Transmitter enables predictive maintenance for machinery health

A typical process plant houses 2,500 machines—60% of which are motor-pump combinations—and mechanical failures in these machines cause 43% of plant incidents. Real-time, online, field-based information is sorely needed to protect assets, especially as more equipment experts retire.

04/01/2005


A typical process plant houses 2,500 machines—60% of which are motor-pump combinations—and mechanical failures in these machines cause 43% of plant incidents. Real-time, online, field-based information is sorely needed to protect assets, especially as more equipment experts retire. Emerson Process Management personnel presented this information at a March 4 media event at the Kennedy Space Center to introduce Emerson's CSI 9210 Machinery Health transmitter. This device is designed to improve how process industries use and maintain rotating equipment by providing reliable information to extend equipment life, initiate timely maintenance, prevent unexpected failures, and avoid unneeded scheduled maintenance.

CSI 9210 monitors sensor outputs of vibration, temperature, motor flux, and machine speed on ac motor-pump machine trains. It then analyzes measured data, calculates machinery health, issues any needed alerts, and recommends actions in real time, in units and measures understood by plant personnel. Emerson says it's the first FOUNDATION fieldbus transmitter that diagnoses conditions, including motor-pump bearing failure, coupling misalignment, motor-electrical failure, pump cavitation, and pump imbalance.

The product targets large and small motor-pump machines essential to chemical, oil and gas, refining, power, pulp and paper, and other process applications, in which unplanned production shutdowns can cost $1 million or more per day. CSI 9210 takes 11 inputs, and expands Emerson's machine health solutions, such as the CSI 4500 Machinery Health Monitor, which can take up to 32 inputs.

"The CSI 9210 Machinery Health Transmitter can alert our operators in real time when equipment problems start to manifest. If a change in upstream head, volatility, or composition results in increased flashing or cavitation, they can make adjustments to eliminate the problem," comments John Rezabek, controls specialist for Lima, OH-based BP Chemicals.

Mark T. Hoske, editor-in-chief





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