 The Topics Covered :

1. Overview
2. Detail System Architecture.
3. Measurement Fundamentals - Field Sensors
4. 3300/3500 Monitoring & Protection System
5. Noise & Errors
6. Training & Test facilities at CES

2
 What Is MCM Systems ?
 An integrated system to protect and monitor the critical Rotating &
Reciprocating machines of our plant.
 Provide crucial information about M/C problems such as rotor
imbalance, misalignment & bearing failure.
 The term protection means system can S/D machinery on alarm
without human interaction.
 Includes primary sensor to measure; Axial shift, Vibration, &
Temperature, electronics signal conditioning devices like Monitors
and a dedicated software DM2K to present basic data to
Operator/Rotary engineers.
 Expert software- MCM2000 to get an automatic diagnostic for any
abnormality of machine being monitor.
3
 INSTALLATION HIGHLIGHTS

 More than 2000 field sensors ( Proximity and Seismic) for

Vibration Measurement.
 More than 1700 Temperature Measurement points.
 29 Data Acquisition stations in PIBs.
 7 Display stations including three diagnostic station at
CES.
 All the DAQ & Display stations are on centralized Fibre
Optic Network.
 More than 135 TDIX/DDIX for transient -steady state
analysis.
 275 Finfan Monitors. (1900/55) 4
INSTALLATION HIGHLIGHTS : Total 228 Machines

COMPRESSORS
CENTRIFUGAL COMPRESSORS = 26
RECIPROCATING COMPRESSORS = 14
SCREW COMPRESSORS = 04
TOTAL COMPRESSORS = 44
PUMPS
CENTRIFUGAL PUMPS = 82
COOLING TOWER PUMPS = 25
TOTAL PUMPS = 107
FANS GT & STG
FD FANS = 44 GT = 08
ID FANS = 19 STG = 04
BLOWERS = 02
TOTAL FANS = 65 TOTAL = 12
5
Measurement Fundamentals
 Measuring Parameters
Machine Protection by measuring of following parameter :
Primary(Vib.) parameters Secondary(Process) parameters
Radial Vibration Pressure
Thrust position Temperature
Velocity Flow
Acceleration Motor Current
Bearing Temp. IGV opening
Keyphasor for Rotor speed
Rod drop for reciprocating Machine.

6
 Measurement Fundamentals
 Transducers
 Vibration is a dynamic motion of the component
and it is measure relative to a known reference.
Mostly we are concern to measure the vibration of
the Rotor, Bearings, Bearing housing and Machine
casing.
 Bently Nevada provides various types of transducer
to measure the vibration.
1. Proximity Transducer 2. Velocity Transducer
3. Acceleration Transducer 4. Velomitor Transducer
7
Measurement Fundamentals
 Types Probe & Transducer
 Proximity Probe: displacement measurements
 For lower frequencies (<100Hz)
 Used for relative measurement (Shaft).
 Velocity Probe: velocity measurement
 For mid-frequencies (50-2000 Hz)
 Used for bearing Housing Vibration
 Accelerometer : Acceleration measurement
For high frequencies (>1000 Hz)
 Used for High Freq. Phenomena like high speed gear
box.
8
Measurement Fundamentals
 Measurement Units
Vibration is described by it’s frequency & amplitude.

Amplitude is expressed in units of either Displacement,

Velocity or Acceleration.
The units are ;
 Peak Value : Simple Zero to peak Amplitude
 Peak to Peak Value : Pk to Pk = 2 x Peak
RMS Value :Root Mean Square = 0.707x Peak
Average Value : Average = 0.637 x Peak

9
Measurement Fundamentals
 Measurement Units

10
Measurement Fundamentals
 Minimum Requirement
There are 5 basic Vibration Signal Characteristic
need to be observed,
 AMPLITUDE - pk to pk measurement.
 FREQUENCY - Vib. Within unit time.
 PHASE - Lead/Lag relationship of 2 signals.
 FORM - Time Base and Orbital.
 POSITION - Shaft centerline.
11
Measurement Fundamentals
 Proximity Transducer System

12
Measurement Fundamentals
 Probe / Extension Cable / Proximitor

13
 Measurement Fundamentals
 Proximity Transducer System
 Proximity Transducer system is made by containing three
individual parts, but no one can work alone.
1. Probe - Probe tip is of PPS( Polyphenylene sulfide) &
case is of AISI 304 ST.
2. Extension Cable - The electrical length of the cable is
combine with the probe’s cable electrical length
must be match with total proximity system
electrical length
3. Proximitor - Power :- -23 V to - 26 VDC
Scale Factor :- 200mV/mil (7.87 V/mm)
Linear Range :- 2mm(200mils)
Linearity :- +/-0.025 mm of straight line.

14
 Measurement Fundamentals
 Proximity Transducer System
OPERATING PRINCIPLE :

 PROXIMETER GENERATES R.F. SIGNAL USING

OSCILATOR CIRCUIT.
 PROBE COIL EMITS THE RF SIGNAL IN
SURROUNDING/TARGET AREA.
 EDDY CURRENT IS DEVELOPED IN CONDUCTING
MATERIAL AND THIS CAUSES LOSS IN RETURNED
SIGNAL STRENGTH.
 PROXIMETER CONVERTS IT INTO LINEAR,
PROPOTIONAL NEGATIVE DC VOLTAGE.
15
 Measurement Fundamentals
 Proximity Transducer System
 Performance Verification :
 The proximitor performance verification (scale factor) can
be calculated by a graph of the transducers linear range
(gap verses out put voltage)
 Scale Factor =change in gap Voltage % change in gap
 Procedure : (By use of TK3 test kit)
1. Adjust the gap between target & probe tip and note down
the gap voltage.
2. Vary the gap in fix steps with help of Micrometer.
3. Plot the curve to check the transducer performance.

16
 Transd ucer Resp o nse C urv e
Basic Field Components

24
Proximity Transducer System
Ga p Vo lt ag e ( -)

20

16

12

P r o b e Gap in m m .

Transducer Response

17
Radial Proximity Probes

18
 Measurement Fundamentals
 Radial Vibration
 Used for indication of bearing condition and Rotor
malfunctions.
 Two probes are installed perpendicular to the shaft
centerline with an angular separation of 90 deg apart at
same longitudinal Location near journal bearing.
 Typical mounting is 45deg left “X” & 45deg right “Y” as
viewed from driver to the driven of machine.
 Keyphasor observes a once per turn mark on the shaft to
correlate shaft rotation.
 Important for diagnostic of Imbalance, misalignment,bent
shaft at running speed.
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Dual Thrust Proximity

Probes

20
 Measurement Fundamentals
 Axial Thrust Position

 Used for determining thrust bearing wear.

 The probe must be mount at the thrust bearing end of
the machine and within 12” of the thrust bearing.
 It is a bidirectional measurement.(active & inactive)
 Adjust the probe gap voltage at the center of the linear
range(-10 Vdc).
 It’s a guard against axial rub between Rotor & Stator.
 Dual voting is recommended as thrust bearing failure is
considered a catastrophic failure.

21
 Measurement Fundamentals
 Keyphasor
 Used for speed indication.
 A Keyphasor is necessary to
determine the direction of
vibration precession (in the same
or the opposite direction of shaft
rotation).
 Keyphasor is used to generate
filtered vibration amplitude and
phase lag measurements.
 Startup or shutdown, cannot be
developed without Keyphasor.

22
Measurement Fundamentals
 Seismic Sensor
 Seismic Sensor -
 Works on piezo-electrical / moving coil principle
 Indirect measurement of shaft vibration.
 Directly mounted on machine casing / bearing house.
 Absolute vibration in terms of mm/sec or g /sec2

23
Measurement Fundamentals
 Velocity Transducer System
 Operating Principle :
 “Self generated signal” - The signal is generated by
the movement of a permanent magnet within a
surrounding wire coil/bobbin.
 The velocity transducer will have an out put scale
factor of 500mV/inch/sec(20mV/mm/sec)
 Frequency Range : 4.5 Hz to 1000 Hz

24
Measurement Fundamentals
 Velocity Transducer System
Bobbin springs

Case with mounting

Bobbin
Magnet. Pole Piece

25
 Measurement Fundamentals
 Accelerometer Transducer System

Accelerometer Interface
Amplifier
Mica Insulator Preload Bolt
Reference Mass
Conductive Plate
Piezoelectric Ceramic
Electrical Insulator
Casing Mass

26
Measurement Fundamentals
 Accelerometer Transducer System
 Operating Principle : The motion at the transducer base
will put cyclic compression on the piezoelectric crystal and
the crystal will induces an electrical charge (in
picocoulombs) across opposing faces of the crystal. The
internal electronics convert the high impedance charge into
a low impedance voltage signal. This charge is proportional
to the acceleration.
 Out put scale factor : 25mV/g pk for low frequency
10mV/ g pk for high
frequency
 Frequency Range : 30 Hz to 10 KHz (1,800 to
600,000cpm)
27
Measurement Fundamentals
 Why Piezoelectric Accelerometer ?
Their rugged & solid state construction enable to
operate them under the most severe conditions.
Theyare unaffected by dirt, oil & most Chem.
Atmosphere.
Usable over a wide temp. range & resist damage from
severe shocks/Vibration.
Highly accurate from very low to very high Freq.
Available in different range of freq. and sensitivity.

28
 Basic Field Components
 Accelerometer Transducer System
• 330400 accelerometer

29
Basic Field Components
 Accelerometer Transducer System

30
 Measurement Fundamentals
 The Velomitor

 The basic construction & theory of operation of the

velomitor is same as accelerometer. The O/P is
developed from a charge induced on a piezoelectric
crystal, amplified and then integrated to provide
velocity information.

31
 Case mounted Seismic probe
used in Jamnagar complex
 190501 Velometer CT in Fin fan application

 47633 Velocity sensor at Heater Fans.

 330400 Accelerometers on Motor Bearing House /
end shield ( Pumps).
 330525 Velometer on Motor end shields.
 23732 Accelerometer in Aromatic plant 232 area.
 9200 with 42680 Housing on Recip Comp. Frame.
32
 Measurement Fundamentals
 RTDs - The Temperature Measurement
 JOURNAL BEARING / THRUST BEARING TEMP
MEASUREMENT
 TO PROVIDE CONTINUOUS INDICATION OF
BEARING TEMPERATURE.
 SENSOR IS EMBEDED IN TO BEARING USUALLY
DUPLEX TYPE
 MONITORS HAVE USER CONFIGURABLE
ALARMS AND TRIP RELAYS

33
Measurement Fundamentals
 ROD Drop-for Reciprocating Machine
This is Indirect measurement of Piston’s rider band wear with
help of non contact type Proximity Probe and keyphasor
probe.

34
 Measurement Fundamentals
 ROD Drop
 Horizontal reciprocating compressor normally have rider
band to minimize wear of the piston rings and to eliminate
cylinder liner damage due to contact between the piston &
cylinder.
 Rod drop measurement is effective for horizontal
compressors with non lubricated or lightly lubricated
cylinders.
 Rod drop monitor continuous monitor the rider band wear &
the position of the piston rod relative to the frame of the
compressor. So the machine can be Shutdown prior to
contact between the piston & cylinder.
35
 Measurement Fundamentals
 Data Required for Rod Drop Monitor
 Monitor calculates Rider band wear by similar triangular
principle from parameter ;
 Probe position
 Piston rod length
 DC gap voltage change (From Rod Drop Proximity Probes).
 Connecting Rod Length
 Stroke length
 Piston angle.

36
How To Measure Rod Drop ?
 Principle Of Similar Triangles
L1 L2

L1 = L1 + L2 MRD
ARD
MRD ARD

Actual Rod Drop = Measured Rod Drop(L1+L2)

L1
After normal operating condition of machine for a period of
time, the position of piston rod rises due to thermal growth of
the piston within the cylinder. To account this piston rise, it is
required to Re-zero the monitor after approximately 4 hours of
machine under process load.
37
 NOISE AND ERRORS
 Definition

Noise is defined to be undesirable signal components which;

1. Distort the data,
2. Interfere with the ability to extract information
3. Contain no relevant data.
4. Can generate identical signal as actual vibration.

• Basic Installation rules :

• Use a single point grounding.
• Use only shielded cables and insure for proper grounded.
• Use separate cable trays for power & signal cables.
• Insure all cables and connectors are in good condition.

38
 NOISE AND ERRORS
 Types of Errors
• Crosstalk : Due to less distance between probes the emf of the
two probes intersect, they will interface with each other.
• Mechanical Runout :Occurs when probe tip to shaft distance
change,but centerline distance is constant.
The reasons are scratches,dents, corrosion,rust,chain
marks,out of round shaft, engravings etc..These can be
measured by dial indicator.
• Electrical Runout : Results from non-uniform conductivity or
permeability properties of the observed shaft.
The reasons are non-uniform alloying,plating,localized
magnetized areas on the shaft.can’t be measure by dial
indicator.
• Bow :due to Shaft is bent in single plane.Exam. Gravity,Thermal
39
 Basic Field Components
 Proximity Transducer System
 Maintanance : Follow the SMPs & Check List which are
available in www.emaint.ril.com site and also available in
Rpl_rdocs. All the MRP list and other MCMS related
information are also available in web site.
 The path for SMPs & Check list are as below;
 www.emaint.ril.com\site specific\JG
instrumentation\systems\mcms\*file name
 \\rpl_dcc\r_docs\r_docs\transfer\J_DOC2000\
SMPs\ All_Plants\Instrument\Equipment
Service Sheets\ MCMS\*file name

40
PROTECTION SYSTEMS
 3300 Monitoring System

41
 PROTECTION SYSTEMS
 3300 Monitoring System
 Three basic parts :
1. Power Supply 3300/12.
2. System Monitor 3300/03
3. The Monitors.
 3300/16 XY Gap Monitor.
 3300/20 Dual Thrust Monitor.
 3300/35 Six Channel Temperature Monitor.
 3300/36 Dual Channel Temperature Monitor.
 3300/50 Tachometer Monitor
 3300/81 Six Channel Rod Drop Monitor.
42
PROTECTION SYSTEMS
 3500 Monitoring System

43
 PROTECTION SYSTEMS
 3500 Monitoring System
 Three basic parts :1. Power Supply 3500/15.
2. Rack Interface Module 3500/20
3. The Monitors.
 3500/40 Proximity Monitor.
 3500/42 Proximity Seismic Monitor.
 3500/50 Tachometer Monitor
 3500/60 Six Channel Temperature Monitor.
 3500/62 Process Variable Monitor.
 3500/25 Keyphasor
 3500/90 Communication Gateway.
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TYPICAL MCMS ARCHITECTURE
Control Room Remote Data collection
by Modem/FO network
CES/Plant
PLANT INFORMATION NETWORK

DCS interface
Communication MONITORING
Processor SYSTEMS
PIB DM2000

Ethernet

Local Data Manager

SDIX/
Data Acquisition/
DDIX,
Display Station
TDXNet

TRANSDUCERS 0 TO -24V
Field ON MACHINE  MACHINE

45
 REFINERY WIDE MCMS FO NETWORK
Th is d r aw ing is c o nf ide ntial & the c o py r ig ht o f W o r m ald A ns u l ( U K ) L td . The c o n te n ts ar e n o t to be us e d,
c o pie d o r d is c lo s e d to an y thir d p ar ty f o r an y pu r p o s e w hats o e ve r w ith o u t o u r pr io r w r itte n c o n s e n t. A LL DIS T ANC E S IN ME T R E S

450
M R S1 M R S2
400
P IB 3 P IB 2 P IB 1 1625
650 650
250 250 P IB 4
1800
350 P IB 5
P O LYP R O P C C
1100 2000
300
P OWER C C
A R O MAT IC S C C
C E NT R AL E NG INE E R ING
W O R KS HO P 2000

3000

P IB 8 P IB 1 1
M AR INE G AT E HO US E 1875 2800 C R UDE & S ULP HUR

400 650
P IB 2 7 P IB 2 8 P IB 2 9
700 C R UDE /S ULP HUR /O &U/C O KE R

2200 KEY 1050 P IB 9 P IB 7 P IB 6 P IB 1 0 P IB 1 3 P IB 1 8

10Base2 T-Piece
1300 400 750 700 2000 1300
Bentley Nevada 1300nm Edge LED s/m

Bentley Nevada 850nm LED m/m

600 P IB 1 6 P IB 1 4 P IB 1 5 P IB 1 7
550
Bentley Nevada 850/1300nm Edge LED m/m R E F INE R Y C C
Allen Bradley 850nm LED m/m 825 825 450
M AR INE T E R M C C
Allen Bradley 850/1300nm LED m/m
T ANK F AR M /E TP /R O AD LO ADING /FC C 3300

2600 1500
1200
P IB 2 0 P IB 1 9 P IB 2 3

M ultim o de 50/125 N etw o rk 34 400 m

S inglem o de 9 .5/1 25 N etw o rk 840 0m

W O R MALD Title : J a m n a g a r R e fin e ry P LC +VIB R ATIO N Ne two rk To p o lo g y

D ra win g R e f: 8 7 0 2 0 8 -E 3 2 _ 1 2
Note :This d ra win g is ba s e d o n b uilding loc a tion s a s indic a te d o n
C lie n t: B e c h te l F ra n c e
C on trol S ys te m s
Be c hte l Dra wing J 1 0-J 6 000-044 Re v 3H a nd fu rth e r in forma tio n
re c e ive d by 2/7 /97 . Not to s c a le . 46
MAN01\PROJECTS\W O870208\VISIO\A4_B&N_REV12.VSD
 Machine Monitoring System
 Detail System architecture
• Field sensor : vibration & temperature Sensors.
• Monitoring Hardware : 3300 & 3500 series monitors
by Bently Nevada.
• Communication Processors : DDIX / TDXNet
• MMI: Data Manager 2000 software for data
acquisition and display
• Remote Display : FO network & Modem for
centralised/ remote Diagnostic from CES & C/R
Display stations.
• Expert System: MCM2000 -Knowledge base
software(rules) to get advance notification & expert
advice for any abnormal machine condition.
47
 Machine Monitoring System
 Detail System architecture
 3300/3500 protection system is connected to respective plant DCS
via serial communication Gateway.
 Comm. Processors & Protection system are connected with
DM200 station located in respective plant PIB.
 Remote display stations are available through Fibre Optic Network
and MODEM(5 no. installed in C/R).
 Data can be given to vendor on need base with password
protection for analysis.
 1900/55 Finfan stand alone monitors are also used in plants for
Vibration monitoring of air cooled exchangers.
 MTL make local indicator also provided near the machine as per
UOP/Bechtel recommendation.
48
 Machine Condition Monitoring System
 Test Facilities At CES Training System
 TEST KIT : TK-3 For Proximity checking & Vib. Simulation.
 : Shaker Tale for Seismic transducer checking
 TEST FACILITY : Sensor / Probe calibration
: 3300/3500 Rack-Monitor
: DM2K/COMM.
Processor testing :
DM2K/MTL Interface
: Hand on training Hardware/software
: 1900/55 Finfan Monitor
 ROTOR KIT : For Vibration Problem simulation.

49
THANK YOU

50