Latest Asset Management System

DM-2000MACHINE MONITORING MACHINE MONITORING

SYSTEM SYSTEM

ByPrem BabooSr. Manager(Prod)National Fertilizers Ltd. IndiaPbaboo@hotmail.com, prem.baboo@nfl.co.inMob +919425735874

CONTENTS INTRODUCTION

MACHINE MONITORING SYSTEM (DM-2000) ntl mon tor n sst me i i g e TDIX DM 2000 details LATEST ASSETS MANAGEMENT SYSTEM (SYSTEM-1 )

INTRODUCTION• Data manager- 2000 for windows –NT

software is used in conjunction with critical machinery that is already fitted with a continuous machinery protection system. DM-2000 provides computerized machinery management with continuous, online data acquisition and display capabilities. Static & dynamic data under both machine steady state , start-up/ shutdown( transient) conditions is collected depending upon the type of communication processor used.

• Basically DM-2000 SYSTEM is a machine condition monitoring system while SYSTEM-1 is a plant asset management system.

3300 SYSTEM OVERVIEW

• 3300 system is manufactured and supplied by m/s Bently Nevada corporation and is used for monitoring of rotating machines.The 3300 system consists of power supply card, system monitor card and 12 dual-Axial /dual-Vibration/ 6-channel temp.monitoring cards. The position of power supply and system monitor cards are fixed and Axial/Vib./temp. monitoring cards positions can vary according to the users requirement.

SYSTEM MONITOR

SETPOINT ADJUST

RESET

COAXIAL CONNECTORS

SUPPLIES OKTRIP MULTIPLY

SYSTEM MONITOR

SYS MON

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3300 RACK (FRONT PANEL)

POWER SUPPLY MODULE :- The power supply card takes an input power

of 110Vac or 220Vac and supplies power to complete rack.Data communication interface options is also provided in power supply input module. According to your option you can select either RS-232 or RS-422 interface for the SDI/ DDI Communication interface links by installation of programmable jumpers. You can also select voltage options for transducers by installation of jumpers ( either –24Vdc or –18 Vdc). The power supply module is also available with barriers or without barriers.

SYSTEM MONITOR FUNCTIONS

• SUPPLY VOLTAGES OK :SEVEN LED’S LOCATED BEHIND THE FRONT PANNEL OF THE SYSTEM MONITOR ARE ON TO INDICATE THE VOLTAGE SUPPLIES ARE FUNCTIONING. THERE IS A GREEN LED ON THE FRONT PANNEL OF SYSTEM MONITOR , WHEN THIS LED IS ON ALL OF THE SEVEN VOLTAGE SUPPLIES ARE FUNCTIONING.

• SYSTEM RESET: PRESSING THE RESET SWITCH ON THE FRONT PANNEL WILL CAUSE THE SYSTEM TO RESET WHEN THE ALARM DISAPPEARS.

• Trip Multiply : The Trip Multiply function causes the monitor alarm setpoints ( both Alert & Danger) to increase by a fixed amount, either two times (2 x) or three times (3 x) according to the users options. A red LED on the system monitor front panel indicates that the trip multiply function is active.

• OK Relay : The purpose of this relay is to provide a means to annunciate a problem that is detected with any of the transducer system connected to he rack. The OK Relay is connected to the OK circuit of each monitor in the rack.If the circuit detects a transducer problem, the OK LED on the front of the affected monitor goes OFF and relay drive signal is sent to the OK Relay in the system monitor.

• Alarm Setpoint adjust : The system monitor has two switches on the front panel that adjust alarm setpoint levels on each monitor.One switch is for upscale adjustment and the other is for downscale adjustment.

• Data Interface : The sytem monitor supports the following Bently Nevada data Interfaces : dynamic data manager(DDM ), transient data manager(TDM),serial data interface (SDI), dynamic data interface (DDI), transient data Interface (TDI).

• Key Phasor Transducer : • The system monitor receives input from

four keyphasor transducers through terminals on the monitor back panel. Buffered keyphasor signals are also available from the co-axial connector on the front panel of the monitor. The system monitor also provides short-circuit protected keyphasor transducers power.

Dual thrust/Dual Vibration/Six channel Temperature Monitor

functions• Probe Gap Voltage switch – probe gap voltage value for each channel is displayed on the front panel indicator by pressing the gap switch.

• OK LED : When the proximeter/thermocouple output voltage is within its upper/lower limits the transducer is defined as OK. The OK detection circuit in the monitor controls the operation of OK LED in the front panel and to the monitor relay drive to the system OK relay.

• Alarms : Pressing the Alert/Danger switches on the front panel of the monitor displays the alert/danger alarm levels setpoint on the front panel indicator.

• Gap Alarm: Pressing the Gap and Alert switches simultaneously displays the Gap Voltage alert setpoints in the indicator

• First Out :Separate first out circuit exists for the alert and danger alarm. First out provision is optional and can be selected by the programmable jumper settings located in the monitor.

• Alarm relays : Monitor alarm can operate in latching or non-latching modes. In the non-latching mode, the alarm resets automatically but in the latching mode the alarm has to be reseted manually by pressing the reset switch located on front panel. Latching or Non-Latching alarm operation can be selected by programmable jumper settings.

• Danger Bypass : Danger alarm can be bypassed by using programmable jumper settings facility.

• Channel Bypass : If a channel remains not OK or not in use or giving frequent problems, you can set the channel bypass switch located on the monitor circuit board to put the channel permanent out of service.

• Buffered Output : The co-axial connectors on the front panel of the monitor is provided. The current axial/Vibration readings can be taken by connecting external devices to these connectors.

• Recorder outputs : The recorder o/p is proportional to the measured vibration signal over the monitor full scale range. The output range is 0 to –10VDC, 1 to 5VDC or 4-20 mA and is user selectable.

• SELF TEST : The monitor has three categories of self tests ; Power - up , cyclic and user invoked.

• Power-up: power-up self test is performed automatically each time when the monitor is turned ON.

• Cyclic test: This test is performed automatically during monitor operation. Errors encountered during cyclic test disables the monitor and flash the error code on the LCD bargraph.

• User invoked : This self test performs the power up self test and lets you to read and clear error codes stored during cyclic test. Stored errors are annunciated by flashing the ok LED’S and displaying the error codes on the front pannel LCD bargraph. This test can be performed by shorting ST pins located in monitor card for approx. 1 sec.

BARGRAPH INDICATOR

A B

TRANSDUCER OK LED

DANGER ALARM LED

ALERT ALARM LED

BYPASS LED

DANGR

ALERT

GAP

A B

COAXIAL CONNECTORS FOR

BUFFERED O/P

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25 25

25 25N

C

DUAL THRUST MONITOR

BARGRAPH INDICATOR

A B

TRANSDUCER OK LED

DANGER ALARM LED

ALERT ALARM LED

BYPASS LED

DANGR

ALERT

GAP

A B

COAXIAL CONNECTORS FOR

BUFFERED O/P

DUAL VIBRATION MONITOR

TDIX( Transient data interface)• The TDIX system consists of the following

components :• Sampler back plane :-It provides the

interface between the TDIX system back plane , the indicator board and to the 12 sampler cards. The sampler back plane also provides the static and dynamic connectors for connecting the TDIX to the monitor rack.

• Indicator board :- It contains the LED status lights that indicates the operating condition of the TDIX. These status LED’S are visible through the window in the TDIX back cover.

• Sampler cards :-The sampler cards collects data from the monitors .since one TDIX can handle up to 12 sampler cards, but the quantity of sampler cards in a TDIX depends upon the number of axial/ vibration monitors used in the bently rack. These sampler cards are interchangeable with each other.

• CPU board :-The cpu board controls the overall operation of the tdix and provides the serial communication between the TDIX and rest of the monitoring system. This board contains the TDIX & SDIX serial connectors, communication protocol, termination switches and system reset/ initialize switch. It also carries control and data signal between the individual TDIX systems.

• Key-Phasor Card :- The key-phasor card obtains the system key-phasor signals and provides connectors for the key-phasor, Alarm-in/Alarm-out and start-up/shut-down circuitry.

• Power Supply Card :- It takes 110/220 VAC & provides the DC Supply voltages required by the TDIX system.

• Protocol Selection Switch :- This protocol switch is located in the TDIX CPU, by sliding this switch you can select either RS-232 or RS-422 communication protocol.

• Last Rack Switch: This switch is located in the TDIX CPU, from this switch you can set the TDIX to last rack by sliding the switch from N to Y.

N YNot last rack

Last rack

DM 2000system overview

• To provide maximum flexibility the DM-2000 system has been designed to opearte in three different configurations

• STAND ALONE SYSTEM• NETWORKED SYSTEM• REMOTE SYSTEM

• STAND ALONE SYSTEM :This system has one computer that retrieves

and displays data from upto twelve Bently Neveda Corp. Communication processors. Stand alone system consists of following components:

a. A suitably equipped computerb. One or more DM-2000 Software modulesc. One to twelve Bently Neveda

communication processors (TDM, DDM, PDM, DDI & TDIX) connected to the appropriate racks with BentlyNeveda 3500, 3300 or 9000 series monitoring system.

3300 Rack S D

S D TDIX 1 H R

TEMP.RACKDDIR DDIH

3300 Rack S D

S D TDIX 2 R H

TEMP.

RACK

DDIR DDIH

3300 Rack S D

3300 Rack S D

S D TDIX 4 R H

S D TDIX 3 R H

3300 Rack S D

S D TDIX 5 R H

TEMP.RACKDDIR DDIH

3300 Rack S D

S D TDIX 6 R H

TEMP.

RACK

DDIR DDIH

3300 Rack S D

3300 Rack S D

S D TDIX 8 R H

S D TDIX 7 R H

DM-2000 SOFTWARE LOADED PC

RS422

• NETWORKED SYSTEM : The DM-2000 system can be setup in an

ethernet network consisting of upto 10 DM-2000 computers. Each station can be connected to 12 communication processors (TDM, DDM, PDM, DDI & TDIX) for a total capacity of 120 communication processors ( 12 CPs x 10 station). A networked system consist of following components.

a. From 2 to 10 suitably equipped computers.b. one or more DM-2000 software modules per

stationc. From 1 to 12 Bently Nevada communication

processors per station, connected to appropriate rack.

DM-2000 SOFTWARE LOADED PC

DM-2000 SOFTWARE LOADED PC

DM-2000 SOFTWARE LOADED PC

ETHERNET NETWORK10 NETWORK STATION MAX.

TDIX System

TDIX System

TDIX System

TDIX System

TDIX System

TDIX System

3300

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Rack 1 Rack 12 Rack 1 Rack 1Rack 12 Rack 12

1 12

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• REMOTE SYSTEM:-The DM-2000 System can be used in remote locations. A remote computer may be connected to either a stand alone system or one of the stations of the networked system by either a modem or by direct connection. A remote system consists of following components :

• A suitabily equipped remote computer.• One or more dm-2000 software modules.• A set of modem or direct connection

cables.

DM-2000 SOFTWARE LOADED PC

DM-2000 SOFTWARE LOADED PC

DM-2000 SOFTWARE LOADED PC

10 NETWORK STATION MAX.

TDIX System

TDIX System

TDIX System

TDIX System

TDIX System

TDIX System

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Remote PC Mod

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DM-2000 FEATURES• A data communication interface between a

computer and bently nevada 3300, 3500, 9000, series monitoring system.

• Communication interface to TDM, TDIX, & DDI communication processors via RS-232 or by RS-422 .

• Communication interface to DDM & PDM communication processors via RS-422 .

• Interconnection of upto twelve TDM, TDIX,DDI, DDM,or PDM communication processor per station ( 120 communication processor maximum for system ).

• Networked data manager system containing upto 10 computer stations .

• Standard ethernet cable support thinnet,standard ethernet & fiber optic.

• Remote access via Modem or direct by connection cables.

• Configuration of any DM-2000 station on the network from any other DM-2000 station.

• Configuration that permits flexible assignments of monitors to Key Phasor transducers.

• Max. No. of alarm events per data acquisition station-400

• Max. No. of transient files per point – up to 255.• Max. No. of system events per data acquisition

station –400• Max. trend file length – 10000 trend intervals,

length depends on trend intervals time selected.

• Automatic alarm notification to remote computer.• User selectable trend intervals.• Storage of 50 vector event and waveform event

files.• Maximum distance between Data Acquisition

Station and 1st communication processor - 1200 mtrs. (4000 feets)

• Maximum distance between communication processors – 1200 mtrs.

• Fast trend static data at 4 seconds resolution for all channels and waveform fast trend data at 40 second resolution.

• Transient data storage of up to 320 static samples (used for polar, bode plots & fast trend plots) and up to 32 waveform samples (used for waterfall plots).

• Startup or shutdown transient data from a contact closure initiated startup or shutdown.

• Graphs in following formats: Trends Fast trends (20 min.) Acceptance region Bar graph Orbit/Time base Machine Train diagram Spectrum / full Spectrum Tabular listing Plant summary report Multivariable Trend Bode Polar Cascade/full cascade

• DM-2000 Computer Specifications (minimum requirements)

RAM - 32 MB Processor - Intel Pentium-I or better CD ROM- Required to load software Keybrd/Mouse- Required Free HD space- 14 MB Network card - Computer specific Operating System- Win NT

4.0,Win2000, Win XP

DATA DESCRIPTION• The DM-2000 system collects and

processes a variety of data from bently nevada communication processors.after the system collects data from the communication processors , it stores data in various files on the computer harddisk . The DM-2000 System collects three types of datas :-

• STATIC DATA.• WAVEFORM DATA.• TRANSIENT DATA.

• STATIC DATA:- Static data consists of current process values viewable at bently monitor front pannel,vibration amplitude & phase data,shaft rotative speed and monitor status (ok,alert,& danger ). Static data is used for trend plots , bargraphs, acceptance region plots,and current value displays. The DM-2000 collects this data at every trend intervals ( 10min, 20 mins, 1hrs, and 2hrs ) for trend storage and at every 5 secs. When viewing the current values or bargraph displays.

• WAVEFORM DATA :- waveform data consists of samples of vibration data taken releative to keyphasor frequency or at a specific frequency (TDIX communication processor only ) . waveform data provides spectrum, timebase, and orbit /timebase displays.

• TRANSIENT DATA :- transient data is a collection of successive static and waveform samples. The samples may be taken on a trime interval or on user specified change in RPM. Transient data is most often use to document startup and coastdowns data and is available only when using TDM or TDIX cps.The DM 2000 software uses transient data to produce waterfall,cascade, polar, bode and fast trend displays.

SYSTEM-1 ® The Latest Asset Management

System• System-1 is GE energy patented software platform for real time optimization of plant condition monitoring and event diagnostics. Similar in concept to a process control system (DCS) which allows user to understand, diagnose and control their process conditions, the system-1 platform provides this capability for the assets that drives your process.

• System-1 can also be used to selected processes not normally addressed by a process control system such as fuel management, combustion optimization and many others.

• System 1 is designed to receive inputs from an extremely broad ranges of sources including permanent and portable condition monitoring hardware/software, process control & automation hardware and software, maintenance & reliability software,spreadsheets,operator logs & many others. It continuously monitors these inputs and when the situations requiring attention, system 1 detects these and then alerts appropriate plant personnel with actionable information advisories that provides recommended corrective actions.

• System 1 can automatically analyze its collected data and transform this into actionable information, advisories for optimization or diagnostics.

• The System 1 database uses microsoft SQL Technology optimized for fast data storage, event capturing, high resolution trending & alarming, and configuration information. An extensive variety of capabilities exist for importing & exporting data between system 1 and process control automation system.

• The system 1 platform has been specially designed for max.scalability & flexibility, allowing user to easily configure the system to reflect their unique assets, processes & operating practices. whether hosting a single data collection as a part of predictive maintenance or addressing 1000 of assets across a global enterprise, the system 1 platform is designed to fit your requirements.

System 1® Features Sophisticated alarm management Powerful analytic and diagnostic capabilities Configurable data acquisition and storage resolutionAnywhere,anytime access via web browser support for virtual private network (VPN) technologies Fully customizable displays One user interface One database

increased safety Improved reliability Optimized maintenance cost Low energy cost Increased thermal efficiency/Optimized

heat rate in boilers.

System 1® Specifications• Support monitor systems : 3300, 3500, 2201, 1701 • communication processors types : TDIX, TDXnet, • Max. No. of Communication Processors per data

acquisition station = 12• Max. No. of field monitors per data acquisition station

= 36• Max. No.of Configurable machine trains = unlimited• Max. No.of Configurable online/scanning points = 2500

(combined online/scanning )• Max. trend file length= unlimited (depends on HDD)• Max. No. of system/alarm events per data acquisition

station = unlimited (depends on HDD space)• Network support = Ethernet

System 1® Application Package• Turbo machinery/Integral gear compressors/ Hydro-

turbine/generators :- Advance on-line condition monitoring and diagnostic software package for critical rotating machinery applications.

• Electrical equipment/Wind turbines :- Advance on-line Electrical equipment condition & diagnostic software package for Motor/Generator,Transformer & Wind Turbine

• Fired equipments :– Real time condition monitoring & diag-nostics for fired equipments such as boiler & furnaces. This package helps to reduce emissions,improve heat rate,minim-ize slagging,boiler tube thickness, & process heat problem.

• Trend Master Pro:- Bently’s trend master pro online scanning system is use for managing assets & balance of plant machinery.

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