CSI 6500 Datasheet_1

CSI 6500 Machinery Health®Monitor

The CSI 6500 Machinery HealthMonitor is designed for processautomation and protection systemupgrade projects. Housed in asingle chassis, the CSI 6500combines proven predictionand protection to providea complete online machinerymonitoring solution. Emerson isthe global leader of integratedtechnologies for processautomation and plant-widepredictive technologies formanaging both fixed androtating assets.

OverviewFive percent of the rotatingmachines in every plant havethe ability to bring productionto a grinding halt. Although yourcritical machines have vibrationshutdown protection systems inplace to prevent catastrophicfailure, is your plant reallyprotected?

What about the shockingrepair costs, missed productiongoals, and unfulfilled customercommitments associated with atrip or a missed trip?

As many as 50% of machinerymalfunctions that lead todowntime are process induced,and 90% are predictable – evencontrollable.

Real-time machinery health feedback integrates with process automation so youcan run your plant with confidence.

� Extend PlantWeb® withAPI 670 machineryprotection monitoring

� Monitor your plant’s mostcritical rotating machines

� Gain real-time machineryhealth feedback integratedwith process automation

� Transform vibrationmonitoring into predictivealerts

� Empower decisions throughtransient analysis ofturbines in AMS®Suite

� Balance of plant machineryhealth monitoring includesPeakVue® technology forrolling element bearing andgearbox analysis

Product Data Sheet0-6500-111908November 2008 Online Machinery Monitoring

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Protect your critical machinery through protection, prediction, performance monitoring, and PlantWeb.


The CSI 6500 is fully compliantwith API 670 and integratesprotection, prediction, real-timeperformance monitoring andprocess automation.

The CSI 6500 is part of Emerson’sPlantWeb digital architecture,which provides enterprise-wideinformation needed for real-timedecision making.

Flexible for RetrofitsYour project may be a majorrevamp, including a controlsystem and vibration monitoringsystem update, or you may bemaking improvements in phases.If phase 1 is only a protectionsystem upgrade, the CSI 6500is uniquely designed to offerprotection-only for obsoletesystem replacement. The CSI6500 can even be deployed ina prediction-only configuration to

overlay on an existing protectionsystem.

Want to use your existinginstrumentation? The CSI 6500works with any negative 24 VDCpowered displacementsensors and drivers.

In Phase 2 of your project,the prediction-only configurationor protection-only configurationcan be upgraded at any timeto a combined configuration bysimply adding a few monitoringmodules. The CSI 6500 offersthe most flexible and powerfulsolution available for retrofitapplications.

A Protection System YouCan Count OnThe protection technology inthe CSI 6000 Machinery HealthMonitor is the workhorse providingAPI 670 protection in the CSI

6500 system. The CSI 6000 seriesmonitors are field proven on theindustry’s most critical equipment:steam turbine generators, gasturbines, boiler feed pumps,offshore compressors, pipelineturbo compressors, chemicalindustry compressors, turboexhausters, blowers, andboosters.

Missed trips, false trips, andrunning blind are not acceptablein your plant.

The CSI 6500 helps preventmissed trips by using module self-health checking, instrumentationhealth monitoring and hotswappable, external, redundantpower. External power removesheat and user “touches” awayfrom the rack. The samearchitecture is used in allEmerson process automationand critical SIS systems.

• API 670 Compliant

• Integrated protection and predictionmonitoring

• Dual, redundant 24VDC, 120 ~ 240VAC,50 ~ 60Hz power input

• PlantWeb Enabled: Ovation®, DeltaV TM

and AMS Suite Comaptible

• Full TSI (turbine supervisoryinstrumentation)

- Case Expansion- Differential Expansion- Thrust Position- Relative Vibration- Absolute Vibration


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False trips are addressed throughfeatures such as 2oo3 voting logicfor increased decision accuracyand limiting channel count totwo-channel modules. Two-channel modules mean thatswapping a protection modulewill affect no more than twochannels – an API 670requirement.

Redundant communicationsensures that the operator isnever blind to machineryhealth information.

Other features that ensure thereliability of the CSI 6500 include:

� Thrust monitoring: dualchannel, complementary,min/max or absolute shaftposition, measuring rangeshift, measuring range invert

� Differential Expansion:flexibility for any type of rampconfiguration

� Eccentricity: max., min.,peak to peak, or distance fromclearance reference

Sometimes less is better. In theCSI 6500, operator tasks andmachinery health informationare combined in one operatorconsole. This provides theoperator the ability to runthe process and enable tripmultiply within the same operatingenvironment. Likewise, vibrationlevels, eccentricity, and differentialexpansion are integrated intothe appropriate operator views,instead of displayed on aseparate PC.

The CSI 6500 is integrated with the Ovation and DeltaV process automation systems and provides asset data tooperations and AMS Suite.


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InstrumentationWhile the CSI 6500 deliversfield-based intelligence, accurateinformation starts with qualityinstrumentation.

Eddy current displacementsensors are the preferred methodfor monitoring sleeve-bearingmachines. These displacementsensors penetrate the machinecase and directly monitor the motionand position of the shaft withoutcontacting the shaft surface.

Accelerometers and velometers arethe industry accepted sensors formonitoring the health of gearboxesand rolling element bearings.Although temperature sensors are

sometimes used to measure health,temperature alone is only a smallpart of the machinery health picture.When a shaft begins to rub thebearing as a result of misalignment,a displacement probe can directlytrack the misalignment behavior.By the time the rub is severeenough to trigger a temperaturealarm, the damage is already done.

Mounting location andinstrumentation bracket designare both critical for quality data.

A complete range of sensors,adapters, cables, connectors,converters, and fittings are availablefor new installations, retrofits, orreplacement of sensors during anoverhaul.

Sensor Types� Thrust position

� Relative radial shaft vibration

� Absolute radial shaft vibration

� Rotor vs. case differentialexpansion

� Bearing case vibration

� Case expansion, LVDT

� Rotor bow (eccentricity)

� Valve position, LVDT

� Key, phase, and speedmeasurements

See instrument spec sheets for completespecifications about dynamic and staticmeasurements.

ATEX Conformity for selected Products in accordancewith EN 50 014 and EN 50 020, certified by the PTB

Case ExpansionMonitor• LVDTs mounted on both

sides of the casemeasure expansionrelative to the foundationon turbines greater than250MW

• It is important to monitorexpansion on both sidesfor bending, which couldcause rotor to statorcontact

Rotor Speed• Speed monitoring –

machine state information,trending and triggeringacquisition

• Zero speed – signals theoperator to engage turninggear or alerts that turninggear has failed

• Rotor acceleration –indicates load changesand coupling health

• Reverse rotation

Phase• Like a vector, vibration has

both magnitude anddirection

• It is alarming when vibrationamplitude changes.

• Vibration can also changedirection, which is phase.It is equally alarming whenphase changes, evenwithout an amplitudechange

Process Input• Accepts 4-20 mA input

and 0-10 volt input

• Inputs temperature,pressure, flow, and otherprocess parameters

Valve Position Monitor• Valve position can be

used to track changesin load

Shaft Absolute• Shaft relative sensors

and seismic sensors areused to mathematicallyproduce a shaft absolutemeasurement

• Absolute vibrationmeasurements arerecommended for turbines250-650MW or greater

Seismic• Electrodynamic seismic

sensor input for bearinghousing vibrationmeasurements


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It’s the NetworkEmerson's experts ensure properdesign and execution for the CSI6500 implementation in the plant.From onsite assessment,installation and projectmanagement to commissioningand analysis of predictivediagnostics, Emerson offers ateam of world-class professionalsand support network to ensuresuccess including:

� Project Engineers design yoursystem

� Onsite Project Managers areyour point of contact throughoutthe project

� Remote analysis personnelexperienced in diagnostics areavailable to offer a secondopinion for increasedconfidence

� Expert customer support isavailable 24/7 to answer theurgent questions that protectionsystems require

� A network of world-wide supportprovides global coverage locally

Proven Machinery HealthThe performance ofturbomachinery is critical, andyou need real-time feedback,recorded machinery condition,and the ability to replay it foranother view with deeperanalysis. And you need itapplied across the entiremachine train, simultaneously.Meeting this demand is oneof the greatest technologychallenges of machineryhealth diagnostics. Theanswer is field-basedpredictive intelligence.

Case Piezoelectric• Used for rolling element bearings

and gearboxes

• Also used for aero-derivativeturbines where rolling elementbearings are used

• Use PeakVue processing on rollingelement bearings and gearboxes

Dual-Thrust Position• Thrust is an axial position near the

thrust bearing and is one of themost critical measurements on ahigh-speed turbine

• At least two thrust sensors, forredundancy and for voting logicare recommended

• Thrust bearing deterioration,failure, or sudden changes in steampressure can quickly move therotor axially and cause collisionswith rotor and stator

Eccentricity• A measure of rotor bow during

startup, typically monitored from0 to 600 rpm

• Rotor bow changes when thermalconditions change duringstartup, shutdown or evenproduction state

• At least one displacement sensorin the high pressure sectiontargets an eccentricity collar

Differential Expansion• Differential expansion is a

radial rotor positionmeasurement

• Differential expansion sensorsare mounted on the case andmeasure the position of therotor relative to the positionof the case

• Recommended for turbines250MW and greater

• Configurations may be rampor complementary


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The CSI 6500 is uniquelydesigned with field-basedintelligence that combinesa protection system and amachinery health monitoringsolution into one simple platform.With it, you have access to allof this information around theplant or around the world.

When a turbine starts up cold,the entire machine grows as itexperiences extreme thermalconditions. The shaft growsrapidly. The case grows moreslowly. Speed increases andtight clearances tighten. For youroperator, seamless integration tothe existing Ovation® or DeltaV™

process automation systemprovides real-time machineryhealth feedback to run theprocess with confidencewithout adding a PC to thecontrol room or learning a newsoftware package. The operator isunaware that these lively updatesare coming directly to theirenvironment from underlyingbus or Ethernet technology.

With Emerson’s PlantWebdigital architecture, your plant isblanketed with predictive, digitalintelligence that gives you backtime -- time to plan, time to makedecisions, and time to stayfocused on your business results.

Real-Time Machinery Health forMaintenence

In a perfect world, machineswould behave as expectedand predictive maintenanceapplications like AMS Suite:Machinery Health Manager wouldautomatically diagnose turbine

malfunctions for you. But in thereal world, sometimes you needpowerful diagnostic tools to justifyand support your machinerydiagnosis.

The CSI 6500 is designed forreal world challenges with field-based intelligence, continuoussimultaneous data recording, livedata viewing on all channels, andplayback capability. You canplayback the turbine shutdown, orstartup, or even the bump in thenight for your staff as you areexplaining the results.

With the CSI 6500, nothing ismissed, everything is captured –no snapshots. Any questionfrom management aboutturbomachinery health can beanswered with continuous dataand playback capability. Withsnapshots it’s a gamble. For high-speed, critical turbomachinery,Emerson brings the mostpowerful predictive diagnosticsin the world to you.

Power of Planning forMaintenanceAnalysis Parameters

In addition to protecting assetsand real-time monitoring ofturbomachinery, the CSI 6500also takes a microscopic lookat your turbine from a faultdevelopment and maintenanceplanning perspective. Up to255 analysis parameters canbe defined per CSI 6500 fordiagnosing various malfunctionsthrough waveform and spectrumdissection.

For each analysis parameter,LOLO, LO, HI and HIHI alerts andalarms can be set. Parameterssuch as multiples of 1x peak andphase, 3-8x energy commonto looseness, sub synchronousbands for oil whirl, 0.5x for rubs,and even diagnosis aroundwaveform shapes arecontinuously at work.

For turbomachinery drivingcompressors or pumps througha gearbox, the CSI 6500 includespatented PeakVue technology formonitoring gearboxes and rollingelement bearings.

Adaptive Monitoring

An increase in vibration isn’tnecessarily a cause for alarm.It may be perfectly normal forvibration to increase when loadincreases – to a degree. TheCSI 6500 has the unique ability toadjust monitoring strategy basedon changing process conditions.This is possible through thefield-based processing engineenabling event-based collectionand adaptive monitoring.

The CSI 6500 will adaptits monitoring strategy based ondifferent operating conditions,such as changing load or speed.Where you once had one trendwindow for a vibration parameter,you can now have two trendwindows – one for 100% load,and one for 110% load – eachwith independent analysis andalerts.


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Field-Based Intelligence

Field-based intelligence powersthe advanced predictive featuresof the CSI 6500. Similar to aprocess automation architecturewhere the field-based controllerperforms monitoring and controlin the field the CSI 6500 controlsrelays for machine shutdownprotection, monitors for machineryhealth alarms, and streamstransient data to users aroundthe globe from the field-basedprocessor. Intelligence in thefield enables:

� Real-time updates of custompredictive parameters toprocess automation throughbus technology

� Event-based adaptivemonitoring and alerts

� 100+ hours of gaplessturbomachinery continuousand simultaneous transientrecording for all channels

� Plant-wide scalable monitoringsolutions

AMS Suite: Integrated Familyof Software Tools

AMS Suite is a family of best-in-class predictive diagnosticssoftware applications thatenable plant-wide assetmanagement.

When applying AMS Suite to yourcritical equipment you gain:

� Predictive monitoring for bothfixed assets and rotating assets

� Powerful predictive analysistools (plotting, trending,transient, spectral analysis,PeakVue technology, autocorrelation, statistical analysis)

� Web-based case history viewer

� Web-based asset prioritizationand maintenance planning

� Real-time machine performance

� Graphical user interface

� Process parameter import

When machinery protection already exists, or is not needed, the CSI 6500 can be deployed for machinery healthmonitoring. When installed in the rear signal termination configuration, the CSI 6500 can accept up to 48 vibration inputs.


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When the Turbine TripsYou are comfortably home forthe evening when the phonerings and you learn the turbinejust tripped. The decision torestart the equipment is yours.Although you feel the pressure,you are confident because youhave two powerful tools to relyon – continuous data recording toreplay and analyze the event anda live mode to provide feedbackduring startup. Hours of liverecorded data before, during andafter the turbine trip is waiting foryou.

As you drive to the site, youreview the facts:

AMS Asset Graphics combines protection, prediction and performance detailsat the equipment layer through intuitive graphical information.

AMS Suite: Asset Graphics

AMS Asset Graphics providesa simple graphical view ofprocess parameters, protectionparameters, machinery healthinformation, and equipmentperformance information.AMS Asset Graphics provides anoperator view, with a machineryhealth focus while residing in themaintenance department. AMSAsset Graphics includes:

� Graphical turbine / machinedisplay with bar charts

� Event / alarm log

� Trending of vibration andprocess parameters

� Notification (email, textmessage)

� Local cabinet graphicaldisplay

� Touch screen support

With the open architecture,you can integrate informationto and from existing applicationsand systems such as existing:

� ModBus-compliant protectionsystems

� ModBus or OPC-compliantprocess control systems

� OPC or SQL-compatiblehistorians

AMS Suite: Machinery HealthManager

After AMS Asset Graphicsidentifies changes and a potentialmachinery malfunction, AMSMachinery Manager providesan accurate assessment andcomprehensive view of eachmonitored machine in your facility.

AMS Machinery Managerintegrates data from multipletechnologies into a singledatabase for analysis andreporting.

Specific for turbomachinery,AMS Machinery Manager includes:

� Transient real-time livesessions

� 100+ hours of recordedturbine data – start-up,shutdown, and productionstate monitoring

� Turbine replay of anyrecorded session

� 3D machine analysis withME’Scope

scenario


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1. You have the proper setup tocapture the data surrounding theevent. You are assured the rightdata and the anomalous event iscaptured.

2. Your online machinery monitoringsystem provides real-timecontinuous waveform recordingto ensure events will not bemissed. With AMS Suite, arunning history is always available.

The field-based processor is acontinuous data recorder andrecords and buffers 50 hours+of continuous time waveformssimultaneously at all bearings.Auto-archiving of data is alsoincluded so that small, one-hoursnapshots can be saved to anetwork server.

3. Your live turbine view willsupport real-time decisions duringstartup.

When you arrive onsite, you learnit was a manual, operator-initiatedtrip. The operator had real-timevibration data from the CSI 6500and real-time oil temperature andpressure diagnostics from theprocess automation systemthat indicated the turbine shouldbe brought down. In fact, themaintenance team had alreadyfound the plugged oil line to thebearing. Now the only questionsare “How much damage wasdone? And can we restart?”

Thankful for multi-channel,continuous data recording,you look at the quick viewsand extract the region ofinterest for more analysis.

You review the data, comparewith baseline, and confirm thevibration is isolated to one bearing.The shaft centerline plots tell youthe bearing clearance was notexceeded. After fixing the oil flowissue, you restart the turbine. Youwatch the startup with AMS Suitefor a real-time “inside the turbine”view.

The integrated online machinerymonitoring solution of prediction,protection, performancemonitoring, and PlantWeballowed you to easily accesscritical information to make aconfident decision.

AMS Suite provides powerful, real-time diagnostics in a graphical interface.

Transient Real-time LiveSessionsField-based intelligence connectsyou directly to the machine.This unique architecture enablesthe AMS Suite to provide powerfulpredictive tools not possiblethrough PC based data acquisitionsystems. Overall vibration trends,orbits, shaft centerline, Bode/Nyquist, cascade, waveformand spectrum can all be viewedlive, for all bearings desired,simultaneously.


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The CSI 6500 provides solutions to address key issues such as assetmalfunction, barring, or chatter in the paper mills and roll process industries.

100+ hour Turbine Data RecorderA 100+ hour buffer of continuoustime waveforms are simultaneouslyrecorded for all sensors, allbearings, across the entiremachine train. If an interestingevent occurs, a manual or autoarchive automatically andpermanently saves a continuousslice of the running window. Thisslice can be analyzed, stored, orrecalled to overlay on current data.

Turbine ReplayReplay the data so you can watchthe anomaly, the startup or theshutdown again. During replay,change the filter on your orbit orchange the 3D perspective of thecascade plot to fine tune youranalysis criteria to highlight theissue to your staff.

3D Machine Analysis withME’ScopeME’Scope uses 3D graphicalanimation to visually showhow your machine or structureis moving. See overall movement,and movement of one part relativeto another. Right-click a transientwaveform through built-in menusto automatically send data toME’Scope to see the animationsin slow motion. You can identifymalfunctions in your machines thatcould not be seen through anyother analysis.

Roll Process IndustrySolutionsIn paper mills and the metalsindustry, a single bearing orasset malfunction can result in a“wreck”. Barring or chatter cancause variation in caliper or basisweight, which means poor productquality.

And simple process changeslike misaligning a stretch rollwithout feedback to the processautomation system can destroybearings and result in downtime.

Asset malfunctions monitoring,product quality monitoring, andfeedback to process automationare the components of a completesolution for the roll processindustries.

The CSI 6500 includes thesepredictive monitoring capabilitiesto address these issues:

� PeakVue

� Order tracking

� Transient analysis

� Adaptive monitoring

� Time-synchonous averaging

� Integration with CSI 2130Machinery Health Analyzerroutes

� Over 24 definable analysisparameters per sensor

� Integration with AMS MachineryManager


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The CSI 6500 prediction solutionis the perfect fit for continuousroll process applications. Thefront termination panel optionis designed specifically forwall-mount enclosures so thefield-based monitor can be installednear the machines. This saves oncable costs and installation costs.

PeakVuePeakVue is the industry standardfor early identification of rollingelement bearing and gearboxproblems. The same technologyused in the CSI 2130 is alsoavailable in the online monitoringsolution. Undetected dryer andinner race cracks are a thing ofthe past when you catch themreal-time, instead of on amonthly route.

Order TrackingOrder tracking is a unique tool forwinders and machines constantlychanging in RPM where spectraldata would otherwise be smearedand useless. View critical data withclarity.

Transient AnalysisTransient analysis, developedfor turbines, allows for monitoringof many channels simultaneously.For press sections and calendarstacks, transient analysis is theonly way to see rapidly changinginformation simultaneously.

Adaptive MonitoringAdaptive Monitoring is madepossible through intelligentmonitoring in the field. Vibrationdata is collected and processed inthe field much like the field-basedcontroller of a process automationsystem.

This allows advanced and flexibleanalysis and calculations in thefield while reducing data sent backto the user.

Time-Syncronous AveragingIn a press nip, multiple rolls arein contact, which means vibrationfrom one roll will be transferredto all the rolls in nip. With time-synchronous averaging, vibrationsensors, and a tachometer oneach roll, vibration can bepinpointed to the specific roll,even when it is in nip.

Portable vibration and onlinevibration data can be viewed in thesame database simultaneously anddragged onto a plot to overlay.Integrated products means lesslearning and more results.

The front termination panel option is specifically designed for wall-mount enclosures in the roll process and metalsindustries.


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©2008, Emerson Process Management.The contents of this publication are presented for informational purposes only, and while every effort hasbeen made to ensure their accuracy, they are not to be construed as warranties or guarantees, expressor implied, regarding the products or services described herein or their use or applicability.All sales are governed by our terms and conditions, which are available on request. We reserve theright to modify or improve the designs or specifications of our products at any time without notice.All rights reserved. AMS, PlantWeb, PeakVue, Ovation, DeltaV, and Machinery Health are marks ofone of the Emerson Process Management group of companies. The Emerson logo is a trademark andservice mark of Emerson Electric Co. All other marks are the property of their respective owners.

Emerson Process ManagementAsset Optimization Division835 Innovation DriveKnoxville, TN 37932 USAT (865) 675-2400F (865) 218-1401

Online Machinery Health Managementpowers PlantWeb through conditonmonitoring of mechanical equipmentto improve availability and performance.

Over 24 Analysis Parameter PerSensorOver 24 analysis parameters forone sensor means flexibility inautomatic diagnostics. Set upmultiple parameter windows, andanalysis characteristics to get thealerts you want without botheringwith routine analysis. The analysisis still there when you need it.

In paper and metals, threeaspects of monitoring are crucial:

� Instant overall vibration feedback for rapidly changingmachine malfunctions

� Product quality to operators

� Detailed machine healthassessment over time to helpmanage maintenance activities

The CSI 6500 delivers the fastestand most powerful predictivecapabilities on the market.

Emerson’s Power andWater Industry CenterDesigned specifically for thepower generation and water/wastewater treatment industries,the Ovation process automationsystem offers integrated assetmanagement through the CSI6500 and seamless incorporationof intelligent field devices foroptimum control of criticalprocesses.

The PlantWeb AdvantageGet off to a strong start withyour technology investment.Use Emerson’s PlantWebServices for Asset Optimizationto ensure you are effectivelyemploying the CSI 6500 andyour online machinery monitoring

solution. Emerson experts canhelp you use diagnostics fromyour critical machinery to fulladvantage.

Our experts will: INSTALL thetechnology and complete yourinitial set up; IMPLEMENT thetechnology by prioritizing yourmechanical assets and optimizingyour alert parameters; and finallyINCORPORATE the technologyin your work processes toincrease your maintenanceand operational efficiency andensure impact to your bottom line.

Ordering InformationPlease see individual MonitoringModule spec sheets for specificfunctionality and part numbers.

Documents

CSI 6500 Datasheet_1