Condition Based Monitoring Solution_Rockwell Automation

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Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 1
Condition Based Monitoring Program
Predictive Maintenance Monitoring to avoid unscheduled downtime
Prepared by: Shawn Lim

Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved. 2PUBLIC
Introduction
Why Monitor Machine Condition?
 In any plant we have assets (big or small) that we want to:
o Protect from damage
o Prevent problems that would
result in a loss of production
o Assure or improve Quality
o Reduce maintenance
costs

Monitoring Machine Condition…
Faults are identified by the frequency of the vibration it causes
 Faults induce repetitive
impact or cyclic forces at
specific, predictable
frequencies (f).
Except for structural
resonances which
simply “ring” at the
resonant frequency
when excited.
Pits or scratches on balls,
broken or damaged gear
teeth... Imbalanced rotors,
misaligned shafts...

Vibration Spectrum Analysis

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Condition Monitoring Main Components
Vibration
Modules
Vibration
sensors
E-Monitor

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Engineering Assets Included:
No Engineering Assets Remarks
1 Vibration Sensors Number of sensors subjected to the
number of equipment and location to be
monitored
2 Dynamix 1444 Number of modules subjected to I/O
3 Compactlogix Controllers
4 E-monitor For vibration spectrum analysis data
presentation
5 Engineering Specialist Analysis of vibration spectrum data

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Emonitor CMS provides the industry’s
most comprehensive suite of tools for
establishing and executing a condition-
based predictive maintenance program.
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Introducing Emonitor CMS
Proven Predictive Maintenance Software
Built on over 30 years of experience, Emonitor version 4.0 is the
continuing evolution of one of industry’s most proven, widely-used and
accepted Condition Based Maintenance solutions.

Emonitor CMS is our most complete
and advanced software package…
• No Functional Levels
• No Tag Limits
8
Introducing Emonitor CMS
Software for Any Condition Based Maintenance Program
Selecting the RIGHT Software, made simple…
• No options • No missing features
• No hidden costs • No limits

Key Features
Logix Online Data
9
 Emonitor’s Logix Online Data data source
allows you to import tags from a Logix
controller into the Emonitor database
 Data can be collected on a Schedule
or when Triggered (by Logix), or both.
 Data Types
• Values
• Vectors
• Spectrum
• Time Waveforms
• Date & Time Stamp

Key Features
Alarms & Frequency Identification
 Alarms
 Overalls
 Statistical –Multi-State
Ability to include up to 4 process
measurements for more accurate statistics
 Spectrum/Narrowband
 Frequency Identification
 Parts database
Over 7000 bearings stored in the system
10

Key Feature
Plot Views
 Plot views
 Over 20 pre-configured plots views
combining a variety plot types.
 Completely customizable
11

Key Feature
Reporting
 Reporting
 Over 30 pre-configured reports
 Customizable using Emonitor Report Builder
 Create plots in MS Excel with a single click
 Export any report to RTF for easy editing within MS Word
12

Key Feature
Calculated Measurements
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 Calculated Measurements
 Apply…
…functions to historical data
 Calculated data is saved, plotted, viewed
and reported the same as raw data
 Wizard enabled to walk you through
setup.
Comparison Constant Date Interpolated
Enumerated Logical Math Phase
Statistics Trend Vector

Include Machine Pictures or Drawings
• Add additional panes, such as machine pictures,
drawings, or boiler plate data can easily be added.

Time Waveform - Comparison

Combination Speed, Phase & Amplitude

Vibration Analysis Plot
View Spectrum History
Zoom-in on details of a single
Spectrum
View the associated Overall
trend

Plots with Alarms
• Alarms are easily displayed
• Choose to display all
alarms, no alarms, or only
specific alarms.

Trend Prediction with Alarm Values
• Emonitor can display a trend
prediction using linear and/or
power curve calculation,
showing likely future trend
values and their relation to
alarm levels.

Overlaying Trends for Several Locations
• Tag multiple trends and overlay them
in a single plot for easy comparison.

X versus Y Plot of Speed vs. Vibration
• Easily plot any 2 single-value measurements
against eachother: Speed vs. Vibration, Load
vs. Temperature, etc.

Time Waveform Viewing

Horizontal, Vertical, and Axial Spectra at One Bearing
Location
• Easily cross-compare spectra
in multiple directions .
• Provides very quick insight
into likely root-cause.

Orbit w/ Time Waveforms Plot

And Much, Much More
• Spectrum band alarms can be frequency-based, or orders-based to automatically adjust to variable speed conditions.

A Number of Customizable Reports
• Standard alarm report, showing %
change.
• Data columns can be added or
removed.
• Sorting can be customized.

Specific Units Custom Reports
• Standard alarm / % change report
modified to only display Spike
Energy (gSE) measurements.

Analysis and Maintenance Notes Report
• Shows the history of all
maintenance notes for each
machine.
• Include all machines, some
machines or just a single
machine.

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 29
Reports Can Include Plots
• Shows the trend plot with alarm
thresholds for any magnitude
measurements currently in alarm.
• Displays the details on the most
recent measurement in alarm.
• Include all machines, some
machines or just a single
machine.

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Why you need Condition Based
Monitoring?
To be able to reduce
operational cost for
end users
To be able to predict
the equipment’s
failure point before
serious breakdown
To be able to
maximize the overall
production capacity
of a plant
To be able to prevent
unscheduled
downtime
To reduce any
likelihood of
accidents or mishaps

Condition Based Monitoring Solution_Rockwell Automation

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