VIBSENS / SOLUTIONS
Cement industry
Monitoring strategies across the cement production process.
A monitoring strategy for every production stage.
Mills & gearboxes
Pumps & compressors
Distinct solutions. Clear choices.
ARoute-based measurementB4–20 mA integrationCOnline transmitters & monitorsDCompact protection & monitoring
ASOLUTION
Route-based measurement
Use a VD-5 portable collector with permanently installed measurement points and an SB-6 switch box for repeatable route-based readings.
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Technical configuration details
Data Collector Model VD-5:The VD-5 is a route-based data collector being compact, rechargeable and handheld with a rugged structure. VD-5 Vibration meter has been designed to conform to ISO10816-3 and has one ICP™ accelerometer input to provide accurate single channel vibration measurement. Up to two steps of integrations is embedded in the software application to optionally have the measurement result in acceleration, velocity or even displacement. Device can store up to 4000 time signal frames to transfer to PC with a dedicated software which can calculate spectrum, overall vibrations and some other diagnostic features.BNC Switch BOX Model SB-6:
Recommended for walk around data collection routines, where the transducer is fixed and installed. Because changing the direction and point of measurement might affect measurement values, permanently mounted Accelerometers provide more reliable and repeatable readings and the local BNC Switch Box allows for faster, safer and more convenient data collection with portable data collectors or vibration analyzers. VIBSENS switch box works with all 3rd party data collectors and vibration analyzers.
BSOLUTION
4–20 mA integration
Bring measurement values into plant instrumentation through 4–20 mA signal outputs. Select the measurement type and range around the machine and control system.
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Technical configuration details
This device uses the industrial instrumentation standard 4-20mA loop that can interface directly with PLC, DCS and 4-20mA monitors. There is a large choice of output type i.e. velocity, acceleration, displacement or even DC gap. Their compact size allows for installation in tight places, without the need for a meter display.Enclosure: VIBRASENS is able to provide a wide variety of custom enclosures that are supplied fully wired and only require transducer input wires, 4-20mA output signal, relay outputs and power supply to be connected to terminal blocks. Complete system installation is provided with two boxes: 1) 30cm x 25cm x 15cm housing for switch box and transmitters 2) 50cm x 40cm x 30cm housing for VC- 400 with optional fiberglass / stainless steel enclosure with a stainless steel back plane, which the customer can easily choose and order with vibration transmitter or monitor modules.CSOLUTION
Online transmitters & monitors
Select dedicated VC-Series modules for vibration, thrust position or rod-drop measurement, with outputs suited to the selected module.
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Technical configuration details
Vibration Transmitter Module VC200A:This stand-alone analogue module which applies dynamic signal protection meets the requirements of API-670 and provides all the features of a standard vibration protection system able to excite relay output & transmit 4-20mA signal proportional to acceleration, velocity, or displacement to PLC/DCS or any standard 3rd party recorder. Moreover, BNC output for reading with portable data collectors, optional internal integrator, and transducer check display LED, current loop check, alarm relay outputs are all provided in just one module. Optional selection between delays in alarm, energized and non-energized relays are also embedded. Terminal for remote reset for alarm ignorance is also provided. It may be connected either to an ICP™ accelerometer or a proximity displacement probe, VC200A is a complete system which simply needs DC power supply and connected transducer with easy setup.Vibration Monitor/ Transmitter Module VC210A :
VC-210A not only has the features of the above mentioned product VC-200A but also provides two separate relay outputs as Alarm and Trip, and has a display which shows the overall vibration values and can transmit 4-20mA signal proportional to acceleration, velocity, or displacement to PLC/DCS or other recorders. Optional signal integration and status LED (OK/Alert /Danger) is provided for each module. Moreover, the ability to select alarm delay, bypass, latching or non-latching relays, energise and non-energised relays, Terminal for remote reset, Modbus RTU (RS-485) protocol communication are also supported in this device.
DSOLUTION
Compact protection & monitoring
Use the V400 compact platform for continuous measurement and protection, with software tools selected around the monitoring requirements.
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Technical configuration details
Compact Machine Protection System V400:V400 vibration measurement protection and condition monitoring system is a high performance fully programmable signal measurement system capable of measurement & monitoring 4 input channels of either types of absolute vibration (accelerometer / velocity transducer), relative shaft vibration (displacement proximity probes) or thrust (axial) position. In addition to this, first channel can be connected to a trigger signal (Keyphasor™) for measurement of rotational speed or vibration phase of other channels relative to a reference. This 9 cm *9 cm *18 cm panel mountable module is designed specifically for machine protection applications, offering a compact and cost effective solution for small and medium sized rotary machines. Terminal for remote reset / Modbus RTU (RS-485) protocol communication / embedded serial port for firmware update is embedded in each module. It can accept signal from all the standard API-670 compatible transducers and active / passive speed probes. All transducer signals are available via front BNC as buffered output for portable data collector connection. Two fully programmable output relays, 4-20 mA output for all input channels, white graphic LCD display, and four button keypad are all present to maximize onsite and local application.Machinery Fault Diagnosis Software (CMS-Pro):
CMS is machine condition monitoring software which acquires, measures & monitors data from V400 measurement system and can send data over local or wide area networks for other clients. It provides overall value and dynamic data acquisition and analysis; wide display choices such as overall vibration level, trend monitoring, time waveform, frequency spectrum, orbit plot, polar plot, waterfall, bode plot, bearing damage frequencies and much more.
SOFTWARE TOOLS
From configuration to analysis.
Vibsens Studio
Web-based configuration & HMI for compatible hardware.
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CMS-Pro
Condition monitoring and vibration analysis.
Explore analysis views ↗Application details & measurement layouts
Cement Industry :
Cement Industry :
Cement as a primary material used for construction has one of the most production rates among industrial products, its application is visible everywhere around us from buildings to bridges and roads. Cement manufacturing companies have got harsh and rough environments as a result of high particle content in the air, which makes a serious requirement for the machinery and systems used in the field to be quite rugged.
Worldwide demand for cement has been growing with modernization and number of companies in the field has always been growing. Without reliable condition monitoring and protection systems cement plant machinery may get involved in problems. VibSens is ready to provide a perfect solution for vibration protection and online condition monitoring of rotary machinery in cement industry including manufacturing, installation, commissioning and training.
Condition Monitoring & Vibration protection:
Cement companies need to run for long times without a shutdown like 6 months. Condition monitoring & vibration protection of rotary machines enables user to detect and prevent failures before creating downtime. Faults which can be detected by vibration measurement is as follows:
-bearing damage & lubrication problems
-imbalance & misalignment
-looseness, resonance and structural related problems
-gearbox & conveyor belt problems and damage
-foundation movement, coupling damage & inadequate support
Cement Production Process:
Cement manufacturing process in many companies is more or less like the one shown below. Steps to manufacture cement is usually as follows:
• Milling of raw input materials in several stages
• Pyro processing of the raw materials to form cement clinker
• Cooling and storage of clinker
• Final finish milling
• Packaging
Cement as a primary material used for construction has one of the most production rates among industrial products, its application is visible everywhere around us from buildings to bridges and roads. Cement manufacturing companies have got harsh and rough environments as a result of high particle content in the air, which makes a serious requirement for the machinery and systems used in the field to be quite rugged.
Worldwide demand for cement has been growing with modernization and number of companies in the field has always been growing. Without reliable condition monitoring and protection systems cement plant machinery may get involved in problems. VibSens is ready to provide a perfect solution for vibration protection and online condition monitoring of rotary machinery in cement industry including manufacturing, installation, commissioning and training.
Condition Monitoring & Vibration protection:
Cement companies need to run for long times without a shutdown like 6 months. Condition monitoring & vibration protection of rotary machines enables user to detect and prevent failures before creating downtime. Faults which can be detected by vibration measurement is as follows:
-bearing damage & lubrication problems
-imbalance & misalignment
-looseness, resonance and structural related problems
-gearbox & conveyor belt problems and damage
-foundation movement, coupling damage & inadequate support
Cement Production Process:
Cement manufacturing process in many companies is more or less like the one shown below. Steps to manufacture cement is usually as follows:
• Milling of raw input materials in several stages
• Pyro processing of the raw materials to form cement clinker
• Cooling and storage of clinker
• Final finish milling
• Packaging
Solution for Each Division of Rotary Machines in Cement Industry:
Solution for Each Division of Rotary Machines in Cement Industry:
According to the above, Vibsens has extracted the most important rotary machines used in cement companies and developed the best solutions for condition monitoring and protection systems as follows. Signal outputs from accelerometers installed can be read periodically by VD-5 or continuously by V400 vibration measurement & protection system. Both devices maybe connected (VD-5 offline, V400 online) to computer and transmit data to CMS-Pro software which contains monitoring functions like time signal, spectrum, waterfall, orbit etc.In each of the machines mentioned above, certain type of sensors & measurement systems are the correct types based on the importance of the machine role in production, operating conditions and company financial investment which Vibsens is ready to provide solutions based on previous experience with other customers.
According to the above, Vibsens has extracted the most important rotary machines used in cement companies and developed the best solutions for condition monitoring and protection systems as follows. Signal outputs from accelerometers installed can be read periodically by VD-5 or continuously by V400 vibration measurement & protection system. Both devices maybe connected (VD-5 offline, V400 online) to computer and transmit data to CMS-Pro software which contains monitoring functions like time signal, spectrum, waterfall, orbit etc.In each of the machines mentioned above, certain type of sensors & measurement systems are the correct types based on the importance of the machine role in production, operating conditions and company financial investment which Vibsens is ready to provide solutions based on previous experience with other customers.
Typical online methods layout:
Typical online methods layout:
Optional no.1:
As mentioned as option no.1 customer can select Signal transmitter VC210 A as a vibration transmitter and protection system for all the machinery and measurement points. This scheme has been shown below.
Optional no.1:
As mentioned as option no.1 customer can select Signal transmitter VC210 A as a vibration transmitter and protection system for all the machinery and measurement points. This scheme has been shown below.
Optional no.2:
Optional no.2:
In the second option user can choose V400 which is not only a protection module but also may be used as a condition monitoring system with a very cost effective budget. This scheme has been shown below.
In the second option user can choose V400 which is not only a protection module but also may be used as a condition monitoring system with a very cost effective budget. This scheme has been shown below.
Transducers Location:
Transducers Location:
For vibration measurements in horizontal direction, accelerometers are mostly installed on the motor or pump bearing housings nearest possible to the bearings. This enables the user measures velocity of vibrations with one step embedded integrators in mm/sec (RMS) as suggested in ISO 10816 to detect unbalance and structural foundation problems. For measurements in vertical direction, accelerometers are installed mostly on the drive end bearings to enable user to get velocity in mm/sec (RMS) to detect misalignment and looseness. This applies to axial direction measurements, too. For some motors like crusher motors, both drive end and non-drive end bearings are monitored and protected against high vibrations. In gearboxes, vibration of both the input and output bearings are measured.Optional axial vibration measurements could give a proper interpretation of the thrust forces acting on the shaft.
For vibration measurements in horizontal direction, accelerometers are mostly installed on the motor or pump bearing housings nearest possible to the bearings. This enables the user measures velocity of vibrations with one step embedded integrators in mm/sec (RMS) as suggested in ISO 10816 to detect unbalance and structural foundation problems. For measurements in vertical direction, accelerometers are installed mostly on the drive end bearings to enable user to get velocity in mm/sec (RMS) to detect misalignment and looseness. This applies to axial direction measurements, too. For some motors like crusher motors, both drive end and non-drive end bearings are monitored and protected against high vibrations. In gearboxes, vibration of both the input and output bearings are measured.Optional axial vibration measurements could give a proper interpretation of the thrust forces acting on the shaft.
Build the solution around your machine.
Share your machine type, bearing arrangement, operating speed and monitoring requirements.
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