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Sabroe Vibration Monitoring system
Functional description
en
Functional description - Sabroe Vibration Monitoring system
0013581 en 2021.03 3/27
Contents
1. Introduction ..................................................................................... 4
2. Navigation......................................................................................... 5
2.1 Vibration monitoring ............................................................... 5
3. Data monitoring and control......................................................... 8
3.1 Monitoring................................................................................ 8
3.2 Controls ................................................................................. 10
3.3 Trending ................................................................................. 12
4. Utility ............................................................................................... 14
4.1 System screens ..................................................................... 14
4.2 User administration ............................................................... 17
4.3 Screen saver.......................................................................... 17
5. Setup ................................................................................................ 19
5.1 Basic setup............................................................................. 19
5.2 Setup of remote communication .......................................... 22
5.3 Setup of date and time ......................................................... 24
5.4 HMI language......................................................................... 25
5.5 PLC input and outputs ........................................................... 26
5.6 IFM Read data........................................................................ 27
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Introduction
1. Introduction
The Sabroe Vibration Monitoring system (SVM) performs continuous monitoring of the compres-
sor and/or motor vibration level. The system consists of up to four sensors/accelerometers
mounted as shown in Fig. 1.
Fig. 1: Sensor mounting on compressor and motor
The accelerometers are connected to an IFM VSE153 diagnostics module where the measured vi-
bration levels are converted to engineer values of registration. The PLC reads the vibration values
and analyses against alarm and shutdown settings to perform safe compressor operation at all
times.
The basic configuration can handle one IFM VSE153 module connected to four vibration sensors
used when monitoring both compressor and motor, or with only two sensors when monitoring on-
ly one part. In an extended configuration, one PLC/HMI can handle two IFM VSE153 modules
when used in a project with dual compressors.
The controls are built around a PLC and a 4” HMI panel. This concept allows the user to configure
some optional functions from the HMI panel without having to change anything, or very little, in
the software from one project to another. The hardware I/O is fixed, and external communication
interfacing setup can be prepared in the software package.
The compressors will be controlled by the UniSAB III while also being surveyed and controlled by
the PLC controller functioning as a data exchange gateway for remote communication with a DCS
system.
Sensor 1:
Compressor NDE
Motor
Sensor 2:
Compressor DE
Sensor 3:
Motor DE
Sensor 4:
Motor NDE
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Navigation
2. Navigation
2.1 Vibration monitoring
Example of screen #1, Main screen - single compressor unit
Screen header template
Navigation buttons and project icon for SVM01
Alarm screen access button
Quick navigation buttons for SVM01
Example of screen #2, Dual compressor unit.
Screen header template
Navigation buttons and project icon for SVM01
Navigation buttons and project icon for SVM02
Quick navigation buttons for SVM02
Touch buttons to access the ‘Compressor’ or ‘Motor’ monitoring screens
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Navigation
Example of screen #3, Compressor monitoring SVM01.
Example of screen #4, General headline dropdown menu.
Use the headline dropdown navigation for direct access to monitoring and control screens.
Use these quick buttons for direct access to:
F1 →Compressor >>SVM01<<
F2 →Motor >> SVM01 <<
F3 →Compressor >> SVM02 <<
F4 →Motor >> SVM02 <<
Note: General use of quick buttons.
The F buttons give access to screens as indicated above. Exceptions: with active compressor
monitor screen, using F1 will switch to ‘Compressor settings’ and vice versa. With active motor
monitor screen, using F2 will switch to ‘Motor settings’ and vice versa. When using F3 + F4 for sin-
gle unit setup, the screens for SVM02 unit will be shown with zero values →use F1 + F2.
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Navigation
Example of screen #5, Trend compressor SVM01.
With active trend screens, the normal headline template will not be visible.
Quick buttons will have a double function:
With active SVM01 Trend compressor:
• F1 →switch to Compressor monitoring screen (leaving trend screens).
• F2 →switch to SVM01 Trend motor.
• F3 →switch to SVM02 Trend compressor.
• F4 →switch to SVM02 Trend motor.
With active SVM01 Trend motor:
• F1 →switch to SVM01 Trend compressor.
• F2 →switch to Motor monitoring screen (leaving trend screens).
• F3 →switch to SVM02 Trend compressor.
• F4 →switch to SVM02 Trend motor.
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Data monitoring and control
3. Data monitoring and control
3.1 Monitoring
Example of screen #6, Compressor monitoring SVM01.
Fig. 2: Compressor monitoring screen
This screen shows the monitoring data of the compressor vibration sensors 1 and 2.
The monitoring screen shows that three objects are monitored on the compressor:
Sensor Position Object Unit Function
Sensor 1 Compressor NDE Bearing m/s2 Monitors frequency ranges that indicate
early signs of bearing wear, ignoring fre-
quencies that may give misleading signal
levels.
Sensor 2 Compressor DE Bearing m/s2
Sensor 2 Compressor DE 1 x mm/s Monitors vibration velocity at 1 x rotation-
al speed.
At the compressor monitoring screen (Fig. 2), the actual vibration level of each object is shown by
a barograph and an actual value reading above (1). The top value field (2) shows the peak value
since last reset activation performed in the compressor setting screen. The rightmost barograph
shows the actual motor speed with a reading (3). The barograph should have the actual max.
RPM as maximum value (4), see the setup section to change this value.
Note: During the first 60 seconds at start-up, the peak value will not be calculated, and the delay
timers for alarm and shutdown will not be timed. This is to ensure that the peak value calculation
has reference to compressor operation, and not only to start-up where a higher vibration level
must be expected.
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Data monitoring and control
Example of screen #7, Motor monitoring SVM01.
Fig. 3: Motor monitoring screen
This screen shows the monitoring data of the motor vibration sensors 3 and 4.
The monitoring screen shows that three objects are monitored on the motor, similarly to the
compressor:
Sensor Position Object Unit Function
Sensor 3 Motor DE Bearing m/s2
Monitors frequency ranges that indicate
early signs of bearing wear, ignoring fre-
quencies that may give misleading signal
levels.
Sensor 3 Motor DE 1 x mm/s Monitors vibration velocity at 1 x rotation-
al speed.
Sensor 4 Motor NDE Bearing m/s2
Monitors frequency ranges that indicate
early signs of bearing wear, ignoring fre-
quencies that may give misleading signal
levels.
At the motor monitoring screen (Fig. 3), the actual vibration level of each object is shown by a
barograph and an actual value reading above (1). The top value field (2) shows the peak value
since last reset activation performed in the motor setting screen. The rightmost barograph shows
the actual motor speed with a reading (3). The barograph should have the actual max. RPM as
maximum value (4), see the setup section to change this value.
Note: During the first 60 sec. at start-up, the peak value will not be calculated, and the delay
timers for alarm and shutdown will not be timed. This is to ensure that the peak value calculation
has reference to compressor operation, and not only to start-up where a higher vibration level
must be expected.
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Data monitoring and control
3.2 Controls
Example of screen #8, Compressor controls SVM01.
Fig. 4: Compressor settings screen
The compressor settings screen (Fig. 4) is used for setting of alarm and shutdown limits. The
three vertical columns showing sensors 1 and 2 alarms and settings are grouped identically with
the vibration data fields seen in the compressor monitoring screen (Fig. 2). Additionally, the col-
our marking relates to the settings for alarm factors and alarm delay settings.
The two upper data fields of ‘Alm’ and ‘SD’ (Fig. 4, (1)) are the final alarm settings in absolute val-
ue that will correspond to the monitoring value fields on the compressor monitoring screen.
The two middle data fields represent the ‘Alm and SD factor’ (2) that will be the multiply value
used to calculate the upper limits during the step 1 sweep session. The two lower data fields of
‘Alm and SD delay’ (3) are the timer setting in seconds to delay the alarm and shutdown action.
• Alarm will be shown in the alarm list and a digital output signal switched ON. Alarm status
has auto reset.
• Shutdown means compressor stop, where the normal ON digital output is switched OFF.
SD status has manual reset and must be acknowledged in the alarm screen and reset on
the red reset button on above screen (4).
Determination of alarm and shutdown limits can be made in one or two steps:
Step 1 is to perform an automatic setting sweep action in which the alarm and shutdown factors
are multiplied to the actual registered vibration value during a compressor running session,
changing the capacity slowly from minimum to maximum capacity. This should possibly be re-
peated to ensure representative initial state values. Step 2 is the possible overwrite of the limits
to operate with comparison values for easier overviews or to use experienced settings.
The left screen side (4) shows the ‘Auto alarm setting’. The upper timer field is the timer setting in
seconds (default 900 seconds) for the maximum sweep session duration time. The barograph
timer and the timer field above that are the actual timer counting of the sweep session. The baro-
graph will show counting from zero of activation and the above timer will do a countdown from
maximum timer setting.
The step 1 sweep session must be started on the green start button , by which the sweep ses-
sion will run either the maximum timer setting or may be stopped manually on the red stop button
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Data monitoring and control
after fulfilled capacity range running. Sweep session is normally used as a “one-off initial sys-
tem commissioning” to register the vibration level for the specific compressor/motor installation.
In other words, a direct “on site” operational condition performance.
See the Quick setup guide - Sabroe Vibration Monitoring for detailed guidance of the sweep
session.
Note: The red reset button is additional to the SD alarm reset also used to zero-set the peak
registration in the compressor and the motor monitoring screens. The reset button in both com-
pressor and motor settings are the same button in function.
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Data monitoring and control
3.3 Trending
Example of screen #9, Trend compressor SVM01.
Trend compressor shows the three trend values of the peak values as known from the compressor
monitoring screen. The left Y-axis has reference to the measured vibration data of the compressor
in the broadband range 0..40 m/s². The right Y-axis has reference to the measured vibration data
of the compressor in the unbalance rotation range 0..10 mm/s.
Example of screen #10, Trend motor SVM01.
Trend motor shows the two trend values of the peak values as known from the motor monitoring
screen. The left Y-axis has reference to the measured vibration data of the motor DE in the broad-
band range 0..40 m/s². The right Y-axis has reference to the measured vibration data of the mo-
tor DE in the unbalance rotation range 0..10 mm/s.
Note: The trending feature for the 4” HMI panel has a maximum of 10 tags total. The 10 tags has
therefore been divided in 5 tags for IFM01 and 5 tags for IFM02 on one PLC system.
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Data monitoring and control
The vertical line with default middle position shown can be moved to a specific X-axis time and by
that, the value reading in the tag line in the bottom screen area will show the exact value on se-
lected time.
Time range and time slot can be changed by using the ‘play’ and/or ‘zoom’ buttons in the lower
screen area.
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Utility
4. Utility
4.1 System screens
Example of screen #11, Utility screen.
The utility screen is used as a navigation access to other screens used for setup and information
of the system.
The top left button opens a new navigation screen named system screens.
Setup, Date & Time and HMI Language open a sub-screen used to edit setup or action changes.
IFM01 buttons open a sub-screen related only to that module control. If IFM02 has been selected
in the setup screen, another two buttons for IFM02 will be visible on the right screen side.
Example of screen #12, System screens.
The system screens contain three different sub-functions that can be divided into information
screens, setup functions and system control buttons.
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Utility
All buttons on the left screen side are access buttons to open sub-screens. The six coloured but-
tons on the right screen side are system control buttons and should only be used by system ad-
ministrator or persons with Siemens programming knowledge.
Example of screen #13, System diagnostic.
Look at the Sabroe logo on the upper left, and note that the polar bear is moving left and right.
This indicates the active communication.
Moving stepwise left to right in 7 steps: Communication CPU to HMI is OK.
If the logo remains steady, check for the most likely reasons:
• Lan cabling CPU-switch-HMI
• HMI in offline mode *)
• CPU in stop mode *)
*) See the system screen for commands that control the active HMI mode.
Moving stepwise right to left in 7 steps: Communication CPU to IFM is OK.
Jumping right to left in one stop, check for the most likely reasons:
• Lan cabling CPU-switch-IFM
• IFM module communication not selected, see section 5.1 Basic setup
• Mismatch of the IP address settings.
The PLC system screen is a diagnostic buffer view and represents a system screen, which can be
used for troubleshooting in case of system malfunction.
Note: This screen is a system screen and does therefore not contain project specific event lines.
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Utility
4.2 User administration
Example of screen #15, User administration.
User administration is the screen used to change default passwords to personalised passwords.
Changing a password can only be done by the administrator. The administrator must log in with
the user name ‘Administrator’ followed by the password ‘Admin’, which will open the screen
shown.
Select the bottom line to add a new user with name, password and group. Delete a user by select-
ing the line, highlight and delete the user name and acknowledge by pressing Enter.
Any place in the project where the operator is prompted for password in order to change a value,
any one of the above default passwords (DMG, DOP or PSW) can be used.
4.3 Screen saver
Example of screen #16, Screen saver.
To activate the screen saver function, the mode must be enabled. The ‘Inactive delay’ value will
be the time in seconds that the screen navigation will be unchanged.
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Utility
Adjust the ‘Brightness Saver’ to a suitable value that reflects screen saver mode in action. Adjust
the ‘Brightness Normal’ to a suitable value that reflects normal screen operation mode in action.
Note: The timer for inactivity is the timing from opening a new screen and will therefore not be
reset by any action on the open screen, such as adjusting values etc.
Example of screen #17, Screen saver, no
alarms
Screen saver, and alarm.
Example of screen #18, Shutdown active Screen saver and shutdown.
Note: The alarm message must be acknowledged on the alarm message screen before the SD re-
set is activated. If not, the warning icon will continue to show alarm message with 0 number of
messages until next active SD has been acknowledged, and the self-hold reset afterwards in that
sequence. Otherwise, a new power-up of the HMI will clear it.
An active shutdown will open the alarm pop-up screen. When closing the alarm screen or touching
the alarm icon, the screen saver will show the sad smiley. Touch the screen to switch back to
alarm screen and continue to highlight the alarm setting screen to analyse the shutdown limit and
then reset the shutdown.
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Setup
Example of screen #20, Setup
Changes require login. Monitoring devices selection
Unfold the dropdown menu and choose
between IFM01 or IFM01 + IFM02.
Unfold the dropdown menu to select project de-
vices i.e. two or four sensors used for vibration
monitoring.
Unfold the dropdown menu and select an
optional feature to read UniSAB III.
Select ‘EC01’ or ‘EC01 + EC02’ by Modbus TCP connection to the UniSAB III main board.
Select reciprocating compressor or screw compressor if no Modbus TCP to UniSAB III, to define
the main screen icon.
With the integrated Modbus TCP driver, the SVM system can read and allocate vital compressor
operation values to a data register.
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