Vibration Monitoring and Machine Protection Systems 1010 E. Main St. , League City, TX 77573 Phone: 281 -334 -0766 Fax: 281 -334 -4255 www. stiweb. com / www. stiwebstore. com SALES TRAINING for Representatives and Distributors Vibration and Temperature Sensors, Transmitters, Monitors, Cables, Mounting Accessories, BNC Switch Boxes, Enclosures, Junction Boxes, Tachometers, Custom Panels and More….
CMCP “Condition Monitoring Custom Products” CMCP-XXX Standard Products CP Custom Products Transmitter Systems Free Standing Cabinets Monitor Systems Custom Integration & Test Industrial Radio Modems Custom Enclosures Low Cost Accelerometers Temperature Sensors Extension Cables Mounting Accessories BNC Switch Boxes Junction Boxes Balance Kits (CMXA) Instrument Wire Rotor Kits Tachometers Eddy Probe Calibrators Field IO (Analog to Digital) HMI Solutions Auto. CAD Drawings Industrial Computers
STI Vibration Monitoring Inc. About STI was founded in 1989 and created Condition Monitoring Custom Products (CMCP) in 1995 to bring more low cost solutions to our customers while providing the flexibility required in today’s competitive market. STI specializes in low cost alternatives to “Rack Based Monitoring”, by bringing single channel transmitters and monitors into the market. By creating a monitoring system based on single channels, the costs of machine protection systems are now much more affordable.
STI’s Strategy Provide our Customers with a easy to use and maintain Low Cost Alternative to expensive, centralized rack based Machine Protection Systems by: • • • Allowing Customers to make use of existing PLC and DCS systems. Making use of Existing Networks. Modular Design. Distributive Design. Low Cost Keep it Simple (Kiss). “Simply the Lowest Cost Approach to Condition Monitoring”
Machine Condition Monitoring Online System: Continuous Monitoring and Protection • Continuous Protection for Critical Machinery • Real Time Data • Ability to Connect to a PLC or DCS System • Easily Expandable Predictive Maintenance: Scheduled Route Based “Check Ups” • Generally for Non-Critical Machinery • Requires Data Collector / Analyzer • Data Must Be Taken From Same Location Each Time • Unsafe Work Areas • Machine Hazards • Requires “Specialist”
Legacy Issues • Large centralized “Rack” based systems. • Control Room mounted. • Originally Capital Projects. • OEM supplied sensors. • All sensors wired to “Rack” • Requires lots of instrument wire and conduit (2 x cost). • Large Racks do nothing that a PLC or DCS system cannot do. • Overall Values. • Time Delay. • Power up inhibit. • OK Circuit. • 99% not wired to “Shutdown”. • Many are ‘Obsolete”. www. cmcpweb. com
Legacy Systems GE Power Systems (Bently Nevada) IRD/Entek 1700 Series 5000 Series 7200 Series 9000 Series 3300 Series Unicell 5802 Series 5806 Series 5815 Series 5915 Series
What’s Changed? Hardware • PLC and DCS Systems are faster, cheaper and more common. • Many Plants are upgrading to New DCS and PLC Systems. • HMI Systems like Wonderware available. People • • Vibration and machinery specialists are retiring, or spread out. A lot of specialty work is contracted. Engineers and Technicians are forced to be “Jack of All Trades”. Operators are being assigned more tasks. Users want smarter, simpler and easier to maintain systems. Users are more budget conscious. Engineers and Technicians are more computer oriented. Major machine flaws have been fixed. www. cmcpweb. com
Vibration Monitoring using PLC Advantages: w w w w w Low Cost (1/2 Legacy Systems) Simple to Install. Can make use of existing sensors. Distributive Architecture. 4 -20 m. A noise free. Digital to save wiring costs Choice of Protocol Easy repair and replacement. Local Dynamic Signal w/BNC. Disadvantages: w No Remote Dynamic or Transient Data. www. cmcpweb. com
CMCP Monitoring Strategy PLC/DCS
CMCP 420 VT & CMCP 420 VT-T Loop Powered Vibration Transmitters “Simply, the Lowest Cost Approach to Machine Protection”
CMCP 420 VT Loop Powered, 2 wire Vibration Transmitter Features Include: · Solid State · Velocity Output · Loop Powered · Integral Accelerometer · 4 -20 m. A Output · 100 mv/g Dynamic Signal Output · 2 -2, 000 HZ · No External Housing Required · No Special Extension Cable – · Optional Bright LED or LCD Display w/ BNC · Optional BNC Adaptor · Optional Temperature w/LED Display w/BNC Adaptor
CMCP 420 VT-T Dual Parameter Loop Powered Vibration and Temperature Transmitter Features Include: · Solid State · Velocity Output · Temperature Output · Loop Powered · Integral Accelerometer · 4 -20 m. A Output · 2 -2, 000 HZ · No External Housing Required · No Special Extension Cable
CMCP 420 VT(T) Accessories CMCP 420 EL CMCP 420 LED CMCP 420 BNC CMCP 420 WF CMCP 203 CMCP 420 XPHD
Why 4 -20 m. A? • ISA Standard 4 -20 m. A and 1 -5 VDC • Standard Instrument Wire (pair) • Extremely Accurate. • Low voltages (typically 24 VDC). • Long distances can be handled. • Voltage has resistance losses. • 4 -20 m. A Current Constant anywhere on loop. • Noise immunity. • Instrument Technicians understand. • Available IO Points
CMCP 500 Series Transmitters and Monitors
CMCP 500 Series Transmitters and Monitors CMCP 500 Transmitter CMCP 500 A Monitor Rated For Use In Hazardous Areas Class I Division II Groups B, C and D
CMCP 500 Series Transmitter and Monitor Configurations CMCP 525 Acceleration CMCP 530 Velocity CMCP 535 Displacement (Velocity) CMCP 540 Displacement (EP) CMCP 545 Thrust Position (EP) CMCP 547 Differential Expansion (TSI) CMCP 548 Case Expansion (TSI) CMCP 549 Valve Position (TSI) CMCP 560 RTD Temperature CMCP 565 Thermocouple Temperature CMCP 570 Solid State Temperature CMCP 575 Speed CMCP 580 Process Variable CMCP 585 Eccentricity (TSI) CMCP 590 Acceleration Enveloping CMCP 595 Buffer Accessory Module
CMCP 500 Series Transmitters Features Include: • Single Channel • Low Cost • Class I Division II Rated • CE • Small Size • Din Rail Mount • 4 -20 m. A Output • 24 VDC Powered • OK Circuit • Optional Filters • Buffered Outputs (2) • Selectable Ranges (5) • All Popular Sensors and Transducers • Easy Troubleshooting and Replacement
CMCP 500 Series Transmitters
CMCP 500 Series Transmitters
CMCP 500 Series Transmitters
CMCP 500 A Series Monitors Features Include: • All Features of Transmitter • 3 Alarms w/Relays • OK • Alert • Danger • Selectable Time Delay (. 1, 1, 3, 6 and 10 sec. ) • Latching or Non-Latching Relays • Reset Terminals • Trip Multiply (2 x or 3 x) • Outputs for Optional Display • Meets API-670 (American Petroleum Institute) • Easy Alarm Setup and Adjustment
CMCP 500 A Series Monitors
CMCP 500 A Series Monitors
CMCP 420 VT vs. CMCP 500 Series Features: CMCP 420 VT CMCP 500 4 -20 m. A Output to PLC/DCS X X Loop Powered (2 -Wire) X 3 -Wire Velocity X X Displacement X Acceleration X Enveloping X OK Circuit X Buffered Output X X Optional Filters X High Temperature Applications X Selectable Ranges X
Standard Monitoring Systems
CMCP 5301 -E(M) Single Channel General Machinery Monitoring System Features Include: · Single Channel · Bright Red LED Display · Reset Button · Low Cost · 4 -20 m. A Output · Alert & Danger Alarms · Adjustable Time Delay · Trip Multiply · Transducer Fault Detection · Buffered Transducer Output
CMCP 5302 -E(M) Two Channel General Machinery Monitoring System Features Include: · Two Channel · Bright Red LED Display · Reset Button · Low Cost · 4 -20 m. A Output · Alert & Danger Alarms · Adjustable Time Delay · Trip Multiply · Transducer Fault Detection · Buffered Transducer Output Great for Cooling Towers, Fin Fans, Hydro Turbines and any low channel count application.
CMCP 5304 -E(M) Four Channel General Machinery Monitor The CMCP 5304 is a 4 channel monitoring system ideal for monitoring rotating machinery such as pumps, fans, compressors, turbines, and motors. The General Machine Monitor is equipped with 4 CMCP/CMCP 530 A Monitors alarming in integrated velocity with a 100 m. V/g ICP Accelerometer input. Also Available with Stainless Steel Housing
CMCP 1000 Dual Limit, Single Channel Vibration Monitor · Solid State Reliability · Class 1 Division 1 Rated · Integral Sensor (Optional External Sensor) · Two Levels of Alarm with Relays · True “OK” Circuitry with Relay · Adjustable Time Delays · Trip Multiply · 4 -20 m. A Output · Remote Reset · Optional Local Reset · Bright LED Digital Readout Applications include Reciprocating Compressor Frame Vibration, Fin Fans and replacement for any mechanical vibration switch.
CMCP 5019 19" Rack Mounted 10 -Channel Monitor Features: • 19" EIA Rack or Panel Mount - 2 DIN High • Individual Bright Red LED or LCD Displays • OK, Alert, and Danger Relays - Meets API-670 • CE Approved • Terminals for Customer Wiring • Universal VAC Power • Optional -24 VDC Power Supply for Eddy Probes • Optional MODBUS or Ethernet TCPIP Direct Replacement for Bently Nevada, Entech IRD and Other 19” Rack Based Systems
CMCP 500 Series Monitors LOW COST CONDITION MONITORING PACKAGES Custom Integration / Packaging · Custom Designs and Layout · Displays (common or individual) · Power Supplies · Custom Enclosures (XP, Nema 4, 4 x) · Intermediate Terminal Strips · IS Barriers · Field IO Interface · Ethernet TCP/IP, RS-485 Interface · Wireless · Web Enabled · Integration and Test (FAT)
Previous CMCP 500 Series Projects (12) CMCP 530 A Vibration Velocity Monitors. Common Display with Channel Selector Switch, Powder Coated Mild Steel, NEMA 4 Enclosure. (7) CMCP 525 Vibration Acceleration Transmitters. High and Low Pass Filters, Intermediate Terminals Fiberglass, NEMA 4 X Enclosure. (4) CMCP 530 Velocity Transmitters, (2) CMCP 545 Eddy Probe Position Transmitters, and (1) CMCP 575 Speed Transmitter. Individual displays, Fiberglass NEMA 4 X enclosure.
Previous CMCP 500 Series Projects (12) CMCP 540 A Displacement Monitors, (2) CMCP 545 Position Monitors, (2) CMCP 530 A Velocity Monitors and (1) Phase reference output. Fiberglass NEMA 4 X. Explosion Proof System with CMCP 530 A Vibration Velocity Monitors, Class I, Div. I, continuous monitoring system for offshore Gas Turbine installation. Requirements included IS Barriers, Slave Relays, Independent Displays, XP Housing and 4 -20 m. A output to interface with a DCS system. TSI System (14) CMCP 540 A Displacement Monitors, (2) CMCP 545 Position Monitors, (1) CMCP 500 A Eccentricity Monitor, (1) CMCP 500 Case Expansion and (1) CMCP 500 Differential Expansion. Painted Steel NEMA 4 Enclosure.
Top Sales Performers
CMCP 1100 Series Industrial Accelerometers Features Include: Standard CMCP 1100 High Temp. CMCP 1100 H Side Mount CMCP 1100 S · LOW COST (Only $99. 00 for 5 Meter System) · Small Size Case, 1/2” x 1. 05” · Small Footprint, 1/2” · Integral Cable (5, 10 or 20 Meters) · 100 m. V/g Sensitivity · 0. 32 Hz to 10 KHz Frequency Range (± 3 d. B) · Waterproof CMCP 1100 C M 8 Connector New!
CMCP 1300 Series Industrial Triaxial Accelerometers Features Include: · Low Cost · Small Size Case, 1. 5” x 0. 9” · Cable (5, 10 or 20 Meters) · 100 m. V/g Sensitivity per channel · 10% Accuracy · 0. 32 Hz to 10 KHz Frequency Range (± 3 d. B) · Waterproof New!
Accelerometer Accessories Mounting Pads Adhesives Motor Fin Mounts Extension Cables NPT Adapters Accelerometer Housing BNC Junction Boxes Piloted End Mill Intermediate Termination Boxes
CMCP 250 Accelerometer Mounting Kit 25 2 2 25 25 1 1 1 12 2 CMCP-200 -02 Mounting Pads CMCP-205 -01 Motor Fin Mount CMCP-205 -02 Motor Fin Mount CMCP-205 -03 Motor Fin Mount CMCP-205 -04 Motor Fin Mount CMCP-230 -01 1/4" x 28 UNF x 1/2" CMCP-230 -02 1/4" x 28 UNF x 3/4" CMCP-701 Spot Reamer CMCP-721 -02 1/4 x 28 UNF Tap Handle CMCP-211 Adhesive and Activator CMCP-212 Silicon Dielectric CMCP-213 Silicone Sealant CMCP-208 Mixing Nozzles CMCP-206 Adhesive Filler
CMCP 300 Series BNC Switchbox Features Include: · Low Cost · 1, 2, 4 and 6 Channel · Available in Fiberglass, Painted Steel or SS · Water Tight & Dust Tight · External or Internal BNC & Switch Available · Provide convenient and safe access to signals
CMCP 310 Series BNC Switchbox Features Included: · Low Cost · 6 and 12 Channel · Terminate & Switch outputs of up to 48 sensors · Available in Fiberglass, Painted Steel or SS · Water Tight & Dust Tight · External or Internal BNC & Switch Available · Provide convenient and safe access to signals
CMCP 305 Quick Access BNC Junction Box Features Include: · Low Cost · 2 and 4 Channel · Provide convenient and safe access to signals · Indoor Use Only
CMCP 312 Din Rail BNC Box Features Include: · Din Rail Mounted · 12 Channel · Low Cost · Provide convenient and safe access to signals · Indoor Use Only
CMCP 303 Triaxial Connection Box Features Include: · Low Cost · 2 and 4 Triaxial Accelerometers · 6 and 12 Ch. · Available in Fiberglass, Painted Steel or SS · Water Tight & Dust Tight · Provide convenient and safe access to Triaxial signals New!
Eddy Probe Accessories CMCP 801 · Meets API 670 external mounting specifications · 304 and 316 Stainless Steel · Provided with four 3/4" NPT Hubs · 3/4" or ½” NPT Case Entry · Machined aluminum · Threaded and slotted to insure position and stability CMCP 805 · Machined 304 Stainless Steel · ½” and ¾” NPT External Threads · ¼” x 28 and 3/8 ” x 24 Internal Threads CMCP 4190
CMCP 610 Eddy Probe Calibrator Features Include: • Verify Voltage Output vs. Gap • For use with 5 mm & 8 mm Probes • Precision Micrometer • 4140 Target • Graph Paper & Excel Spreadsheet
Wireless Industrial Radios Features Include: Ethernet Model · Class I, Div II, Group’s A, B, C, D. · Superior noise immunity. · Frequency Hoping. · Worldwide Unlicensed 2. 4 GHz. · Ethernet (TCP/IP, Ethernet/IP, Modbus/TCP, etc. ) · MODBUS RTU RS-485, RS-422, RS-232. · 32 Frequency Channels. · Up to 16 mile range w/ Hi Gain Antennas. · Can be extended with Repeaters. · 250 Kbps RF Data Rate. · Easy to Configure. Lowers Cost of Wiring and Installation
CMCP 1210 Series Spring Loaded Temp. Sensors Features Include: • Tip Sensitive RTD or Thermocouple • For use to 260º C (500º F) • Adjustable Spring-Loaded Holder with Fluid Seal • Aluminum Connector Head – Optional XP Head
CMCP 800 Balancing Accessories Kit · Hard Carry Case · CMCP 6160 Printer Adapter · Digital Scale · CMCP 630 A/B Switch · (2) CMCP 2100 Accelerometers · (2) CMCP 625 2 Pin to BNC Adapter · (3) 25’ BNC/BNC Cables (A, B, Phase) · (2) CMCP 908 -MD Magnet · Optical or Laser Phase Reference Kit · CMCP 6156 Magnetic. Goose Neck · Custom Vice Grip · Assorted Balance Weights · Banana to BNC Adapter · Hex Key Set · Tape Measure · 6” Stainless Steel Rule · 6” 180º Protractor · Compass · Clip Board · Polar Plot Tablet (50 sheets) CMCP 811 Balance Weight Starter Kit
CMCP 810 Electrical Runout Kit Features Include: · Oscilloscope · Optical Phase Reference Kit · Eddy Probe System · Power Supply · Magnetic Mounts · Custom Vice Grips · “Bucking” Amplifier · Hard Carrying Case · Optional Gauss Meter · Option Software
CMCP TACH 3 -XP Explosion Proof Class I Division I Tachometer Features Include: · Replaces Old Dymac M 746 · Front Panel Programmable · 5 -999, 999 RPM Selectable Range · 1 or Multiple Pulses per Revolution · 0. 001% Accuracy · Alert and Danger Alarms · 4 -20 m. A and 0 -5 Vdc Output. RS 232 Output · Eddy Current Probe Input · High & Low RPM Recall · 0. 56” H, Seven Segment LE
CMCP 601 Rotor Kits Measurements may be obtained to study: CMCP 601 Dynamic Motion Demonstrator Available in Short or Long Base · Frequency Based Signals · Time Based Signals · Orbital Analysis · Shaft Runout · Shaft Bow · Identify Rotor Critical Speeds · Resonance Amplitude Factor · Phase Analysis · Balancing · Shaft Relative & Case Absolute · Rotor Dynamic Studies
CMCP 600 Bearing Fault Demonstrator Features Include: Bearing Fault Demonstrator · 1700/1400 RPM AC Motor · Quick Bearing Change · Easy to Use · Repeatable Results · Carrying Case · (2) Rolling Element Bearings (1) “Good Bearing” (1) “Fault Induced Bearing”
Custom Products and Integration
CP Products (Custom Products) • Custom Enclosures • Free Standing Cabinets • Component Integration • Drawing and Engineering Services • Custom HMI Applications • Custom Cables • Specialty Sensors • Custom Enclosures • Free Standing Cabinets • Drawing & Engineering Services (Auto. CAD) • Custom Packaging (Kits) • Battery Powered Monitors • Wonderware HMI • Integration Services • Test and FAT
Cabinet / Panel Design and System Integration Over 250 integrated Custom Panels and Enclosures Customers Include: · Aramco (Abqaiq, Sadaf, Ras Tanura, Shayba, Riyadh) · Black & Veatch · Brown & Root · Caltex · Fisher Rosemont · BHEL · Wyle Labs · Chevron USA · BP Amoco · M&M Mars · Champion Paper · E. I. Dupont · Ebara International. · Baxter Wilson Unit 1 and 2 · City of Portland, Oregon … and many more
Case Histories
Case History #1, Wireless MCT Customer: Dynegy System Type: Coal Crushers Location: 2 Locations, Illinois, USA Salesperson: Gary Gbur Value: $40, 000. 00 Phase 1 $200, 000. 00 Phase 2 Year Installed: 2004 / 2005 /2008
Case History #1, Problem and Solution
Case History #1, Problem and Solution The Problem • Coal crushers with embedded accelerometers needed • • monitoring. User wanted to use existing DCS system. Existing system was not working properly. User unwilling to pay for conduit and instrument wire. Low speed bearings needed enveloping. The Solution • Velocity and Envelope Acceleration Transmitters (some • • slow speed). 16 Channel A/D Converter using Modbus TCP/IP Ethernet Industrial Ethernet Radio Modem No lost packets. Very robust system Both Modbus RS-485 and TCP used.
Case History #1, Implementation Two vendor solutions were employed side-by-side, each system monitoring different parts of the pulverizer.
Case History #1, CMCP Success Story After eight weeks STI was chosen to provide the wireless vibration monitoring solution, when the other vendor’s solution failed to provide reliable and continuous service.
Case History #2 Customer: Xcel Energy System Type: TSI System Location: Saint Paul, Minnesota, USA Salesperson: Frank Howard Value: $60, 000. 00 Year Installed: 2004
Case History #2, Problem and Solution
Case History #2, Problem and Solution Problem: • TSI system for GE Turbine Generator Set • Customer wanted to use existing new DCS system • Wanted local display for operators • Intermediate terminals to save installation time Solution: • CMCP 500 Series Transmitters. • Pre-wired integrated custom panel. • 4 -20 m. A loop to DCS. • Custom mimic panel w/displays.
Case History #2
Case History #3 Customer: WDC System Type: Critical Fans Location: Pine Bluff, Arkansas, USA Salesperson: David Gallagher Value: $160, 000. 00 Year Installed: 2004
Case History #3, Problem and Solution Problem: • 6 IRD/Entek 5815 monitors mounted in outdoor cabinets. • Critical service on high temperature furnace fans. • IRD/Entek no longer supported. • Primary competition: BNC • 1 vibration channel. • 8 temperature channels. Solution: • CMCP 530 transmitter. • Analog to digital converters with direct RTD input. • 15” industrial touch screen rack mount computers. • Custom Wonderware HMI with bargraphs.
Case History #3
Case History #3
Case History #3
Case History #3 Main Screen Alarm List Historical Trend Real Time Trend Setup
Case History #4 Customer: Xcel Energy System Type: TSI System Location: Saint Paul, Minnesota, USA Salesperson: Frank Howard Value: $60, 000. 00 Year Installed: 2004
Case History #4 Problem: • Large Kinetic UPS System Monitoring. • Vibration, Enveloping, Temperatures, Speed, Pressures. • Flywheel Diameter Calculation. Solution: • CMSS 530, CMSS 590, CMCP 540 and CMCP 545 Transmitters. • Process Variables direct to ADC. • 12. 1” Touch Screen Rack Mount Industrial Computer. • Custom Wonderware HMI.
Case History #4
Case History #4 Main Screen Real Time Trend Alarm List Historical Trend Real Time Trend Setup
Case History #5 Customer: Aramco System Type: Reciprocating Compressor Location: Saudi Arabia Salesperson: Zyad Al-Irhayim Value: $120, 000. 00 Year Installed: 1999
Case History #5
Case History #5, Problem and Solution Problem: • Monitor Large Reciprocating Compressor in Hydrogen Service. • Frame and Crosshead Vibration. • Rod Drop. • Valve Temperature Monitoring (Averaging) Solution: • CMSS 530, CMSS 545, CMCP 560 Transmitters. • Field IO. • Explosion Proof Enclosures • 17” Touch Screen Rack Dell Computer. • Custom Wonderware HMI.
Case History #5 Main Screen Bar Graph Screen Current Alarm List Historical Alarm List
Case History #5 Historical Trend Real Time Trend Historical Trend Setup
Case History #6 Customer: Exxon System Type: 13 x Ex. MCT Systems Location: Singapore Salesperson: Mike Howard Value: $ 100, 000. 00 Year Installed: 2010
Case History #6
Case History #6, Problem and Solution Ø Equipment to monitor: 13 x Vertical Pump motors / 350 KW Ø Motor Drive & non- Driven end Problem: • Open environment in intrinsically safe area (Refinery segment) • Access to buffered signal • Display for each channel • Cost considerations Solution: • 13 MCT systems in explosion-proof enclosures • BNC Junction boxes for easy access to the buffered signal • Safety barriers
Case History #6 Explosion proof Monitoring System 4 channels with local display Power Supply Intrinsically safety barriers and BNC junction box
Case History #6
Case History #6 Ready for Shipment from Houston
Case History #6 Installation
Who To Contact? Distributer Sales and Support: Matt Howard matthoward@stiweb. com 281. 334. 0766 ext. 1 Custom Applications/Technical Support: Mike Howard mhoward@stiweb. com 281. 334. 0766 ext 4 Accounting: Natalie Henderson nhenderson@stiweb. com 281. 334. 0766 ext 3 Order Status: Mark Tomlin mtomlin@stiweb. com 281. 334. 0766 ext 5 Purchase Online Quick and Easy at www. stiwebstore. com
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