ProvibTechs Application Note_ Compressor

www.provibTech.com
ProvibTechs Compressor Solution
Application_Compressor_1
ApplicationLayout

ProvibTechs Application Note_ Compressor

www.provibTech.com
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Application_ Compressor_2
ApplicationLayout

ProvibTechs Application Note_ Compressor
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Application_Compressor_3
ApplicationLayout
ProvibTechs Application Note_ Compressor
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ProvibTech Products
Transducers
TM0180
TheTM0180(8mm)isdesignedforlonglifecyclesandaresuitableforharshenvironments.
ProvibTechrealizesoneofthemostsignificantproblemsinproximityprobeinstallationsareground
loopsandlossofisolationdueto
damagedcablejackets.ProvibTechs
customruggedcablejacketprevents
theprobecablefrombreakingand
tearingandishighlyresistiveto
corrosiveenvironments.
TheTM0180probeandTM0181(extensioncable)areequippedwithastandardprotectiverubber
boot,whichcoverstheconnectorsandpreventsoilanddirtpenetration.
TheTM0180seriesprobescomein0.5mand1.0mcablelengths,aswellas,speciallengthsof5.0m
and9.0mwithanintegratedprobeandextensioncabledesign.
TheprobemaybeselectedinEnglishormetricunits,aswellas,reversemountingoptions.Reverse
mountprobesareusedwithTM0393Xprobehousingsforhazardousareas.
Withupto2mm(80mil)linearrange,TM0180isgenerallyappliedforradialvibration,thrustposition,
rotationspeed,eccentricityandphasereference.ItisfrequentlyusedwithProvibTechsextension
cableTM0181anddriverTM0182andreverseprobehousingTM0393X.

TM0110
The11mmprobehasupto4mm(160mil)linear
range.TheTM0110probeisrecommendedwhena
longerlinearrangeisrequired.TheTM0110proximityprobesystemisdesignedtomeetAPI670
industrialstandard.
TM0110isgenerallyappliedforthrustposition.Itisfrequentlyusedwith
ProvibTechsextensioncableTM0181anddriverTM0182.
TM0120
The25mmprobehasupto12mm(470mil)linearrange.Theprobeis

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designedformeasuringdifferentialexpansion.TheTM0120integratestheprobe,extensioncable
andthedriverintooneunit.Thisintegralproximityprobeisdesignedforeasyfieldinstallation.
TheTM0120probecomesinlengthsof1m,5mand9mstandardcable(2conductorshieldedcable).

TM0793V/TM0782A
TM0793Viswithsensitivity4.0mV/mm/sec(100mV/in/sec).TM0782A
iswithsensitivity100mV/g.TM0782AandTM0793Varepiezoelectric
accelerometer/velocitytransducerdirectlyinterfaceswith
ProvibTechssignalconditionersPT2060,DTMs,DM200orTR1101.

TM0602
Forsteamturbineapplications,therelativecaseexpansionduetothermaleffectshouldbe
monitored.Caseexpansionisthethermalgrowthofthemachinecaseasitexpandsduringmachine
startupandonlineoperations.TheTM0602istypicallymountedonthefoundationattheopposite
endfromwheretheturbinecasingisattachedtothefoundation.Thecaseexpansiontransducer
systemprovidesinformationonthegrowthofthemachinecaserelativetothefoundation.
LVDTs(linearvariabledifferentialtransformers)areusedtomeasurethecaseexpansion.Three
differentlinearrangesareavailable:25mm(1.0),
50mm(2.0)and100mm(4.0).Thecase
expansiontransducerassemblyconsistsofanLVDT
thatishousedinaweatherproofprotective
enclosure.
Monitors
PT2060/10/20/31/35/40/43/53/91/96/98/90/99

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PT2060/10
Proximity Module (4 channels)
Radial vibration
Axial/ Thrust position
Eccentricity
Differential expansion
Low-frequency vibration
Speed output
Zero speed and speed
Reverse rotational protection output
PT2060/20
Seismic Module (4 channels)
Acceleration, Velocity and Displacement
Low Frequency acceleration, Velocity or Displacement
Case Expansion
Case expansion outputpaired
Case expansion outputsingle
PT2060/31
Temperature Module(8 channels )
RTD, TC
PT2060/35
Process Input Module
16 channels per module
PT2060/40
Relay Module(16 channels)
Relay output (SPDT)

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PT2060/43
Redundant Relay Module(8 channels)
Relay output(DPDT)
PT2060/53
Over Speed Module(1 or 3 channels)
Over-speed protection
The following function only for channel 3 and channel 4.
Radial vibration: monitoring shaft vibration, single or dual XY
Axial/ Thrust position: monitoring shaft thrust position, with 5mm,
8mm, and 11 mm proximity probes
Eccentricity
Differential expansion
Low-frequency vibration
Speed output
zero speed
Reverse rotational protection output
PT2060/91
System Interface Module
Connect to a configuration station
Communicate to PT2060 system racks
Communicate to other control systems (PLC/DCS or Historian)
Provides two phase references channels
Provide storage of system and alarm events
PT2060/98
Display Module
ID each channel, and arrange the routing
Setup data collection strategy
Display machine photo and real-time data and status on top of the
photo
Real-time bar graph/ status list/ alarm status of each channel
Alarm events
Trend plot on each channel
Touch-panel for easy operation
Network to control systems (PLC/DCS or Historian) via Modbus

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PT2060/90
Power Supply Module
Redundant Power supply
PT2060/99
Standard 19 or 12 rack

DTM10/DTM20/DTM96

DTM10301 ProximityDistributedTransmitterMonitor.
Withinternaldriver,forRadialVibration
DTM10302 ProximityDistributedTransmitterMonitor.
Withinternaldriver,forAxialPosition
DTM10502 ProximityDistributedTransmitterMonitor.
Withinternaldriver,forRotationSpeed/PhaseReference
DTM10201 ProximityDistributedTransmitterMonitor.
Withexternaldriver,forRadialVibration
DTM10202 ProximityDistributedTransmitterMonitor.
Withexternaldriver,forAxialPosition

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DTM10501 ProximityDistributedTransmitterMonitor.
Withexternaldriver,forRotationSpeed/PhaseReference
DTM20101 SeismicVibrationDistributedTransmitterMonitor.
Runwithcurrentmodeaccelerometerwith100mV/g,velocitysensorwith
4mV/mm/sorseismicvelocitysensor
DTM96 Communicationmodule.Opticalisolated,RS485,RS422,RS232
PCM360 Online Condition Monitoring System
IntroductionofPCM360
ProvibTechsPCM360isamachine
conditionmanagementsystemthatcollects,
stores,analyzesandiscapableof
transmittingmachinestatusmonitoring
informationoverlocalorwideareanetwork.
ThePCM360providesstatic,dynamicand
transientdatacollectionandanalysis;such
asgraphicalindicationofvibrationlevel,
trend,waveform,spectrum,bodeplots,
cascadeplotsandmuchmore.
AllProvibTechsmonitorsandtransmitters
canquicklyandeasilybeintegratedtouploadmachinestatusanditsdynamicdatatothePCM360.
ThePCM360obtainsbothcriticalmachineryrunningstatusandbalanceofplantrunningstatus.
Additionally,thePCM360collectsprocessdataas420mAinputordigitalmonitorinputviaModbus,
etc.ThePCM360providesanintegratedsystemsolutionforassetmanagementresultinginatotal
solutionformachinemaintenance and protection.
LeadingFeaturesofPCM360
Integratesplantconditionmonitoringandprocessdataintoonedatabase
Userfriendlyinterfaceforinstantdataanalysiswithminimaltrainingrequiredoffieldstaff
Maximumflexibilityandexpandabilityofthesoftwaresystemwithobjectorientedmodular
design
Transient,dynamicandprocessdatacollection
BuiltonMicrosoftSQLServerdatabasetoassurebetterdatamanagementandreliable
networking

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Client/Serverarchitectureenablesusertoaccessdataanywhereonintranet/internet
Readilyintegrateswiththirdpartyvibrationmonitorsandprocessmonitorswithminimum
hardwarerequirements
MultipledigitalI/OProtocols,suchasModbusRTU/TCP
Multiplehardwareoutputmodulesreadyforfurtherdatatransferandannunciationinrelays
andcurrenttransmission
24hournotificationthroughonsitealarms,operatorinterfaceandevenSMSmessagingon
GPRSmobile
RemotenotificationwithSMSmessagestoanycellularphonewithmachinerunningstatus
Advancedpostprocessingoftransientdataminimizesdataloss,maximizinganalysiscapability
PCM360DataFlowIntroduction
Inadditiontorunningwellwithtransmitters/monitorsofProvibTechitself,withgreatintegrate
abilityandversatileinterface,PCM360isalsoabletointerfacewithdiversetransmitters/monitors
/sensorsor ModbusTCPServerorOPCserverfromthirdpartywhichtakesgreatconveniencefor
retrofitprojectsandmakestheplantmanagementmoreefficientandeffectivelywithoutspending
muchmoney.
Apartfromthese,PCM360alsocanplayaroleasModbusTCPServerorOPCServerwhichmakes
interfacingwiththirdpartyconditionmonitoringsystemavailable.
Inconclusion,PCM360isveryflexibleandfunctional.Withitsreliability,itnotonlycanacquirethe
datafromthirdpartybutalsoshareitsdatawiththirdparty.

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PlotsSupportedByDifferentMeasurementPoints
MeasurementPoint
Device
Type
Channel
Type
DataType
Single
Channel
Dual
Channel
PlotsandLists

bargraph,waveform,spectrum,
bode,polar,cascade,
(dynamic,transient)waterfall,
(dynamic,transient,historical)trend,
statuslist,alarmlist,transientlist
Acceleratio
n,Velocity
Dynamic
data,
Transient
data

bargraph,waveform,spectrum,
fullspectrum,shaftXYvibration,
bode,polar,cascade,fullcascade,
(dynamic,transient)waterfall,
(dynamic,transient,historical)trend,
statuslist,alarmlist,transientlist

bargraph,waveform,spectrum,
bode,polar,cascade,
waveformwithDCcoupling,
(dynamic,transient)waterfall,
(dynamic,transient,historical)trend,
statuslist,alarmlist,transientlist
DAQ
Card:
6013,
6220,6
250
Vibration[f
romProx]
Dynamic
data,
Transient
data
bargraph,waveform,spectrum,
fullspectrum,shaftXYvibration,
shaftcenterline,
waveformwithDCcoupling,
shaftXYvibrationwithDCcoupling,

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bode,polar,cascade,fullcascade,
(dynamic,transient)waterfall,
(dynamic,transient,historical)trend,
statuslist,alarmlist,transientlist
Position[fr
omProx],
Process
Staticdata

bargraph,statictrend,
statuslist,alarmlist

Modbu
sDAQ
for
Proces
s
Acceleratio
n,Velocity,
Vibration[f
romProx],
Position[fr
omProx],
Process
Staticdata

bargraph,statictrend,
statuslist,alarmlist

bargraph,waveform,spectrum,
dynamicwaterfall,alarmlist,
(static,dynamic)trend,statuslist
Modbu
sDAQ
forDW

Dynamic
data,Static
data

bargraph,waveform,spectrum,
fullspectrum,shaftXYvibration,
dynamicwaterfall,alarmlist,
(static,dynamic)trend,statuslist

OPC
Client
Acceleratio
n,Velocity,
Vibration[f
romProx],
Position[fr
omProx],
Process
Staticdata

bargraph,statictrend,
statuslist,alarmlist

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Plots
Waveform
plot
(realtimeandhistorical)
Waveform
plotwithDCcoupling
(realtimeandhistorical)
Spectrum
plot(realtimeandhistorical)
Full
spectrumplot(realtimeandhistorical)

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ShaftXY
vibration
(realtimeandhistorical)
ShaftXY
vibrationwithDCcoupling
(realtimeandhistorical)
Trendplot
(static,dynamic,transient,historical,andrealtime,gap)
Waterfall
plot
(dynamicandtransient)

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BarGraph
shaft
centerlineplot(realtimeandhistorical)
Bodeplot
Cascade
plot
Full
cascadeplot
Polarplot

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Shaftcenterlinemodeshape

ShaftXYvibrationmodeshape
Lists
Transientlist

Alarmlist

Statuslist

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Measurement Illustration
ShaftX,YVibration(RadialVibration)
ShaftX,YVibrationisforshaftdynamicmotion
whichisgenerallymeasuredinadirection
perpendiculartotheshaftaxis,itisalsocalled
radialvibrationorlateralvibration.Itisindicated
byPKPKwithunitmorMil.5mmor8mm
proximityprobesareoftenusedtoobserveShaftX,
YVibration.ProvibTechsproximityprobe
TM0105(5mm)andTM0180(8mm)willsupply
completesolution.

PleaserefertotheFigure1.1andFigure1.2.Theyareshowingthetypicalwayforprobeinstallation
forRadialVibration.

ApartfromtheinstallationwayofFigure1.1and
Figure1.2,theresanotherinstallationway,please
refertoFigure1.3.ProbeXishorizontallyinstalled
andProbeYisverticallyinstalled.

Sometimes,proximityprobeswillbemounted
insidethemachinebyprobeclamp,andsometimesprobeswillbemountedwithhelpofprobe
holder.ProvibTechsTM0393Xsupplyaverycost
effectivesolutionformountingtheproximityprobes
forthesemachineswhateverfornormalpressureor
highpressurepurpose.Customercanreplacethe
probewithoutopeningthemachinecasewhichtakes
greatconvenienceandsavelotsoftimeand
maintenancecost.Adjustablepenetrationdepth
+/13mm(0.512)makestheinstallationveryflexible.
PleaserefertoFigure1.4andFigure1.5for
installationreference.

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ThrustPosition(AxialPosition)
ThrustPositionistomeasurethemovementofshaftin
theaxialdirectionwithrespecttosomefixedreference.
Typically,thereferenceisthethrustbearingsupport
structureorothercasingmembertowhichthe
displacementprobeismounted.Theprobeisgenerally
toobservethethrustcollardirectlyoraxialshaftsurface.
ThrustPositionisalsocalledAxialPosition,anditis
indicatedbyaveragewithunitmorMil.5mmor8mm
proximityprobes
areoftenusedto
observeThrustPosition.ProvibTechsproximityprobe
TM0110(11mm)andTM0180(8mm)willsupplycomplete
solution.

DueThrustPositionisveryimportantforsomeessential
machines,itisstronglyrecommendedtousedualproximity
probestomonitorThrustPositionastheredundancywill
increasethereliabilityofthemonitoring.
PleaserefertoFigure2.1andFigure2.2.

SeismicVibration(CasingVibration)
SeismicVibrationmeasurestheabsolutevibrationofmachinecaseorstructure.Thismeasurement
doesntrequireotherobjectspositionormovementasareference.Accelerometersandvelocity
sensorsareoftenusedforSeimicVibration.ItisalsocalledCasingVibration.Itwillbeindicatedby
PKorPKPKorRMS.
Theinstallationdirectioncouldbehorizontalorvertical.PleaserefertoFigure3.1.

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RotationSpeed
Rotorspeedisimportantmeasurementsduringnormalmachineoperatingconditionsaswellas
duringstartupandcoastdown.Suddenunexpectedchangesinrotorspeedmaybeanindicationof
machineryorprocessmalfunction.

OverSpeed
OverSpeedprotectionsystemismandatoryforcriticalmachinesespeciallylikesteamturbines.Due
therotationspeedforthesteamturbineisthemostimportantfactor,sogenerallyweusetwo
proximityprobesorthreeproximityprobestocomposeasystem.Itcouldbe2outof 2or2outof
3.

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ReverseRotation
Forboilerfeedpumporsomemachines,ReverseRotationmonitoringisnecessaryasthereverse
flowwillcausethetotalmachineshutdownfinallystopwatersupplying.TypicallyReverseRotation
requirestwoproximityprobestomountonthegearorshaftwithanotch.Pleaserefertobelow
Figure6.1fordetails.

ZeroSpeed
Whenthesteamturbineormachineisunderturningstate,therotationspeedshouldnotbevery
slow.Ifitrotatesslowerthanitshouldbe,thenitwilltrip.ZeroSpeedissimilarlikespeed
monitoring,butSpeedmonitoringistotripwhenitrotatetoofastthanitshouldbe,andZeroSpeed
monitoringistotripwhenitrotatetooslowthanitshouldbe.

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PhaseReference
PhaseReferenceisatransducerthatproducesavoltagepulseforeachturnoftheshaft.Thissignal
isusedprimarilytomeasureshaftrotativespeedandservesasareferenceformeasuringvibration
phaselagangle.Typicallyproximityprobe,magneticpickup,opticalpickupareusedformeasuring
PhaseReference.
PleaserefertobelowFigure7.1fordetails.

DifferentialExpansion
DifferentialExpansionistomeasuretheaxialpositionoftherotorwithrespecttothemachine
casingatsomedistancefromthethrustbearing.DifferentialExpansionisusuallymeasuredwhen
machinestartupandshutdownasthemachinehasabigthermalexpansionduringthatperiod.

Themeasurementistypicallymadewithaproximityprobetransducermountedtothemachine
casingandobservinganaxialoftherotor.

Theproximityprobecouldbemountedbytwoways.Oneisbynormalshaftdirection,pleaserefer
tobelowFigure9.1.

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Anotherwayismountedbyrampshaftdirection.PleaserefertobelowFigure9.2.

CaseExpansion
CaseExpansionistomeasureaxialpositionofthemachinecaserelativetoafixedreference,usually
thefoundation.Changesincasingaxialpositionaretheresultofthermalexpansionandcontraction
ofthecasingduringstartupandshutdown.ItisgenerallymeasuredbyLVDT(LinearVariable
DifferentialTransformer).
PleaserefertobelowFigure10.1forCaseExpansion.

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Eccentricity
Eccentricityisveryimportantformonitoringturbinerotorbow.PT2060/10PROXproximitymodule
canprovidesophisticatedonlineeccentricitymonitoring.Themonitorissuitableforvirtuallyall
typesofrotatingmachineryintermsofeccentricity.ThePT2060/10PROXproximitymodulewillbe
continuouslymeasureandmonitoringinuptotwochannelspermodule.

Eccentricitymeasurementsindicatethedeviationoftherotorphysicalcenterandthetheoretical
center.Thedifferencehastobesmallenoughtoallowmachinestartupwithoutcausingdamage.
ThePT2060/10PROXproximitymoduleprovidespeaktopeakeccentricitymeasurement,which
measurethedifferencebetweenthepositiveandthenegativeextremesoftherotorbow.Italsohas
onemorechannelthatoutputthepositionoftherotor.

Operatorsuseeccentricitymeasurementstodeterminewhenacombinationofslowrollandheating
havereducedtherotoreccentricitytothepoint
wheretheturbinecansafelybebroughtupto
speedwithoutdamagefromexcessivevibrationor
rotortostatorcontact.
EccentricityisthemeasurementofRotorBowat
rotorslowrollwhichmaybecausedbyanyora
combinationof
Fixedmechanicalbow
Temporarythermalbow
Gravitybow

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ValvePosition
ValvePositionistomeasurethepositionoftheprocessinlet
valvesonamachine,usuallyexpressedasapercentageof
thevalveopening;zeropercentisfullyclosed,100percentis
fullyopen.

PleaseseebelowFigure12.1forValvePosition.

Temperature
Temperaturemonitoringisalsoanimportantparameterto
monitorthemachinehealthstatus.Whensomethingwrong
insidethemachine,itwillcausemorefrictionwhichwillcausetemperaturegettinghigher.Typically
welluseRTD/TCsensortoacquiretheprocesssignalandtransfertotransmitters/monitors,finally
transfertoconditionmonitoringsystem.
FlowRate,Pressureandotherprocessvariables
Alltheseparametersareliketemperatureastheyareprocessvariables,andthesearetocontrol
somethingorfeedbackthehealthstatusofthemachine.Typicallywellusedifferentkindsof
sensorstogettheprocesssignalsandfinallytransfertoconditionmonitoringsystem.