional Materials

Materials available on the Literature Library

Data Sheet 1442-TD001User Manual ICM-UM004Application Guide 1444-AT001

Rockwell Automation Integrated Condition Monitoring

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