Online Machinery Monitoring Product Data Sheet

O-6500-010614 January 2014

CSI 6500 Machinery Health™ Monitor

„„Extend PlantWeb® with API 670 machinery
protection monitoring
„„Integrate machinery protection monitoring with
DeltaV™ and Ovation™ automation systems in
three easy steps
„„Monitor your plant’s most critical rotating
machines
„„Gain real-time machinery health feedback
integrated with process automation
„„Transform vibration monitoring into predictive
alerts
„„Empower decisions through transient analysis of
turbines in AMS Suite
„„Balance of plant machinery health monitoring Real-time machinery health feedback integrates with process
includes PeakVue™ technology for rolling element automation so you can run your plant with confidence.
bearing and gearbox analysis

Overview The CSI 6500 Machinery Health Monitor is designed for process
automation and protection system upgrade projects. Housed
Five percent of the rotating machines in every plant have the in a single chassis, the CSI 6500 combines proven prediction
ability to bring production to a grinding halt. Although your and protection to provide a complete online machinery
critical machines have vibration shutdown protection systems monitoring solution. Emerson is the global leader of integrated
in place to prevent catastrophic failure, is your plant really technologies for process automation and plant-wide predictive
protected? technologies for managing both fixed and rotating assets.
What about the shocking repair costs, missed production The CSI 6500 is fully compliant with API 670 and integrates
goals, and unfulfilled customer commitments associated with a protection, prediction, real-time performance monitoring
trip or a missed trip? and process automation.
As many as 50% of machinery malfunctions that lead to The CSI 6500 is part of Emerson’s PlantWeb digital architecture,
downtime are process induced, and 90% are predictable – which provides enterprise-wide information needed for
even controllable. realtime decision making.
Online Machinery Monitoring January 2014

ƒƒ API 670 Compliant

ƒƒ Integrated protection and

prediction monitoring

ƒƒ Dual, redundant 24VDC, 120–

240VAC, 50–60Hz power input

ƒƒ PlantWeb Enabled: Ovation,

DeltaV and AMS Suite Compatible

ƒƒ Full TSI (turbine supervisory

instrumentation)

- Case Expansion

- Differential Expansion

- Thrust Position

- Relative Vibration

- Absolute Vibration

ƒƒ Small 3U protection only rack

available

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

Flexible for Retrofits A Protection System You Can

Your project may be a major revamp, including a control
Count On
system and vibration monitoring system update, or you may
The CSI 6500 is field-proven, providing API 670 protection
be making improvements in phases.
on the industry’s most critical equipment: steam turbine
If Phase 1 is only a protection system upgrade, the CSI 6500 is generators, gas turbines, boiler feed pumps, offshore
uniquely designed to offer protection-only for obsolete system compressors, pipeline turbo compressors, chemical industry
replacement. compressors, turbo exhausters, blowers, and boosters.

The CSI 6500 can even be deployed in a prediction-only Missed trips, false trips, and running blind are not acceptable
configuration to overlay on an existing protection system. in your plant.

Want to use your existing instrumentation? The CSI 6500 The CSI 6500 helps prevent missed trips by using module
works with any negative 24 VDC powered displacement self-health checking, instrumentation health monitoring and
sensors and drivers. hot swappable, external, redundant power. External power
removes heat and user “touches” away from the rack. The
In Phase 2 of your project, the prediction-only configuration or
same architecture is used in all Emerson process automation
protection-only configuration can be upgraded at any time to a
and critical SIS systems.
combined configuration by simply adding a few monitoring
modules. The CSI 6500 offers the most flexible and powerful
solution available for retrofit applications.

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The CSI 6500 is integrated with the Ovation and DeltaV process automation systems through an easy three step process to reduce
integration time from weeks to minutes. In addition, control strategies and graphical elements are automatically created, making GUI
development a snap.

False trips are addressed through features such as 2oo3 voting Integrated Machinery Protection and Prediction from Emerson
logic for increased decision accuracy and limiting channel count saves hundreds of man-hours and gives you a complete, error
to two channel modules. Two channel modules mean that free integration of machinery information with the DeltaV or
swapping a protection module will affect no more than two Ovation digital control system.
channels – an API 670 requirement.
Typical machinery protection systems can require 2,400 steps
Redundant communications ensures that the operator is never for 24 vibration channels to complete the integration process.
blind to machinery health information. It typically takes up to five days for complete integration. With
this many steps, network issues, additional testing time, and
Other features that demonstrate the flexibility of the CSI 6500
nuisance alarms are easily introduced. All too often, plants
include:
don’t have the time or staff to complete the integration,
„„Thrust monitoring: dual channel, complementary, min/max leaving plant operators without key machinery health
or absolute shaft position, measuring range shift, measuring diagnostics.
range invert
The CSI 6500 eliminates this risk by easily providing machinery
„„Differential Expansion: flexibility for any type of ramp health diagnostics to operators through the simple three step
configuration Easy Integration with your control system.
„„Eccentricity: max., min., peak to peak, or distance from
clearance reference

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Instrumentation Mounting location and instrumentation bracket design are

While the CSI 6500 delivers field-based intelligence, accurate both critical for quality data.
information starts with quality instrumentation. A complete range of sensors, adapters, cables, connectors,
Eddy current displacement sensors are the preferred method converters, and fittings are available for new installations,
for monitoring sleeve-bearing machines. These displacement retrofits, or replacement of sensors during an overhaul.
sensors penetrate the machine case and directly monitor the
„„Thrust position
motion and position of the shaft without contacting the shaft
„„Relative radial shaft vibration
surface.
„„Absolute radial shaft vibration
Accelerometers and velometers are the industry accepted
sensors for monitoring the health of gearboxes and rolling „„Rotor vs. case differential expansion

element bearings. Although temperature sensors are „„Bearing case vibration

sometimes used to measure health, temperature alone is only a
„„Case expansion, LVDT
small part of the machinery health picture. When a shaft begins
to rub the bearing as a result of misalignment, a displacement „„Rotor bow (eccentricity)

probe can directly track the misalignment behavior. By the time „„Valve position, LVDT
the rub is severe enough to trigger a temperature alarm, the
„„Key, phase, and speed measurements
damage is already done.

Large Steam Turbine Typical Instrumentation

Differential Expansion A X Vibration X Vibration X Vib
Differential Expansion B
X Vibration
X Vibration X Vibration

BRG-11 EXC BRG-10

GENERATOR BRG-9 BRG-10 BRG-8
LPC BRG-7 BRG-6

Y Vibration Y Vibration
Y Vibration

Y Vibration Y Vibration Y Vib

Case Expansion Rotor Speed Phase Process Input Shaft Absolute

Monitor
ƒƒ LVDTs mounted on both ƒƒ Speed monitoring – ƒƒ Vibration data is a vector ƒƒ Accepts 4-20 mA input and ƒƒ Shaft relative sensors
sides of the case measure machine state information, with phase and magnitude 0-10 volt input and seismic sensors are
expansion relative to the trending and triggering used to mathematically
foundation on turbines acquisition ƒƒ Changes in phase are as ƒƒ Accepts RTDs and produce a shaft absolute
greater than 250MW important to know as thermocouples directly measurement
ƒƒ Zero speed – signals the changes in amplitude
ƒƒ It is important to monitor operator to engage turning ƒƒ Inputs temperature, ƒƒ Absolute vibration
expansion on both sides for gear or alerts that turning ƒƒ A change in phase is a key pressure, flow, and other measurements are
bending, which could cause gear has failed indicator of a possible process parameters recommended for turbines
rotor to stator contact cracked shaft 250-650MW or greater
ƒƒ Rotor acceleration – Valve Position Monitor
indicates load changes and Seismic
coupling health ƒƒ Valve position can be used
to track changes in load ƒƒ Electrodynamic seismic
ƒƒ Reverse rotation sensor input for bearing
housing vibration
measurements

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See instrument spec sheets for complete specifications about It’s the Network
dynamic and static measurements. Emerson's experts ensure proper design and execution for the
ATEX Conformity for selected Products in accordance CSI 6500 implementation in the plant. From onsite assessment,
with EN 50 014 and EN 50 020, certified by the PTB
installation and project management to commissioning and
analysis of predictive diagnostics, Emerson offers a team of
CAN/CSA-C22.2 No. 61010-1-04: Safety Requirements for Electrical Equipment for
Measurement, Control, and Laboratory Use, Part 1: General Requirements world-class professionals and support network to ensure
UL Std. No. 61010-1 (2nd Edition): Safety Requirements for Electrical Equipment for success including:
Measurement, Control, and Laboratory Use, Part 1: General Requirements

„„Project Engineers design your system

„„Onsite Project Managers are your point of contact

throughout the project
„„Remote analysis personnel experienced in diagnostics are
available to offer a second opinion for increased confidence
„„Expert customer support is available 24/7 to answer the
urgent questions that protection systems require
„„A network of world-wide support provides global coverage
locally

continued...
Rotor Position A Governor Valve Pos 2 Governor Valve Pos 4
Rotor Position B LVDT LVDT
X Vibration
Eccentricity
bration X Vibration X Vibration X Vibration Case Expansion Right
Differential Expansion B
Differential Expansion A
X Vibration

LVDT

LPB LPA HP
H
R
BRG-5 U BRG-4 BRG-3 BRG-2 BRG-1
S
T

LVDT

Vibration
Y Vibration
Case Expansion Left
Y Vibration

bration Y Vibration
Y Vibration Governor Valve Pos 1 Governor Valve Pos 3
Phase B (SPR)
Phase A (Prime) LVDT LVDT

Case Piezoelectric Dual-Thrust Position Eccentricity Differential Expansion

ƒƒ Used for rolling element bearings and ƒƒ Thrust is an axial position near the ƒƒ A measure of rotor bow during ƒƒ Differential expansion is a radial
gearboxes thrust bearing and is one of the most startup, typically monitored from 0 rotor position measurement
critical measurements on a high-speed to 600 rpm
ƒƒ Also used for aero-derivative turbines turbine ƒƒ Differential expansion sensors
where rolling element bearings are ƒƒ Rotor bow changes when thermal are mounted on the case and
used ƒƒ At least two thrust sensors, for conditions change during startup, measure the position of the
redundancy and for voting logic are shutdown or even production state rotor relative to the position of
ƒƒ Use PeakVue processing on rolling recommended the case
element bearings and gearboxes ƒƒ At least one displacement sensor in
ƒƒ Thrust bearing deterioration, failure, the high pressure section targets an ƒƒ Recommended for turbines
or sudden changes in steam pressure eccentricity collar 250MW and greater
can quickly move the rotor axially and
cause collisions with rotor and stator ƒƒ Configurations may be ramp or
complementary

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With Emerson’s PlantWeb digital architecture, your plant is

blanketed with predictive, digital intelligence that gives you
back time – time to plan, time to make decisions, and time to
stay focused on your business results.

Real-Time Machinery Health for Maintenance

In a perfect world, machines would behave as expected and
predictive maintenance applications like AMS Suite: Machinery
Health Manager would automatically diagnose turbine
malfunctions for you. But in the real world, sometimes you
need powerful diagnostic tools to justify and support your
machinery diagnosis.

The CSI 6500 is designed for real world challenges with

field-based intelligence, continuous simultaneous data
When machinery protection already exists, or is not needed, recording, live data viewing on all channels, and playback
the CSI 6500 can be deployed for machinery health monitoring. capability. You can playback the turbine shutdown, or
When installed in the rear signal termination configuration, startup, or even the bump in the night for your staff as
the CSI 6500 can accept up to 48 vibration inputs. you are explaining the results.

With the CSI 6500 transient analysis option, nothing is missed,

Proven Machinery Health everything is captured – no snapshots. Any question from
The performance of turbomachinery is critical, and you need management about turbomachinery health can be answered
real-time feedback, recorded machinery condition, and the with continuous data and playback capability. With snapshots
ability to replay it for another view with deeper analysis. it’s a gamble. For high speed, critical turbomachinery, Emerson
And you need it applied across the entire machine train, brings the most powerful predictive diagnostics in the world to
simultaneously. Meeting this demand is one of the greatest you.
technology challenges of machinery health diagnostics. The
answer is field-based predictive intelligence. Power of Planning for Maintenance
Analysis Parameters
The CSI 6500 is uniquely designed with field-based intelligence
In addition to protecting assets and real-time monitoring of
that combines a protection system and a machinery health
turbomachinery, the CSI 6500 also takes a microscopic look
monitoring solution into one simple platform. With it, you have
at your turbine from a fault development and maintenance
access to all of this information around the plant or around the
planning perspective. Up to 255 analysis parameters can be
world.
defined per CSI 6500 for diagnosing various malfunctions
When a turbine starts up cold, the entire machine grows as through waveform and spectrum dissection.
it experiences extreme thermal conditions. The shaft grows
For each analysis parameter, LOLO, LO, HI and HIHI alerts and
rapidly. The case grows more slowly. Speed increases and tight
alarms can be set. Parameters such as multiples of 1x peak
clearances tighten. For your operator, seamless integration to
and phase, 3-8x energy common to looseness, sub
the existing Ovation or DeltaV process automation system
synchronous bands for oil whirl, 0.5x for rubs, and even
provides real-time machinery health feedback to run the
diagnosis around waveform shapes are continuously at work.
process with confidence without adding a PC to the control
For turbomachinery driving compressors or pumps through a
room or learning a new software package. The operator is
gearbox, the CSI 6500 includes patented PeakVue technology
unaware that these lively updates are coming directly to their
for monitoring gearboxes and rolling element bearings.
environment from underlying bus or Ethernet technology.

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

Adaptive Monitoring „„Real-time updates of custom predictive parameters to

An increase in vibration isn’t necessarily a cause for alarm. It process automation through bus technology
may be perfectly normal for vibration to increase when load „„Event-based adaptive monitoring and alerts
increases – to a degree. The CSI 6500 has the unique ability to
„„100+ hours of gapless turbomachinery continuous and
adjust monitoring strategy based on changing process
simultaneous transient recording for all channels
conditions. This is possible through the field-based processing
engine enabling event-based collection and adaptive „„Plant-wide scalable monitoring solutions

monitoring. AMS Suite: Integrated Family of Software Tools

The CSI 6500 will adapt its monitoring strategy based on AMS Suite is a family of best-in-class predictive diagnostics
different operating conditions, such as changing load or speed. software applications that enables both plant-wide LAN and
Where you once had one trend window for a vibration WAN asset management.
parameter, you can now have two trend windows – one for When applying AMS Suite to your critical equipment you gain:
100% load, and one for 110% load – each with independent
analysis and alerts. „„Predictive monitoring for both fixed assets and rotating
assets
Field-Based Intelligence
„„Powerful predictive analysis tools (plotting, trending,
Field-based intelligence powers the advanced predictive
transient, spectral analysis, PeakVue technology, auto
features of the CSI 6500. Similar to a process automation
correlation, statistical analysis)
architecture where the field-based controller performs
monitoring and control in the field the CSI 6500 controls relays „„Web-based case history viewer

for machine shutdown protection, monitors for machinery „„Web-based asset prioritization and maintenance planning
health alarms, and streams transient data to users around the
„„Real-time machine performance
globe from the field-based processor. Intelligence in the field
„„Graphical user interface
enables:
„„Process parameter import

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AMS Asset Graphics combines protection, prediction and Use the Live 3D Shaft Animation to see the motion of the shaft
performance details at the equipment layer through intuitive around the average bearing shaft centerline. All aspects of the
graphical information. display, including angle of view and playback speed, are controlled
by the user.
AMS Suite: Asset Graphics
AMS Asset Graphics provides a simple graphical view of process Specific for turbomachinery, AMS Machinery Manager includes:
parameters, protection parameters, machinery health „„Transient real-time live sessions
information, and equipment performance information. AMS
„„100+ hours of recorded turbine data – start-up, shutdown,
Asset Graphics provides an operator view, with a machinery
and production state monitoring
health focus while residing in the maintenance department.
„„Turbine replay of any recorded session
AMS Asset Graphics includes:
„„3D machine analysis with ME’Scope
„„Graphical turbine / machine display with bar charts
„„Local cabinet graphical display
„„Event / alarm log
„„Touch screen support
„„Trending of vibration and process parameters
„„3D shaft animation for in-depth analysis
„„Notification (email, text message)
„„Web-based Machine History Viewer
„„Local cabinet graphical display
„„Collaboration tool for knowledge exchange
„„Touch screen support
„„Waveform audio replay
With the open architecture, you can integrate information to
„„Configurable online watch updates
and from existing applications and systems such as existing:
„„Full spectrum analysis, including shaft rub detection
„„ModBus-compliant protection systems
„„Shaft centerline resting position detection
„„ModBus or OPC-compliant process control system

„„OPC or SQL-compatible historians

Transient Real-Time Live Sessions
Field-based intelligence connects you directly to the machine.
AMS Suite: Machinery Health Manager This unique architecture enables the AMS Suite to provide
After AMS Asset Graphics identifies changes and a potential powerful predictive tools not possible through PC based data
machinery malfunction, AMS Machinery Manager provides an acquisition systems. Overall vibration trends, orbits, shaft
accurate assessment and comprehensive view of each centerline, Bode/Nyquist, cascade, waveform and spectrum
monitored machine in your facility. can all be viewed live, for all bearings desired, simultaneously.
AMS Machinery Manager integrates data from multiple
technologies into a single database for analysis and reporting.

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scenario
When the Turbine Trips 3. Your live turbine view will support real-time decisions

You are comfortably home for the evening when the phone during startup.

rings and you learn the turbine just tripped. The decision to When you arrive onsite, you learn it was a manual, operator-
restart the equipment is yours. Although you feel the initiated trip. The operator had real-time vibration data from
pressure, you are confident because you have two powerful the CSI 6500 and real-time oil temperature and pressure
tools to rely on – continuous data recording to replay and diagnostics from the process automation system that
analyze the event and a live mode to provide feedback indicated the turbine should be brought down. In fact, the
during startup. Hours of live recorded data before, during maintenance team had already found the plugged oil line to
and after the turbine trip is waiting for you. the bearing. Now the only questions are “How much damage

As you drive to the site, you review the facts: was done? And can we restart?” Thankful for multi-channel,
continuous data recording, you look at the quick views and
1. You have the proper setup to capture the data
extract the region of interest for more analysis.
surrounding the event. You are assured the right data and
the anomalous event is captured. You review the data, compare with baseline, and confirm the
vibration is isolated to one bearing. The shaft centerline plots
2. Your online machinery monitoring system provides
tell you the bearing clearance was not exceeded. After fixing
real-time continuous waveform recording to ensure events
the oil flow issue, you restart the turbine. You watch the
will not be missed. With AMS Suite, a running history is
startup with AMS Suite for a real-time “inside the turbine”
always available. The field-based processor is a continuous
view.
data recorder and records and buffers up to 100+ hours of
continuous time waveforms simultaneously at all bearings. The integrated online machinery monitoring solution of

Auto-archiving of data is also included so that small, prediction, protection, performance monitoring, and

one-hour snapshots can be saved to a network server. PlantWeb allowed you to easily access critical information to
make a confident decision.

100+ Hour - Turbine Data Recorder Turbine Replay

A 100+ hour buffer of continuous time waveforms are Replay the data so you can watch the anomaly, the startup or
simultaneously recorded for all sensors, all bearings, across the the shutdown again. During replay, change the filter on your
entire machine train. If an interesting event occurs, a manual or orbit or change the 3D perspective of the cascade plot to fine
auto archive automatically and permanently saves a continuous tune your analysis criteria to highlight the issue to your staff.
slice of the running window. This slice can be analyzed, stored,
or recalled to overlay on current data.

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3D Machine Analysis with ME’Scope

ME’Scope uses 3D graphical animation to visually show how
your machine or structure is moving. See overall movement,
and movement of one part relative to another. Right-click a
transient waveform through built-in menus to automatically
send data to ME’Scope to see the animations in slow motion.
You can identify malfunctions in your machines that could not
be seen through any other analysis.

The front termination panel option is specifically designed for

wall-mount enclosures in the roll process and metals industries.

The CSI 6500 includes these predictive monitoring capabilities

to address these issues:

„„PeakVue

„„Order tracking
The CSI 6500 provides solutions to address key issues such as asset
malfunction, barring, or chatter in the paper mills and roll process „„Transient analysis

industries. „„Adaptive monitoring

„„Time-synchronous averaging

Roll Process Industry Solutions „„Integration with CSI 2130 Machinery Health Analyzer routes
In paper mills and the metals industry, a single bearing or asset „„Over 24 definable analysis parameters per sensor
malfunction can result in a “wreck”. Barring or chatter can
„„Integration with AMS Machinery Manager
cause variation in caliper or basis weight, which means poor
product quality. The CSI 6500 prediction solution is the perfect fit for continuous
roll process applications. The front termination panel option is
And simple process changes like misaligning a stretch roll
designed specifically for wall-mount enclosures so the
without feedback to the process automation system can
field-based monitor can be installed near the machines. This
destroy bearings and result in downtime.
saves on cable costs and installation costs.
Asset malfunctions monitoring, product quality monitoring,
and feedback to process automation are the components of a
PeakVue
PeakVue is the industry standard for early identification of
complete solution for the roll process industries.
rolling element bearing and gearbox problems. The same
technology used in the CSI 2130 is also available in the online
monitoring solution. Undetected dryer and inner race cracks
are a thing of the past when you catch them real-time, instead
of on a monthly route.

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The CSI 6500 can be configured for protection only and provided in Prediction monitoring capabilities can be configured into a small
a 3U rack when space is a concern. rack to give you powerful capabilities while requiring minimal
space.
Order Tracking
Order tracking is a unique tool for winders and machines Portable vibration and online vibration data can be viewed in
constantly changing in RPM where spectral data would the same database simultaneously and dragged onto a plot to
otherwise be smeared and useless. View critical data with overlay. Integrated products means less learning and more
clarity. results.

Transient Analysis Over 24 Analysis Parameters per Sensor

Transient analysis, developed for turbines, allows for Over 24 analysis parameters for one sensor means flexibility
monitoring of many channels simultaneously. For press in automatic diagnostics. Set up multiple parameter windows,
sections and calendar stacks, transient analysis is the only and analysis characteristics to get the alerts you want without
way to see rapidly changing information simultaneously. bothering with routine analysis. The analysis is still there when
you need it.
Adaptive Monitoring
Adaptive Monitoring is made possible through intelligent In paper and metals, three aspects of monitoring are crucial:
monitoring in the field. Vibration data is collected and „„Instant overall vibration feedback for rapidly changing
processed in the field much like the field-based controller machine malfunctions
of a process automation system. This allows advanced and
„„Product quality to operators
flexible analysis and calculations in the field while reducing
data sent back to the user. „„Detailed machine health assessment over time to help
manage maintenance activities
Time-Synchronous Averaging
The CSI 6500 delivers the fastest and most powerful predictive
In a press nip, multiple rolls are in contact, which means
capabilities on the market.
vibration from one roll will be transferred to all the rolls in nip.
With time synchronous averaging, vibration sensors, and a
tachometer on each roll, vibration can be pinpointed to the
specific roll, even when it is in nip.

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O-6500-010614 January 2014

Emerson’s Power and Water Our experts will: INSTALL the technology and complete your
initial set up; then IMPLEMENT the technology by prioritizing
Industry Center your mechanical assets and optimizing your alert parameters
Designed specifically for the power generation and water/ to integrate the technology in your work processes to increase
wastewater treatment industries, the Ovation process your maintenance and operational efficiency and ensure impact
automation system offers integrated asset management to your bottom line.
through the CSI 6500 and seamless incorporation of intelligent
field devices for optimum control of critical processes. Ordering Information
Please see individual Monitoring Module spec sheets for specific
The PlantWeb Advantage functionality and part numbers.
Get off to a strong start with your technology investment.
Use Emerson’s Asset Optimization Services to ensure you
are effectively employing the CSI 6500 and your online
machinery monitoring solution. Emerson experts can
help you use diagnostics from your critical machinery
to full advantage.

©2014, Emerson Process Management.

The contents of this publication are presented for informational purposes only, and while every effort
has been made to ensure their accuracy, they are not to be construed as warranties or guarantees,
Emerson Process Management
express or implied, regarding the products or services described herein or their use or applicability. All
Asset Optimization
sales are governed by our terms and conditions, which are available on request. We reserve the right
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T (865)675-2400 All rights reserved. AMS, PlantWeb, PeakVue, Ovation, DeltaV, and Machinery Health are marks of
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