Opening the door to smart con mon
May 1st 2005

Emerson Process Management unveiled its new CSI 9210 Machinery Health Transmitter this month. Here Todd Reeves puts the new technology in context While smart field devices and new communications protocols have made it possible to monitor the operating condition of a good deal of chemical process equipment and even obtain field-based diagnostics, continuous online monitoring of most rotating machinery has been uncommon. However, a new technology is now combining automated vibration monitoring with the diagnostic capabilities of smart instrumentation, enabling continuous reporting of the condition of motor-pump machine trains.

The new field transmitter gathers vibration and other data at the machine, analyses the information, compares it with performance trends, determines if anything is amiss, alerts the operator if necessary of developing problems and gives suggested actions to improve the condition.

By applying its knowledge in predictive diagnostics, digital plant architecture, asset management, and field communications, as well as vibration monitoring and analysis, Emerson’s engineers have created a whole new class of instruments designed to help prevent unexpected failures and avoid process upsets. By embedding an analytical capability inside a field device, the engineers made it possible to monitor vibration in all types of rotating machinery continuously and analyse the data right in the field.

Motor-pump trains tend to have similar failure patterns, which the embedded intelligence recognises. Probable cause and effect relationships based on these patterns are used in determining what is happening in the machine and whether a warning is justified. Results are delivered directly to a user through the process automation system using the fieldbus protocol. This technology functions as a component of Emerson's PlantWeb® digital plant architecture, providing for reduced-risk projects and better operations. The door has now opened to the real opportunities of integrated online monitoring not previously available with rotating machinery.

The smart analytical field device has been developed specifically for one type of machine – the AC induction motor coupled to a centrifugal pump – the most common type of motor-pump train found in process industry plants. This instrument receives continuous inputs from six different locations on a motor-pump train, tachometer readings for shaft speed, motor flux inputs from a flux coil, and temperatures measured at the motor surface. The new CSI 9210 Machinery Health Transmitter combines and instantly analyses all this information, generating a composite view of machine condition.

While alerts identify changing conditions that need attention, operators don’t have to interpret the inputs; they can use the actionable recommendations provided in order to alter the process as necessary to avoid an upset. When operators carry out a suggested course of action, they are able to see in real-time the dynamic interaction between the process and operating machine, the effect that the process is having on that machine, and vice versa.

Some problems may be eliminated or minimised by simple adjustment once the operator is aware that a certain condition exists. For example, if a process situation causes pump cavitation, that condition will be relayed to the control system, so the operators can tune the process for improved performance, efficiency, and longer asset life.

In other cases, they may have to take immediate action to minimise secondary component damage and production losses.

The maintenance department should also be involved in evaluating the data and determining when repairs should be made.

An overall machinery health value, based on various physical characteristics, can be assigned a numerical rank from 1 to 100 with the top number indicating 100 percent health. By checking periodically on machinery health values, operators can get a quick fix on the condition of any monitored motor-pump train.

Personnel with minimal knowledge of vibration analysis methods can install and configure these transmitters, but Emerson provides installation and support services to ensure users receive full value from this technology. This transmitter is similar to other smart instruments with respect to configuration and commissioning. Integrating continuous vibration monitoring with analysis-in-the-field and delivery of results to the process control system transforms the practice of condition monitoring into smart Machinery Health Management, which is a clear response to the needs and desires of pump users.

In time, this technology will be applied to other pumps, and it can also be extended to other types of rotating machinery, such as blowers, fans and compressors.

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