CSI4500 Machinery Health Monitor - Guest Home Pageeuedocs.emersonprocess.co.uk/.../allds0505e_csi4500.pdfCSI 4500 Machinery Health TM Monitor Product Data Sheet D351165X012/0-4500-042005

CSI 4500 Machinery HealthTM Monitor

Product Data SheetD351165X012/0-4500-042005May 2005

■ Automated, continuous,predictive machineryhealth monitoring ofyour plant’s most criticalrotating machines

■ Real-time machineryhealth feedback integratesto process control so youcan run your processwith confidence

■ Field-based intelligenceand event-based adaptivemonitoring transformsvibration monitoring intopredictive machineryhealth alerts

■ PeakVue® provides unique bearing faultdetection capabilities tomaintenance personnel

■ Transient analysis for turbines empowers decisions through the l ive user interface like nothing on the market

the machine itself and saving the production schedule. Predictionis protection for your bottom line.

The CSI 4500 Machinery HealthMonitor provides machinery prediction that complements an existing protection system providing real-time feedback toboth maintenance and operations.As part of Emerson’s PlantWeb®

digital plant architecture, the CSI4500 delivers real-time machineryhealth information when and whereit is needed. Integration with theplant’s process automation systemand AMS™ Suite: Machinery HealthManager software empowersdecision-making and reduces

Five percent of the machines in every plant have the ability tobring production to a halt. Thesecritical machines require specialattention by both maintenance andoperations–and almost alwayshave shutdown protection in placeto prevent catastrophic failure.But is that really enough to ensureproduction schedules will be met?Is the plant really protected?

Today more facilities are upgradingtheir protection systems with prediction capabilities. With prediction, the machine can beallowed to continue performingwithin acceptable parameters and repaired at the time most economically convenient to theplant. Adding prediction is the difference between just saving

Machinery HealthTM Management

www.assetweb.com

Delivers real-time machinery health information so you can run your process with confidence.

Product Data SheetMay 2005

machinery health faults. When both prediction and protection arerequired, Emerson delivers with a complete asset managementstrategy for your most critical rotating machines.

Real-time MachineryHealth Feedback toProcess Automation

Machinery health information is nothing new–maintenance personnel have long benefitedfrom the predictive capabilities of vibration analysis and otherintegrated technologies. But without vibration monitoring feedback to process automation,operators don’t know the effectstheir actions have on the health of rotating machines. In fact,40% of machine faults are theresult of process variations.

The CSI 4500 and the AMSMachinery Manager send real-timeoverall vibration levels to operators.If process adjustments are made,operators see the live impact onmachinery health. With vibrationdata integrated with processautomation, informed real-timedecisions are possible. For example,if a mill operator adjusts a stretchroll on the paper machine andcocks the roll, vibration increasesimmediately. Feedback to theoperator is provided and furtheradjustments head-off prematurefailure of the roll.

PlantWeb Alerts give clear, powerful indications of developing problemsto an operator at a DeltaV station.

The CSI 4500 provides machinery prediction that complements an existing protection system.

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Machinery HealthTM Management

PlantWeb Alerts provide actionable information.There are certain process variationsthat impact rotating machines innegative ways. For instance, lowtank or head levels may increase-vibration on a pump or hydro turbine. Faulty valves, incorrectprocess running conditions,upstream loads or downstreambackups may also impact machinery health.

Process event monitoring withadaptive automated vibrationanalysis will send PlantWeb Alerts,containing information about thefault, to operators at Emerson’sDeltaV™ digital automation system.As an example, when a tank levelsensor indicates the level hasexceeded a designated low setpoint, the CSI 4500 detects andautomatically adapts its monitoringstrategy to begin “watching” for acavitation parameter to exceed adefined fault level. An easy-to-readparameter labeled cavitation isthen delivered as a PlantWeb Alert to the operator at the DeltaVstation. The operator can takeaction such as adjusting the levelof an upstream tank to decreasevibration and increase efficiencyon a pump, adjusting tank levels to stop cavitations, or increasingspeed of a machine to eliminate a resonance condition.

Machinery Health feedback integrates to process automation systems,such as Emerson’s Ovation® and DeltaV digital automation systems.

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Product Data SheetMay 2005 Machinery HealthTM Management

Information for fast,accurate decision-making.As plant personnel go about theirdaily activities, the CSI 4500’s built in, exception-based processor collects and distributes informationto the right system or user onlywhen machinery health changes.The CSI 4500 continuously monitorsthe health of your machine, butsends alerts or new trend data to Emerson’s DeltaV or Ovationautomation system on an exceptionbasis when health changes. Inaddition, the CSI 4500 and theAMS Machinery Manager with theGT2 processor option can delivertransient analysis and live viewsspecifically designed for large and critical turbo machinery.

AMS Machinery Manager alsointegrates with AMS™ Suite:Asset Portal™ where machinehealth is combined with otherasset condition and performanceinformation for a plant-wide view.

Event-based monitoring links vibration information to process states.With other monitoring systems,an increasing load means increasing vibration levels andfalse alarms. This can necessitatesetting vibration alarms extremelyhigh to account for all process scenarios or events. Much like a process automation system,the CSI 4500’s built-in predictiveprocessor more accurately monitors process events such

as speed inputs, changing load,temperature, tank level or relay closures. The CSI 4500 MachineryHealth Monitor processes events,adapts its monitoring, and producesa real alarm when machine healthchanges versus a false alarm when the load changes. Alarms are much tighter and false alarmsare decreased. This adaptive strategy is not limited to adjustingalert levels; analysis types and the frequency of analysis can automatically be adapted as well.

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Calendar rolls, winders, nip rolls, vacuum rolls, and changing machinespeeds require event-based adaptive monitoring.


Predictive MachineryHealth Monitoring for Early Warning andPlanning for theMaintenance Department

Exception-based reportingdrives you to the problem andreduces troubleshooting timeException-based reporting allowsthe CSI 4500 to keep a closewatch on the assets, but only alert your maintenance staffwhen the machine healthchanges. Exception-based reporting produces specific alertsand decreases the amount of datarequired for review when it is timeto troubleshoot that alert. With the CSI 4500, troubleshootingtime can be reduced 90%

through powerful analysis toolssuch as transient analysis for turbines, PeakVue bearing health technology, and customizablereporting capabilities.

PeakVue technology is best-available bearing and gearbox anomaly detectorPeakVue technology providesearly, accurate and trendable rollerbearing and gearbox anomalydetection unmatched by all otherbearing health tools on the market.PeakVue’s patented method ofprocessing preserves the peakamplitude of the stress wave emitted from a bearing or geardefect. Preserving this peak amplitude allows trendable bearing health diagnostics.

Other bearing tools on the marketuse demodulation techniques,which subtract carrier frequenciesand use low pass filters. Theseprocesses have adverse effects onthe original peaks that PeakVuemaintains. If the carrier frequencyduring demodulation is amplitudemodulated, then the amplitude ofthe resultant bearing energy ischanging and will be less than theoriginal bearing energy collected.Furthermore, the amplitude ofthe bearing energy after the lowpass filter has been applied,will increase as the frequency of the defect increases.

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Through AMS Suite: Machinery Health Manager, the PeakVue technologyallows clear spikes to poke through the noise floor providing early fault detection of a Yankee dryer gearbox.


When the Turbine TripsYou are comfortably home for the evening when the phone ringsand you learn the turbine justtripped. The decision to restart theequipment is yours. Although youfeel the pressure, you are confidentbecause you have two powerfultools to rely on–all the necessarydata was captured to assess theevent and a live user interface willprovide assurance during start-up.

Information before, during and after the turbine trip is waiting for you.As you drive to the site,you review the facts:

1. You have the proper setup tocapture the right data surroundingthe event. With virtually no setup,you can be assured the right dataand the anomalous event will be captured.

CSI 4500 Monitor TurbineMonitoring Includes a Live User Interface,Data Recorder andDiagnostic Analysis

To illustrate the results fromEmerson’s Machinery Healthtechnologies working together to provide turbine protection,here is a short scenario.

scenarioThe AMS Machinery Manager shows live cascade and orbit plots for visual comparison provided from the GT2 Processor.

AMS Machinery Manager allows users to selectl ive plots for all bearings simultaneously.

Data extraction session for post processing eventsor baseline comparisons.


2. Real-time continuous datarecording ensures events will notbe missed. With the CSI 4500,all of the data is recorded andbuffered all of the time. The CSI 4500’s continuous datarecorder contains 60 Gb of memorythat will record and buffer from 60hours to over one week, dependingon the number of sensor inputs.Auto archiving of data is alsoincluded so that small, one hour,snapshots can be permanentlyand automatically saved.

3. The live user interface willenable real-time decisions during start up.

When you arrive on site, they havealready found a plugged oil line tothe bearing. Now the question is“how much damage was done,and can we restart?”

Multi-channel, continuous datarecording saves you from evermissing an event and ensures theright information is available to digdeeper into the problem. You lookat the quick views and then extractthe region of interest for moredetails, which quickly drives you to the source of the problem.

You can review the data, comparewith the baseline, and confirm thevibration is isolated to one bearing.The shaft centerline plots tell youthe bearing clearance was notexceeded. After fixing the oil flowissue, you advise restarting theturbine as you watch the live user interface.

The live user interface providesreal-time decision-making during start-up.The live user interface, availablewith the CSI 4500 transient system,

provides live plots that were notpossible before the GT2 processor.Live real-time plots such as overalllevels, orbits, shaft centerline, Bode/Nyquist, cascade, waveform andspectrum, on all bearings, allow aturbine specialist to make real-timedecisions. Simple Windows displaysmake manipulating screens andplots easy. Dual monitor modehelps you organize your views so you are staged for the startup.You can overlay baseline plots(from portable or online systems)on known good start-up plots to view the differences.

With the transient live user interface, you can make real-timedecisions with operators and production staff to bring the turbine up for critical productionneeds or to shut down again to save the asset.

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In this scenario, the CSI 4500along with the AMS MachineryManager allowed the user to easily see the information to makea confident decision. Emerson’spredictive technologies, such asthe AMS Suite of applications and the CSI 4500 along with complementary PlantWeb Services, allow you to maximizeavailability and performance ofkey production assets to ensureoperational excellence.


Chassis Options

CSI 4500M Monitor

The CSI 4500M Monitor is the most common model for applications in power, refining, oil& gas, petrochemical, chemical,pulp and paper, and offshoreindustries. The CSI 4500MMonitor (with up to 32 sensorinput channels, 16 tachometerinput channels and up to 16relays) offers the best choice inflexibility and cost per channel.The CSI 4500M Monitor is alsoupgradeable to the CSI 4500TMonitor, which includes transientanalysis for turbines.

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CSI 4500M Monitor with G2 Processor.


CSI 4500MS Monitor

The CSI 4500MS Monitor has the same functionality as the CSI 4500M Monitor, but with asmaller rack footprint of 12 sensorinputs, 2 tachometer inputs, and 2 relays. The CSI 4500MS Monitoris the best choice for remotemachines or for machine centricmonitoring applications. The CSI 4500MS Monitor is perfect for OEM applications, or when amachine needs dedicated monitoringand requires fewer sensor inputs.

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CSI 4500MS Monitor for small channel-count applications.

CSI 4500M Machinery Health Monitor Enclosure SpecificationsPN A4500Mx, Where x = 1, 2, 3, 4, 5, 6, 7, 8Overall System Characteristics

Enclosure Dimensions 22.25" width x 26.00" height x 11.56" depth180

oopening required for enclosure door

Environmental 0 to 100°F (-17 to 50°C); 0 to 120°F (-17 to60°C) w/ fan tray accessory (PN B4500FT)0 to 95% R.H. noncondensing

Ratings CE EN50081-2 EmissionsCE EN50082-2 Immunity(FM Class 1 Div. 2 Groups C & D available on PN A4500Q)

Ordering Information

A4500Mx x = 1, 16 sensor input, 0 tachometer, 0 relaysx = 2, 32 sensor input, 0 tachometer, 0 relaysx = 3, 16 sensor input, 16 tachometer, 0 relaysx = 4, 32 sensor input, 16 tachometer, 0 relaysx = 5, 16 sensor input, 0 tachometer, 16 relaysx = 6, 32 sensor input, 0 tachometer, 16 relaysx = 7, 16 sensor input, 16 tachometer, 16 relaysx = 8, 32 sensor input, 16 tachometer, 16 relays


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CSI 4500M Machinery Health MonitorOverall System Characteristics

Input Power 120 – 240 VAC 50/60 Hz

System Power Dissipation <20 watts for 32 ch, 16 ta, 16 relay

Optional Accessory Output Power -24 vdc @ 0.4A for displacement probes

4500 Chassis Dimensions 13.975" width x 12.2" height x 8" depth

Chassis Card Slots Total 6 slots: 2 slots for sensor cards,1 slot for tachometer card,1 slot for relay card,1 slot for Machinery Health processor card,1 slot for power supply card

Options

PeakVue® Bearing and Gearbox PN A474504 Fault Detection Technology

Fan Tray PN B4500FT


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CSI 4500M Machinery Health Monitor Processor CardSpecifications PN B4500G2G2 General

Memory Capacity 32 Mb SDRAM, 32 Mb Flash

Network Communications 10/100 BaseT Ethernet NIC

HUB May be used for daisy chaintype network architecture

Local Communications HUB for laptop or local display, and serial port

Local Display Includes overall vibration readout and4500 Monitor chassis temperature

Onboard Test Generator All sensor channels, tachometer channels,AC, DC amplitude and phase

4500 Rack Health Relay One relay will change states based loss ofpower or rack reboot

G2 Real Time ProcessorSensor Channel Scan: 16 ch rms per 500 msecOverall Vibration Scan

DC Scan Rate Simultaneously scanned with overall vibration scan (includes DC Gap, temperature, and accelerometer bias)

Overall Level and DC Accuracy <1% software corrected

Overall Level and DC Resolution 16 bits

Data Acquisition Event Bases Relay input (polled or interrupt driven), RPM,DC, AC or software controlled

G2 Machinery Health Predictive ProcessorData Collection Event based, adaptive

Data Collection Interval Event based and/or time based

Data Storage Interval Exception based and/or time based

ADC Resolution 24 bit, 2 channel simultaneous

Dynamic Range >100 dB, all ranges

Spectral Resolution 100 to 6400 lines

Analysis Bandwidth Fmax 10 Hz to 40 kHz, discrete steps

Spectral Scan Rate 1 second per two channels, 400 lines,400 Hz, 1 avg. (depends on analysis configuration)

Amplitude Accuracy <1% software corrected

Frequency Accuracy 0.01%, crystal based

THD <-90 dB, all ranges

Phase Accuracy 2%

G2 Predictive AnalysisAnalysis and Trend Types Total Energy, Energy in a range, non-sync

energy in a range, sync energy in a range,sync peak, sync phase, true peak, HFD,waveform peak to peak, RPM, gap, orbit,configurable with user defined parameter names

Analysis Setup Multiple analysis types per machine and per sensor

Averaging Normal, PeakVue, Order Tracking,Synchronous Time Averaging

Units English, Metric, Hz, CPM, Order

Scaling Linear, log, dB

Windows Hanning, uniform

The G2 second generationprocessor provides:

■ Dual processors; one dedicated for protection and one dedicated for prediction

■ 5 times faster processing gets you results faster

■ 7 times the dynamic rangeincreases ability to detect anomalies earlier

■ Twice as much built-in memory increases network and server fault tolerance

■ An optional third processor,the GT2, for onboard transient data capture and live displays


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CSI 4500M Machinery Health Monitor Sensor Input CardSpecifications PN B4500MX

CSI 4500M Machinery Health Monitor Sensor Input CardSpecifications PN B4500MX

B4500MX Specifications

Sensor Input Types Dynamic displacement probe, accelerometer,velocity probe, AC input custom definable(Flux, dynamic pressure sensor, dynamic basis weight input, etc.), DC input custom definable (temperature or other process input), 4-20 mA signal. With B4500GT2, B4500MX has truepeak to peak input.

Number of Sensor Inputs 16 inputs per card, 2 cards per rack, multiple racks linked by Ethernet

Analysis Bandwidth DC to 40 kHz

AC Coupling Corner Frequency <0.5 Hz

AC Channel Accuracy <1% software corrected

Analog Integration 1 per channel (acceleration to velocity or velocity to displacement)

Analog Integrator Accuracy <2% (frequency and amplitude), software corrected

Input Ranges ±0.5 v, ±1.0 v, ±5 v, ±10 v, AC or DC, ±24 vdc,±34 vdc CM auto-ranging or software selectable

Powered Sensor Types Accelerometer and velocity probes by each sensor channel, and displacement probes by built-in aux. power supply on power supply card

Sensor Power >4 mA constant current with 22 v compliance per channel

Powered ch Input Impedance 500 KW (single ended)

Non Powered ch Input Impedance 1 MW (differential)

Non Powered Sensor Types Displacement, AC or DC process

RMS to DC Converter 1 per channel, 1 Hz to 40 kHz

Mux Card Analog Outputs ChX, ChY, RMS, DC/Process

B4500PS Specifications

Input Power 120 – 240 VAC 50/60 Hz

System Power Dissipation <20 watts for 32 ch, 16 ta, 16 relay

Optional Accessory Output Power -24 vdc @ 0.4 A for displacement probes

Supplies Power to the Tack 5 vdc, 12 vdc, 24 vdc, 3.3 vdc, -12 vdc

Supplies Power to +24 vdc, 0.3 A output for optional fan tray Auxiliary Equipment ±24 vdc, 0.6 A auxiliary output for displacement

transducers or other


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CSI 4500M Machinery Health Monitor Fan TraySpecifications PN B4500FTB4500FT Specifications

The fan tray is intended to be used where ambient air temperature aroundthe stainless steel enclosure of the 4500 rack is between 100°F and 120°F.When ordered with a new CSI 4500 Monitor, the fan tray will be delivered installed.

Power to the fan tray is provided by a fan tray power auxiliary output from the front panel of the Power Supply card of the 4500 Monitor.

NOTE: In conditions above 120°F ambient, active cooling or conditioned plant air should be installed.


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CSI 4500M Machinery Health Monitor Tachometer CardSpecifications PN B4500TAB4500TA Specifications

Number of Tachometer Channels 16 inputs per rack, 1 card per rack,multiple racks linked by Ethernet

Tachometer Frequency Inputs 0.1 Hz to 2 kHz (6 RPM to 120,000 RPM)

Tachometer Frequency Accuracy 0.1%

Tachometer Resolution 0.002 Hz @ 60 Hz (0.1RPM)

Tachometer Types Eddy current displacement probe,TTL, passive magnetic

Tachometer Input and trigger range ±0.5 v to ±24 v, ±25 CM

Pulse Characteristics 1 pulse per revolution, 500 µS/min. pulse width,tach divider on card

Modes Volt compare, automatic adaptive, divide by N

Input Impedance 1 MW (differential)

CSI 4500M Machinery Health Monitor Relay CardSpecifications PN B4500IO-x (x = 1, 2, 3, 4 or 5)B4500IO Specifications

Number of Channels 16 input or output relay channels, 1card per rack, multiple racks linked together by Ethernet

Relay Types Each channel socketed for a standard Opto22 style digital plug in module.These 4 KV optically isolated modules are available in AC/DC inputs or outputs from 4 V to 280 V or dry contact outputs.

Response Time 50 µsec to 50 msec depending on module

System Interface Software polled or interrupt driven

Interrupt Output Interrupt on pattern match or change


x = 1, [4] inputs IDC5B & [12] outputs ODC5 (standard)x = 2, [12] inputs IDC5B & [4] outputs ODC5x = 3, [8] inputs IDC5B & [8] outputs ODC5x = 4, [16] inputs IDC5Bx = 5, [16] outputs ODC5


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CSI 4500MS Machinery Health Monitor EnclosureSpecifications PN A4500SM

Overall System Characteristics

Enclosure Dimensions 11" width x 16.00" height x 11.56" depth180° opening required for enclosure door

Environmental 0 to 100°F (-17 to 50°C); 0 to 120°F (-17 to 60°C) w/ fan tray accessory (PN B4500FT)0 - 95% R.H. noncondensing

Ratings CE EN50081-2 EmissionsCE EN50082-2 Immunity

Options

PeakVue® Bearing and Gearbox PN A474514Fault Detection Technology

Mounting Kit for 4500MS PN A4500SKWithout Enclosure


www.assetweb.com


©2005, Emerson Process Management.

The contents of this publication are presented for informational purposes only, and while every efforthas been made to ensure their accuracy, they are not to be construed as warranties or guarantees,express or implied, regarding the products or services described herein or their use or applicability.All sales are governed by our terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifications of our products at any time without notice.

Emerson Process Management, PlantWeb, AMS, DeltaV, Ovation, PeakVue, CSI and Machinery Health are marks of one of the Emerson Process management family of companies. The Emerson logo is a trademarkand service mark of Emerson Electric Co. All other marks are the property of their respective owners.

Emerson Process Management

Asset Optimization Division

835 Innovation Drive

Knoxville, Tennessee 37932

T (865) 675-2400

F (865) 218-1401

Online Machinery Health Management powers PlantWeb through condition monitoring ofmechanical equipment to improveavailability and performance.

CSI 4500MS Machinery Health Monitor Sensor CardSpecifications PN B4500MM-XB4500MX Specifications

Number of Sensor Channels 12 sensor inputs, specifications same as B4500MUX

Number of Tachometer Channels 2 tachometer inputs, specifications same as B4500TA

Number of Relay Channels 2 relay channels, specifications same as B4500IO

Number of Cards Per Rack 1 sensor/tachometer/relay card,1 processor card, 1 power supply card,multiple racks can be linked by Ethernet


Relay Options B4500MM-x, where x = 2, 3, 4x = 2, [2] inputs IDC5Bx = 3, [2] outputs ODC5x = 4, [1] inputs IDC5B & [1] outputs ODC5

CSI 4500T Machinery Health Monitor TransientSpecifications PN B4500GT2B4500GT2 Specifications

Number of Channels 32 channels

AC Channel Accuracy <1%, software corrected, 3% Mag/Phase

Frequency Range 2 KHz/ch

ADC Resolution 16 bits

Spectral Resolution 200 lines - 6400 lines

Dynamic Range >80 dB

Number of Tach Channels 4 fixed channels from the 4500 tach card.Requires at least 1 of 4

Data Memory Up to 64 Mb SDRAM, 60 G+ hard drive

Communication 10 \100base-T Ethernet HUB and NIC

4500 Rack Health Relay One relay will change states based on loss of power or rack reboot

The GT2 processor powers the optional live transient display, continuous monitoring and event data capture for turbo machinery. The live displays availableare like nothing on the market. The user can “go live” with a connection directly tothe turbine from their desktop.

Documents

CSI4500 Machinery Health Monitor - Guest Home Pageeuedocs.emersonprocess.co.uk/.../allds0505e_csi4500.pdfCSI 4500 Machinery Health TM Monitor Product Data Sheet D351165X012/0-4500-042005