CSI 6500 Machinery Health Monitor: Online Machinery Monitoring Product Data Sheet
CSI 6500 Machinery Health Monitor: Online Machinery Monitoring Product Data Sheet
January 2016
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 technologies for process automation and plant-wide predictive
really 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 protection, prediction, real-time performance monitoring
a 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 2016
- Case Expansion
- Differential Expansion
- Thrust Position
- Relative Vibration
- Absolute Vibration
Protect your critical machinery through protection, prediction, performance monitoring, and PlantWeb.
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
Other features that demonstrate the flexibility of the
time, and nuisance alarms are easily introduced. All too
CSI 6500 include:
often, plants don’t have the time or staff to complete the
Thrust monitoring: dual channel, complementary, min/max integration, leaving plant operators without key machinery
or absolute shaft position, measuring range shift, measuring health diagnostics.
range invert
The CSI 6500 eliminates this risk by easily providing machinery
Differential Expansion: flexibility for any type of health diagnostics to operators through the simple three step
ramp configuration Easy Integration with your control system.
Eccentricity: max., min., peak to peak, or distance from
clearance reference
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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.
Y Vibration Y Vibration
Y Vibration
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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
CSI 6500 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
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
T
H
LPB BRG-5
R
U
S
T
BRG-4
LPA BRG-3 BRG-2
HP BRG-1
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
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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
100+ hours of gapless turbomachinery continuous and
to 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 Plant-wide scalable monitoring solutions.
relays for machine shutdown protection, monitors for Web-based asset prioritization and maintenance planning.
machinery health alarms, and streams transient data to users
Real-time machine performance.
around the globe from the field-based processor. Intelligence
Graphical user interface.
in the field 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.
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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
2. Your online machinery monitoring system provides
plots tell you the bearing clearance was not exceeded. After
real-time continuous waveform recording to ensure events
fixing the oil flow issue, you restart the turbine. You watch
will not be missed. With AMS Suite, a running history is
the startup with AMS Suite for a real-time “inside the
always available. The field-based processor is a continuous
turbine” 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.
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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 Transient analysis.
Time-synchronous averaging.
Roll Process Industry Solutions Integration with CSI 2140 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 2140 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
a 3U rack when space is a concern. small 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 overlay. Integrated products means less learning and
with clarity. more results.
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Online Machinery Monitoring Product Data Sheet
January 2016
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.