Proven Condition Monitoring Solutions

Proven Condition Monitoring Solutions

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. Overview Condition monitoring for rotating machinery is widely acknowledged as a valuable tool for implementing a preventive maintenance strategy, helping to identify faults as they develop, and allowing appropriate planning of remedial actions to be carried out before costly breakdowns occur. Investment in a comprehensive continuous data monitoring system is often realised within months through: Optimised plant usage Avoidance of costly penalties Minimising unnecessary plant stoppages Reduced spares holding Beran Instruments have been providing on-line monitoring systems for over 20 years into the power generation, steel and petrochemical industries, and to a wide variety of plant manufacturers. The systems offer cost-effective, adaptable, and flexible monitoring for all rotating plant. Now in its fifth generation, Beran s PlantProtech Online Condition Monitoring Systems harnesses unrivalled experience to provide state-of-the-art solutions that meet the needs of today s condition based maintenance strategies, being: Reliable Easy to Use Industry Proven Page 1

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. Overview The Beran Condition Monitoring System features multichannel parallel dynamic acquisition for both steady-state (on-load, barring) and variable speed (runup, 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 operating concurrently with data recording. Multiple users can access real-time and historic data displays utilising an easy to use 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: Turbines Pumps Fans Compressors Combustion cans User Interface Easy both to configure and use Windows front end LAN, WAN or dial-up compatible Password protected access levels Data handling Fast data capture Comparison of real-time data with historic in real time 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 Industrialised gas turbines Gas circulators Page 2

System Architecture The building blocks for the Beran Condition Monitoring System are the PlantProtech TM 766/768 Analysers, which are networked together via an Ethernet LAN / WAN enabling local and remote machine support. Overview Using the appropriate PlantProtech analysers; 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 PlantProtech units can be installed later to monitor additional plant as required. Real-Time Data Exporting Data values may be exported into an optional spreadsheetstyle workbook in CSV format, mathematically processed via user entered 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. Robust and fault tolerant Each PlantProtech analyser 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 PlantProtech analyser are unaffected by any failures in the network, central PC or display terminal, or another PlantProtech analyser, ensuring a highly reliable and fault tolerant system. All data is processed and stored within an on-board hard disk in each Beran PlantProtech analyser. The data is accessed and displayed using a Windows PC running the PlantProtech Vision software, these PC s are located wherever they are needed, providing any number of users with simultaneous access to condition monitoring data across the plant. Remote users can also gain access to the data via corporate WAN or modem links. Modem links can be made available to allow remote offsite Vibration Analysts to access any monitored plant item and view identical condition displays to those at the plant - even in real-time. 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, any process parameter change or combination or parameters. 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 preceding 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, optimising the Beran System storage capability. Page 3

Flexible Measurement Options The Beran PlantProtech analysers provide robust modular conditioning for many types of applications. PlantProtech 766 Analyser The PlantProtech 766 analyser 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 PlantProtech analyser 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, OPC or Alstom s AMODIS. PlantProtech 766 Analyser PlantProtech 768 Analyser The PlantProtech 768 analyser 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 PlantProtect 768 analyser 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. PlantProtech 768 Analyser Key Points Modular Construction 19 Rack Mounting Up to 64 dynamic vibration channels Acceleration, velocity & displacement inputs Up to 4 x 1/Rev phase marker inputs Links to station DCS systems E-mail vibration alerts Page 4

Portable Condition Monitoring The Beran PlantProtech 767 system offers portable parallel multichannel plant monitoring either for temporary usage or return to service works. Robust fast data capture, Ethernet, modem and internal solid state data storage. PlantProtech 767 Portable Analyser 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 analyser is ideal for on-site commissioning, balancing, return-to-service and fault finding applications. Offering unparalleled facilities in a compact, rugged and easily portable unit weighing less than 12.5kg. Full control of measurement, analysis and alarm configuration is achieved via an Ethernet capable 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 realtime 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 the PC is not required, giving greater security and eliminating the possibility of the PC being removed without authorisation. 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. Key Points Up to 32 parallel vibration channels Acceleration, Velocity, Displacement dynamic vibration inputs 16 DC input channels & 8 Digital inputs Up to 4 x 1/Rev phase marker inputs Various carry case options Remote access via modem Ethernet Internal solid-state storage 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 high and low pass filters are integral. The unit is equipped with comprehensive alarm detection and alarm-initiated actions, including configurable Page 5

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 condition monitoring data. Overview Multiple simultaneous users can access the Beran PlantProtech systems and 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 Centre Line, 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. 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 realtime display or view the alarm log to assist in determining plant condition. Display types include : Real-time data display Historic data display Customised machine Mimic Bode Orbit Waterfall FFT Shaft Centre Line Trended data display Histograms XY Plots Polar Bearing Clearance Tabular Display Export to CSV Page 6

Display Formats Easy to use menu driven graph templates allow quick review of plant data. Histogram 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. Multiplots Multiplots 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. 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. 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. Page 7

Display Formats Data Displays can be copied into other applications for fast report generation or emailed to colleagues. Trends be viewed at the current and three previous shaft speeds. Trend display s show long-term variations in vibration over time, enabling slowly increasing vibration levels to be detected. Data can be filtered to show only specific data meeting user selected rules. 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. 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. 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 the 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 Page 8

Display Formats The Beran PlantProtech Vision software provides an easy to use method of viewing plant information. Multi-windows displays enable display of real-time and historic data simultaneously with other information such as alarm logs or histograms. Polar plots Polar plot showing vector change of dynamic data during a run up. Enabling colour trace and automatic annotation assists with the interpretation of the data. Vector difference Vector Difference screening provides a pictorial display of the vector difference between Run-up or Run-down data and enable the analyst to review changes in data sets and make important plant operational decisions. 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. Colour waterfall Single bearing FFT waterfall displayed with speed as the trace colour change parameter and order tracking lines enabled. The colour parameter may be selected from RPM, time, static parameter, etc. Log Files The PlantProtech systems automatically log all alarm events, changes in plant operational mode, system configuration changes and user access to the system. The system also allows users to enter free text allowing plant operational information to be shared with others. Page 9

Alarm Management A powerful and comprehensive suite of alarms are integral to the Beran On-line Condition Monitoring System, providing early warning of changes to monitored plant. Overview 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 may 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) Change data storage rate Storing spectral data Relay contact closure Key Points User configured custom alarms Password controlled configuration Above or below limits Within boundaries Step alarms Vector alarms Combination alarm based on machine mode and process parameter Alarm status can be sent to DCS Alarm e-mails Alarm event logs Alarm relay module Page 10

LAN/WAN/Internet Data Management Auto Archive Downloader The Beran PlantProtech systems have built in temporary storage, longer term data storage is automatically performed using PlantProtech Auto Archive Downloader tool. Description The PlantProtech Auto Archive Downloader application has been designed to automatically retrieve data files and alarm logs from Beran PlantProtech Monitors on demand or at a scheduled time. The retrieved data from multiple PlantProtech Monitors may then be: Reviewed using PlantProtech Vision software and Basestation applications. Converted into an open format. Read by customised data screening applications. Beran PlantProtech Archiver(s) Archived using standard IT backup infrastructure. The Auto Archive Downloader is scalable from one PlantProtech analyser to fleet wide installations, providing either Archiving, Data file downloading or both. The archiving function automatically downloads PlantProtech analyser data files to a central location and manages the internal data storage. It is recommended that the data is further backed up to a long term storage medium using a third party industry standard IT solution. LAN/WAN/Internet PlantProtech Auto Archive Downloader. Optional PlantProtech Basestation. Standard IT Backup PlantProtech Vision Software Page 11

Transducer Calibration For vibration sensors Calibration of installed vibration sensors is vital to prevent machine operational issues and potential damage. 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 1kg. 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 plant protection systems and On-line Vibration Monitoring Systems. Beran 455 System Page 12

Total Capability, Full Support Project management & support From the initial project concept stage through commissioning and warranty, Beran offer continual support. After sales support is vital to you ensuring you maximise your return on the investment made in the condition monitoring system. 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 Vibration diagnostic training Signal Conditioning Capability Service and After-Sales Support In the event that a fault is suspected, Beran engineers can access the installation via 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 support cover after the initial warranty period, providing complete peace of mind and protecting the original capital investment made. Different support levels are offered including off-site support or a Beran engineer to attend site to investigate and repair systems if required. 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. Page 13

Company Profile Since the formation of Beran Instruments in 1984, three fundamental issues have dominated the Company s direction - Quality, Innovation and Service. 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 Europe, and distributors around the world. Beran Instruments product range includes:- Condition Monitoring Systems for rotating machinery Automated Calibration Systems for vibration and microphone transducers ISO 9001:2000 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 www.helitune.com. 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 Credit: NASA This document is not contractual. Beran maintain a policy of continuous product development and improvement. This specification may change without notice. Beran Instruments is registered to BS EN ISO 9001 / AS9100 Issue 3 Beran Instruments Ltd. Hatchmoor Industrial Estate Torrington, Devon EX38 7HP United Kingdom Phone +44 (0) 1805 624304 Fax +44 (0) 1805 624093 www.beraninstruments.com Registered in England & Wales Reg. No. 01802762 VAT Reg. No. GB 762 442 630 Beran USA 190 Gordon Street Elk Grove Village IL 60007, USA Page 14

www.beraninstruments.com Beran Instruments Ltd. Hatchmoor Industrial Estate Torrington, Devon EX38 7HP United Kingdom Phone +44 (0) 1805 624304 Fax +44 (0) 1805 624093 Beran USA Beran Instruments 190 Gordon Street Elk Grove Village IL 60007, USA A CMG Company