Philosophy

Instrumentation is art, science and technology

of measurement, transmission and control.

In case of Process Units the emphasis is on safe

operation and precise control.

In case of Rotary M/Cs the emphasis is on safe

operation and monitoring .
Rotary M/c Automation

áMachine Conditioning & Monitoring System

Measurements
Machine protection

áMachine Safeguarding.

áInterlock.

áControl
Measurements

j Health of a Rotary machine is best monitored by

measuring and monitoring the following machine
parameters
3 Jibration levels of casing and / or shaft
3 Shaft RPM
3 Relative location of the shaft with respect to a
predetermined mark ( e.g.-Key phasor )
3 Axial shift of shaft
3 Temperature of thrust bearing pads
3 Temperature of bearing housing
3 Temperature of lube oil return line
3 Oil/gas flow/pressure to seals
Jibration Measurement-Seismic sensor

j 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
Jibration Measurement-Proximity
Sensor

R Proximity Sensor -
Works on eddy current principle
Non -Contact shaft observing probes giving direct shaft
vibration / displacement / rpm.
Relative vibration / displacement in microns / mils / mm.
Mounting of Proximity Probe

3 Non contact type Proximity probes for

Radial Jibration for shaft ( X and Y)
Ô
 
 
   
Rod drop measurement for
reciprocating Machines
G Indirect measurement of wear & tare of Piston¶s
rider band with help of non contact type probes
 Reciprocating compressor

O
  

  
To get early warning of lubricant de-gradation due to process
material which accelerate wear in rider band.
To monitor rider band wear for lightly or un- lubricated
reciprocating compressor.
Reciprocating machine need to be monitored for rod drop for
predictive maintenance of piston rings.
Safe Guarding

For ensuring safe and smooth operation and to

avoid unwanted costly M/C breakdowns the
above measured parameters are ÿ
Trended
Used to generate Alarms so as to attract the operator
attention
Used in the Startup Logic to ensure that all the
associated parameters are safe to start the M/C
Used in the Shutdown logic to ensure safe shut down of
the machine in case any parameter crosses the
predetermined Danger Limit
Machine safe guarding - interlocks

R Start up logic
Suction Pressure & temperature
Lube oil Pressure
Seal gas pressure
Cooling water pressure
Steam pressure and temperature ( Steam turbine
only)
Machine safe guarding - interlocks

R Trip logic
Suction Pressure low
Lube oil Pressure
Seal gas/oil pressure
Cooling water pressure
Steam pressure and temperature ( Steam turbine
only)
Shaft vibration / casing vibration
Axial position
Over speed
Bearing temperature
2



j Auto start of stand by lube oil pump.

j Lube Oil / Seal Oil back up system
j Sequential start / stop (speed ramping of
turbines) to avoid human error
j Capacity control
j Surge control system
Control System Block Diagram

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Surge in centrifugal compressor

Surge occurs in a centrifugal compressor

when the flow rate falls below a certain minimum
level corresponding to the compression ratio,
often resulting in flow reversal. Such a reversal if
severe can damage the rotor, seal and bearings
of the compressor.
Performance map of compressor

 


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1. Surge limit line 3. Performance curve

2. Surge control line 4. Operating point
Surge description

j Flow reverses in 20 to 50 milliseconds

j Surge cycles at a rate of 0.3 s to 3 s per cycle
j Compressor vibrates
j Temperature rises
j ³Whooshing´ noise
j Trips may occur
j Conventional instruments and human operators
may fail to recognize surge
Some surge consequences

j Unstable flow and pressure resulting in process

upset
j Damage in sequence with increasing severity to
seals, bearing, impellers, shaft
j Increased seal clearances and leakage
j Lower energy efficiency
j Reduced compressor life
Surge Control Techniques

j Controlled Opening of

The vent or Blow off valve.

The recycle valve(discharge to suction)
Antisurge Control System

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Control

R Capacity Control:
‰ The capacity control of a centrifugal
compressor is achieved by controlling one
or combination of the following parameters.
Speed control
Inlet guide vane control
Suction or discharge pressure control.

R For the Reciprocating compressors

capacity control is achieved by
unloading one or two cylinders
Reliability

R The Reliability of the Rotary M/C

Automation is further enhanced by
÷ installing at least 2 measuring elements for
each parameter
÷ Through the 2002 or 2003 trip logic
÷ use of the Redundant
3 Power Supply Units
3 Communication Links
3 Processors.
Conclusions:

´ Manmachine interface for monitoring & analysis

of machine health.
´ Helps in predictive maintenance by
èarly symptom of misalignment & abnormal vibration
Bearing wear / Bearing clearance.

´ Avoids un-scheduled machine shut down

´ Increased equipment availability
´ Provides common platform to co-relate process
& vibration temperature data for detail analysis.
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