Category: Emerson

A6210 Thrust Position, Differential Expansion and Rod Position Monitor for AMS 6500 Machinery Health Monitor

The A6210 monitor has 3 different operating modes: thrust position, differential expansion or rod position.

The thrust position mode precisely monitors the thrust position and reliably protects the machine by comparing the measured axial position with the alarm position.

Reliably provides machine protection by comparing the measured axial position with the alarm setpoint.

Setpoints – drive alarms and relay outputs, thus reliably providing protection for the machine.

Axial thrust monitoring is one of the most critical measurements on turbomachinery.

Sudden and small axial movements should be detected within 40 milliseconds or less to minimise or avoid rotor-to-casing contact.

or avoid rotor-to-case contact. Redundant sensors and voting logic are recommended.

Thrust bearing temperature measurement is strongly recommended as a supplement to thrust position monitoring.

Shaft thrust monitoring consists of one to three displacement sensors mounted on the shaft end or thrust collar in the axial direction parallel to the shaft.

The displacement sensors are non-contact sensors that measure shaft position.

For critically important safety applications, the A6250 monitor provides triple redundant thrust protection.

The A6210 monitor can also be configured for differential expansion measurement.

During turbine start-up, both the casing and the rotor expand due to changes in thermal conditions.

Differential expansion therefore measures the relative difference between the displacement sensor mounted on the housing and the target of the sensor mounted on the shaft. If

housing and shaft grow at approximately the same dcs-sis.com rate, the differential expansion remains ideally close to zero.

Differential expansion measurement modes are supported in series/complementary or cone/slope modes.

Finally, the A6210 monitor can be configured in average rod drop mode to monitor riding belt wear in reciprocating compressors.

Over time, the rider band in a horizontal reciprocating compressor wears due to the force of gravity acting on the horizontally orientated piston in the compressor cylinder.

If the rider belt wears beyond the point where the piston would come into contact with the cylinder wall, damage to the machine and possible malfunction occurs.

By installing at least one displacement probe to measure the piston rod position, you will be notified when the piston drops – a sign of a worn rider band.

You can then set the shutdown protection threshold for automatic tripping.

CSI A6120 Enclosure Seismic Vibration Monitor for CSI 6500 Machinery Health Monitor

The Case Seismic Vibration Monitor for use with electromechanical seismic sensors is designed for high reliability on the plant’s most critical rotating machinery.

This 1-slot monitor is used in conjunction with other CSI 6500 monitors to form a complete API 670 machinery protection monitor.

Applications include steam, gas, compressors and hydraulic turbines. Casing measurements are common in nuclear power applications.

The primary function of the casing seismic vibration monitor is to accurately monitor casing seismic vibration, the

and to reliably protect machinery by comparing vibration parameters with alarm set points, actuated alarms and relays.

A case seismic vibration sensor, sometimes referred to as a case absolute vibration sensor (not to be confused with a shaft absolute vibration sensor), is an electrodynamic, internally spring-loaded, and magnetically actuated vibration sensor.

It is an electrodynamic, internal spring and magnet, velocity output type sensor.

A housing seismic vibration monitor monitors the overall vibration of a bearing housing at millimetres per second (inches per second).

Since the sensor is mounted on the bearing housing, vibration in the housing can be affected by many different sources.

These include rotor motion, foundation and bearing box stiffness, blade vibration, adjacent machinery, etc.

When replacing ffeld sensors, many are being updated to piezoelectric sensors, which provide internal integration from acceleration to velocity.

Piezoelectric sensors are a new type of electronic sensor rather than the older electromechanical type.

Case Seismic Vibration Monitors are backward compatible with electromechanical sensors installed in the ffeld.

The CSI 6500 Machinery Health Monitor is an integral part of PlantWeb® and the AMS Suite.

PlantWeb combines Ovation® and DeltaV™ process control systems to provide operators with an integrated view of machinery health.

The AMS Suite provides maintenance personnel with advanced predictive and performance diagnostic tools to accurately determine machine failures at an early stage.

Features:

Dual-channel, 3U-sized, 1-slot plug-in module that cuts cabinet space requirements in half compared to traditional four-channel 6U cards

API 670-compliant hot-swappable modules

Remotely selectable limit multiplication and trip bypass

Pre- and post-buffered and proportional outputs, 0/4-20 mA outputs, 0 – 10 V outputs

Use with electric (electromechanical) sensors 9266. 9267. or 9268

Sensor Inputs

Number of inputs: two independent channels

Input Type: Electro-mechanical, Differential

Emerson sensor inputs: Part No. 9266. 9267. or 9268

Isolation: Galvanically isolated from power supply

Input resistance: >100 kΩ

Input voltage range: – 5 – +15 VDC

Input frequency range:

Lower cut-off frequency 1 or 5 Hz

Upper cut-off frequency 50 – 2000 Hz adjustable

About DeltaV™ System Power Supplies

Power supplies – systems can’t operate without them.DeltaV™ System Power Supplies provide you with the most efficient and reliable power solutions available.

DeltaV power supply kits provide power to the system electronics and to the field. This is all the power you need for your DeltaV system.

Benefits

DC/DC system power supplies are plug-and-play components. They fit any power carrier, including horizontal 2-width and vertical 4-width carriers.

These carriers contain an internal power bus that connects to the controller and I/O interfaces, eliminating the need for external wiring. The carriers are easily mounted on T-shaped DIN rails!

Flexible and cost-effective, DeltaV DC/DC system power dcs-sis.com supplies accept 12V DC and 24V DC input power.

Modular construction and load-sharing capabilities of the power supplies allow you to add more power to your system or provide power redundancy.

Safety. Your I/O is always accurate because I/O subsystems and controllers are always supplied with stable, accurate 12V DC or 5V DC power. Power supplies are EMC- and CSA-compliant; notification is immediate in the event of a power failure; and system and field power supplies are completely isolated.

Simplified system power supply. System power supplies provide more current on the 12 VDC I/O interface power bus, eliminating the need for 24 to 12 VDC bulk power supplies. All controller and I/O power is now available from the factory 24 VDC bulk power supply.

INTRODUCTION

The MX controller provides communication and control between ffeld devices and other nodes on the control network. Control strategies and system configurations created on earlier DeltaV™ systems can be used in this powerful controller.The MX controller has all the features and functionality of the MD Plus controller, but twice the capacity.

The control language implemented in the controller is described in the Control Software Suite product data sheet.

Advantages

Right-Sized Controller

The MX controllers complement the MQ controllers by providing a larger capacity controller for applications requiring greater control capability:

2 X control capacity

2 X user configurable memory

2 X DST counts

DeltaV™ MX controllers and DeltaV I/O subsystems are easy and quick to install.

Post change. You can easily upgrade an dcs-sis.com MQ controller to an MX to handle project scope changes later in the project The MX has the same installed footprint as an MQ controller, but twice the performance. Simply replace the MQ with the MX, and then

All existing configurations, documentation, and hardware design remain intact.

Redundant Architecture: MX controllers support 1:1 redundancy for increased availability. Existing MD/MD Plus or MQ controllers are upgradable and powerful online!

Introduction 

Emerson’s Ovation™ control technology is designed to support long-term process reliability and expandability.  

With modular plug-in components, Ovation I/O delivers embedded advanced control applications with built-in fault tolerance and system diagnostics. 

With their inherent flexibility, Ovation I/O modules convert input signals and create output signals, performing a multitude of functions. Specialized I/O modules are also available. 

Simplified Maintenance 

Standardized assembly style simplifies maintenance and reduces spare parts inventory costs. 

Single-point DIN rail fastening makes installation and configuration quick and easy. Built-in connectors eliminate power and communications wiring. 

Ovation I/O modules are software configurable, therefore no jumpers or thumb wheels are necessary. Their advanced electronics also deliver low power consumption.

Features 

▪ Modular, plug-in components support long-term process reliability 

▪ Modules are installed and configured quickly and easily with single-point DIN rail fastening 

▪ Built-in connectors eliminate power and communications wiring 

▪ Electronic ID identifies module type, group, serial number and revision 

▪ Fewer module styles reduce spare parts inventory costs 

▪ Redundant power supplies deliver system reliability 

▪ “Hot swapping” streamlines system maintenance 

▪ Standardized status indicators offer color-coded diagnostic messages 

▪ Remote Ovation I/O provides a flexible, costeffective means to dcs-sis.com distribute I/O modules to strategic locations throughout the plant 

Ovation I/O Architecture 

The Base 

Ovation packaging reduces the system footprint by using base units which attach to mounting plates by DIN rail; these hold four independent Ovation I/O modules of any style. This approach simplifies maintenance by making it easy to install, move or replace individual base units. 

Base unit features include:  

▪ Field terminal blocks that accept two 14 AWG or a single 12 AWG 

▪ I/O bus communications built into the base 

▪ I/O modules automatically addressed by location 

▪ I/O modules may reside in any location 

▪ I/O module redundant power distribution 

▪ No interconnecting cables for I/O bases 

▪ Built-in spare fuse holders and strip gauge in base 

Features 

▪ Collects plant information from disparate systems to form a single data source for secure, remote visualization, and monitoring  

▪ Provides staff with read-only access to near real-time and archived plant information,

regardless of geographic location 

▪ Presents comprehensive views of assets to all levels of an organization  

▪ Enables proactive response to process changes, operational abnormalities, or equipment issues 

▪ Scalable from a single unit to widely dispersed plants with numerous deployment options 

▪ Measures, monitors, and reports Key Performance Indicators (KPIs) 

▪ Fully supported through Emerson’s lifecycle services programs

Applications 

EDS is a powerful tool that simplifies information management by consolidating data from disparate systems into a single source for remote monitoring and analysis.  

EDS delivers increased awareness of plant operations by securely connecting staff to near-real time and archived data, regardless of geographic location. Timely and accurate representation of plant performance enables more informed decision-making to enhance operations and streamline maintenance.  

For example, severe weather events pose many forms of danger to any industrial process site, which could require plant staff, both on and off duty, to quickly troubleshoot problems before they escalate. EDS provides critical process data to the right people at the right time, helping to mitigate emerging issues.  

Using EDS data and tools, power generators can assess abnormal conditions that could lead to infrastructure damage or widespread power outages. Water plants can monitor increased flows within distribution networks to better predict flooding, thus helping to prevent overflows and associated environmental impact. 

As an option, Ovation EDS can automate operator round activities, including interfaces to computer maintenance or lab information systems and customized route and data collection templates. 

EDS data can also monitor key performance indicators (KPIs) for measuring against objectives and generating required performance reports. Example KPIs include: 

▪ Power generation: fuel usage, plant availability, dcs-sis.com emissions, generation revenue, or efficiency (heat rate). 

▪ Water and wastewater plants: quality, compliance, energy usage, chemical usage, or operating and maintenance expenses. 

As an integrated information source, EDS provides valuable insights to all levels of an organization: 

▪ Executives or corporate management can obtain a complete view of district- or fleet-wide operations. 

▪ Plant management can view and trend information to make informed operating or maintenance decisions. 

▪ Plant supervisors, engineers, and technicians can easily evaluate process or plant status. 

The Valve and Shell Expansion Monitor is designed to provide high reliability for the plant’s most critical rotating machinery.

This 1-slot monitor is used with other AMS 6500 monitors to form a complete API 670 machinery protection monitor.

Applications include steam, gas, compressors and water turbines.

The primary function of the Valve and Case Expansion Monitor is to accurately monitor valve position and case expansion.

The main function of the valve and case expansion monitor is to accurately monitor valve position and case expansion and to reliably protect the machinery by comparing parameters with alarm set points, actuated alarms and relays.

Valve position is a measurement of the position of the main steam inlet valve stem, usually displayed as a percentage of opening.

The valve position measurement provides the operator with an indication of the current load on the turbine.

Casing expansion monitoring typically consists of two inductive displacement transducers (or LVDTs) mounted axially, parallel to the shaft, on either side of the turbine casing.

Unlike non-contact eddy current sensors, inductive sensors are contact sensors.

Casing expansion monitoring is important during startup so that the proper expansion rate can be monitored on both sides of the turbine casing.

Because the turbine can slide on the guide rails as it expands, if neither side is free to expand, the turbine will “bend” (housing flex), causing the rotor to collide with the housing.

Channel 1 can be used to measure static values, such as case expansion, as well as dynamic quantities

such as displacement, angle, force, torsion or other physical quantities measured by inductive sensors.

Physical quantities measured by inductive sensors. Channel 2 is used for static measurements and relative displacements (relative to channel 1).

The AMS 6500 Machinery Health Monitor dcs-sis.com is an integral part of PlantWeb® and AMS software.

PlantWeb provides integrated machine health operation in conjunction with the Ovation® and DeltaV™ process control systems.

AMS software provides maintenance personnel with advanced predictive and performance diagnostic tools to accurately determine machine failures at an early stage.

Features

Dual-channel, 3U-sized, 1-slot plug-in module cuts cabinet space requirements in half compared to traditional four-channel 6U cards

API 670-compliant hot-swappable modules

Password-protected user configuration

Self-test features include monitoring hardware, power inputs, hardware temperature, sensors and cables

Hardware temperature, sensors and cables

Pre- and post-buffered and proportional outputs, 0/4-20 mA outputs, 0 – 10 V outputs

For use with Inductive Displacement Sensor 9350

The A6630 temperature monitor is designed to provide extreme reliability for the most critical rotating machinery in your plant.

This 1-slot, multi-channel monitor can be used with other AMS 6500 monitors to form a complete API 670 machinery protection monitor.

Applications include steam, gas, compressors and water turbines.

The primary function of the temperature monitor is to input RTD and thermocouple temperature sensors, to

The main function of the temperature monitor is to input RTD and thermocouple temperature sensors and reliably protect machinery by comparing temperature levels with alarm set points and actuating alarms and relays.

Temperature monitoring as well as vibration and position measurements provide better fault confirmation, thus increasing availability and safety.

Machinery protection applications include radial and thrust bearing metal temperatures.

Important process temperature values include generator, rotor and stator winding temperatures, oil supply temperatures, steam temperatures, and ambient temperatures.

The AMS 6500 is an integral part of the PlantWeb® digital plant architecture and AMS software.

PlantWeb provides operators with a comprehensive view of machine health in conjunction with the Ovation® and DeltaV™ process control systems.

AMS software provides maintenance personnel with advanced predictive and performance diagnostic tools, enabling them to determine machine failures early with confidence and accuracy.

Components of the AMS 6500 Machine dcs-sis.com Monitoring System

Suitable for thermocouple and RTD (resistance temperature detector) temperature sensors

No additional sensor transmitters required

Access to a single card via front-end RS232 port for configuration and

visualisation of monitoring information

Reading of all measurement data via serial interface

Extended self-test functions for electronic circuits and sensors

Hot-swappable, replaceable monitors during operation

Measurements according to API 670

Sensor inputs

API 670-compliant hot-swappable modules

Remotely selectable limit multiplication and trip bypass

Post-buffered proportional outputs, 0/4-20 mA outputs

Self-test features include monitoring hardware, power inputs, hardware temperature, sensors and cables

Used with displacement sensors 6422. 6423. 6424 and 6425 and drivers

con 011/91. 021/91. 041/91

6TE Wide Module for AMS 6000 19″ Rack Mount Chassis

8TE wide module for use with AMS 6500 19″ rack mount enclosure

Sensor Inputs

Number of Inputs Two, independent

Input Type Eddy Current, Differential

Emerson Sensor Input Part Numbers: 6422. 6423. 6424. 6425

Isolation Galvanic isolation

Isolated from power supply

Input resistance >100 kΩ

Input Voltage Range 0 to ±27.3 VDC

Input Frequency Range 0 – 20.000 Hz at 65.535 RPM

Measurement Range

Range Continuously adjustable via configuration software

Minimum range 2 V

Maximum range 0 – 30 V

Sensor power supply Individually buffered sensor power supply galvanically isolated from all system voltages and system supply voltages Open and short circuit protected

Nominal voltage -26.75 VDC

Available current 20 mA nominal, 35 mA maximum

Front Panel Outputs

Green LED: Two LEDs indicating channel OK dcs-sis.com for each channel

Yellow LEDs: Four LEDs indicating alarms and hazards for each channel.

Separate display for each channel

Front panel buffered outputs:

Two, ±10 V, signal input level reduction factor 0.15. >100 kΩ load, frequency range 0 Hz – 16 kHz (-3 dB)

Mini DIN configuration socket:

Module interface connection for configuration, parameter and status monitoring

RS-232

Handle: for easy removal of the card and to provide module and transducer identification boards

Since the displacement transducer is mounted on the bearing, the monitored parameter is known as shaft relative vibration, i.e. shaft vibration relative to the bearing box.

Shaft relative vibration is an important measurement parameter used for prediction and protection monitoring on all plain bearing machines.

Shaft relative vibration should be selected when the machine housing is large compared to the rotor and the bearing housing does not vibrate between the zero speed of the machine and the production state speed.

Absolute shaft vibration is sometimes selected when the bearing housing and rotor are relatively close in mass, when the bearing housing is more likely to vibrate and affect the relative shaft reading.

The AMS 6500 is an integral part of PlantWeb® and AMS software.

PlantWeb provides a comprehensive view of machine health in conjunction with the Ovation® and DeltaV™ process control systems.

AMS software provides maintenance personnel with advanced predictive and performance diagnostic tools that enable them to confidently and accurately determine machine failures early.

Features:

Dual-channel, 3U-sized, 1-slot plug-in module that cuts cabinet space requirements in half compared to traditional four-channel 6U cards

API 670-compliant hot-swappable modules

Remotely selectable limit multiplication and trip bypass

Pre- and post-buffered and proportional outputs, 0/4-20 mA outputs, 0 – 10 V outputs

Self-test features include monitoring hardware, power inputs, dcs-sis.com hardware temperature, sensors and cables,

Hardware temperature, sensors and cables

For use with displacement sensors PR6422. PR6423. PR6424. PR6425 and drivers CON 011/91. 021/91. 041/91

Sensor inputs

Number of inputs: two, independent or combined

Monitoring mode

Input types: eddy current, differential

Emerson sensor inputs: Part numbers: 6422. 6423. 6424. 6425

Isolation: Galvanically isolated from power supply

Input resistance: >100 kΩ

Input Voltage Range: 0 to -22 VDC

Input Frequency Range

Lower cut-off frequency 1 or 5 Hz

Upper cut-off frequency 50 – 2000 Hz adjustable