IRD8800 - API 670 Compliant Vibration Monitoring System

IRD8800 - API 670 Compliant Vibration and Condition Monitoring System

Made in India, Made for the World, IRD8800 is a Series of Vibration and Condition Monitoring System which is API 670 Compliant and is used to Monitor and Protect Critical Assets of a Plant such as Motors, Pumps, Fans, Turbines, Compressors, etc.

IRD8800 at a glance

An API 670 compliant, rack-mounted machinery protection and condition monitoring system, designed and built in India by IRD Mechanalysis (founded in 1955) to protect critical motors, pumps, fans, turbines and compressors.

Hot-swappable modules for casing and shaft vibration, axial shift, differential expansion, eccentricity, speed, reverse rotation, temperature and other process inputs
Reverse rotation monitoring via the M88925 module (dual eddy-current probes; direction indicated by front-panel LEDs)
Two power sources can feed each module; an OR-ing diode in the module’s SMPS enables seamless power redundancy.
Isolated 4–20 mA output per channel, redundant MODBUS RTU/TCP-IP, alarm, trip and transducer-fail relays, buffered waveform via BNC
Every module, rack and panel burn-in tested for at least 4 hours before dispatch; extended burn-in as part of FAT on request
3-year warranty on the online system

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Our Cabinets

IRD8800 systems are built, wired and burn-in tested in free standing cabinets at our Works in Thane before dispatch.

Row of IRD8800 free standing cabinets with illuminated module displays during burn-in test — **Burn-in test** – a row of finished IRD8800 cabinets under power before dispatch.

IRD8800 racks of M88200 monitor modules behind the glass door of a Rittal cabinet — **Front view** – two 8-slot IRD8800 racks behind a glazed Rittal door.

Rear wiring of an IRD8800 cabinet with four labelled rack backplanes and cable ducts — **Rear wiring** – four rack backplanes, neatly routed in cable ducts.

Labelled MCBs for mains, redundant and auxiliary power inside an IRD8800 cabinet — **Redundant power** – separate MCBs for mains, redundant and auxiliary supplies.

IRD8800 cabinets with racks and modules fitted, on factory floor for testing — **Factory testing** – cabinets on burn-in at our Works.

Internal Wiring and Elements of a Panel

IRD8800 API 670 Compliant Monitoring System is usually supplied in Free Standing Cabinets. These Cabinets can be of Size 2200 (H) x 800 (W) x 800 mm (D) (most popular) or 1500 (H) x 600 (W) x 600 (D) mm. For the convenience of the User, our Panels are equipped with the following as standard:

Industrial-grade screwless DIN-rail terminals for Signal Input, Current Output, Relay Contacts and MODBUS RTU Output connections
Industrial-grade service socket for connecting auxiliaries
LED Lamp with Door Switch for convenience of User at time of access
Ventilation and exhaust fans for system cooling and longer life
Isolated and Non Isolated Earth Bus Bars

A typical free standing cabinet 2200 (H) x 800 (W) x 800 (D) mm can contain upto 1000 terminals for Input/Output/Relay connections

Salient Features

Hot-swappable modules compliant to API 670. Two power sources can feed each module, and an OR-ing diode in the module’s SMPS enables seamless power redundancy.

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Burn-In Test

All Modules, Racks and Panels of IRD8800 manufactured at our Works undergo a Minimum of 4 Hours of Burn-In Test. It is a part of our Standard Practice and an important step in our Quality Check.

If Customers demand - we also carry out 24 hours, 48 hours, 96 hours or 120 hours Burn-in Test as part of Factory Acceptance Test (FAT) prior to dispatch.

During the Burn-in Test - the modules, racks and panels are subjected to the same conditions - power supply, inputs, outputs and ambient temperature and humidity - that they shall face when they are put to use.

Internal Wiring and Elements of a Panel

Industrial-grade screwless DIN-rail terminals for Signal Input, Current Output, Relay Contacts and MODBUS RTU Output connections
Industrial-grade service socket for connecting auxiliaries
LED Lamp with Door Switch for convenience of User at time of access
Ventilation and exhaust fans for system cooling and longer life
Isolated and Non Isolated Earth Bus Bars

A typical free standing cabinet 2200 (H) x 800 (W) x 800 (D) mm can contain upto 1000 terminals for Input/Output/Relay connections

NEXT Button

Being able to quickly view Sensor Bias/Gap Voltages, Alarm Setpoints, Trip Setpoints and Machine RPM is a Boon. To help users of IRD8800 do so - each IRD8800 Module is equipped with a NEXT button. Long pressing it allows the user to see the Bias/Gap Voltages first for each channel, thereafter each press of NEXT button takes user to the screens where they can quickly view Alarm Setpoints, Trip Setpoints, Machine RPM and Firmware Version for the Module.

Getting this information of a Blind Module is a more challenging task and thus we take pride in giving our users this feature for their convenience.

General Specifications of IRD8800 Series Signal Modules

Programmable

Measurement units, ranges, warning (alarm), trip levels, sensor sensitivity, band pass filters etc can be set from the password protected front keypad at any time. For a Customer convenience, specified units and ranges will be factory set at time of order.

Display

The front panel has 100 segment Dual Bar Graph and two rows of 16 character Digital displays. Signals are displayed as a percentage of the Full Scale Range of the Bar Graph, as well as the Warning (Alarm) and Trip values, when selected. This user-friendly feature enables Operators to view the relationship in terms of percentage (%) between the measured value and the warning or trip settings. Actual signal levels in native units are also shown on the Digital Display along with sensor bias/gap voltage and speed (with a tacho signal) by selection.

Communications

DCS – The system provides industry standard isolated 4-20mA DC signal output per channel for interfacing with Distributed Control System (DCS) as well as RS485/MODBUS connectivity as standard.
SCADA - The RS232 output is available as an option to SCADA systems.
Multi-Channel Simultaneous Diagnostics - Taking you Further, BNC connectors are also at the rear back plane of each module for providing buffered Time Wave Form (TWF) signals to any on-line multi-channel simultaneous or scanning diagnostics system. This offers comprehensive turbine diagnostics, applying the Dual Redundancy Parallel Processing (DRPP) architecture that provides greater system reliability.
Analyzer Outputs – Where applicable, three BNC connectors, one for each channel and the third for tacho/phase reference are located on the front panel for use with a portable dual channel FFT vibration analyzer. Shaft phase measurement is available when a Tacho Module is installed. The same vibration BNC signal sockets are repeated at the rear of the rack.

Independent Warning (Alarm) Relay

The Warning (Alarm) Relay operates when an alarm occurs in any module. One change-over (SPDT) potential free contact rated at 5A resistive @ 230V AC is provided. Normally de-energized (non fail-safe), or field changeable to normally energize (fail-safe). Reset is manual and is actuated only when the signal level goes below the pre-set alarm level.

Independent Trip Relay

The Trip Relay operates when trip occurs in any module. Two change-over (DPDT) potential free contacts rated at 5A resistive @ 230V AC are provided. Normally de-energized (non fail-safe), or field changeable to normally energize (fail safe). Reset is manual and is actuated only when the signal level goes below the pre-set trip level.

Common TX Fail Relay

The TX Fail Relay operates when any transducer failure (change in bias voltage) is detected; it is displayed by a flashing bar graph on the front panel of the module. One change-over (DPDT) potential free contact rated at 8A @ 230V AC or 24 V DC is provided. Normally de-energized (non fail-safe), Reset is automatic when fault condition returns to normal. Alarm and Trip relays are deactivated and also the 4-20mA DC output is pulled below 4mA to 2.8mA in TX Fail condition.

Start-up Protection

Start-up control bus deactivates Alarm and Trip relays and also pulls 4-20mA DC output below 4mA indicating invalid signal to the DCS.

Power Supplies

90 – 270V AC, 50/60Hz, single phase, 30VA per module. The redundant power source can be either 230V AC or 110V AC or +48V DC or +110V DC or +220V DC. Two power sources can feed each module; an OR-ing diode in the module’s SMPS enables seamless power redundancy.

Calibration

Each vibration module is calibrated to National Standards via the IRD Mechanalysis state-of-the-art full frequency digital calibration system with an international traceable certification that is always valid.

Wiring

Barrier terminal strips are provided for all external wiring. Conduit entry holes are available at the bottom of the Main Rack Frame.

Type Tests

The following primary Type Tests have been passed and will remain current:

Dry Heat Cyclic, IS:9000 P-III
Damp Heat Cyclic, IS: 9000 P-V
Bump IEC 68-2, Vibration IEC 68-2, Humidity IEC 68-2
Mark, European Union – IEC61326 EMI/EMC and IEC61010 Safety

Environmental

Storage temp: -18°C to 70°C
Operating temp: 0°C to 65°C ambient
Humidity: 95% non condensing

Available Modules and Compatible Inputs

IRD8800 is a Rack Based Monitoring System. The Rack slots can be filled with Hot-Swappable Modules which can be wired to different types of Input Sensors to perform different types of Measurements.

The Table below summarises the module options available and the compatible input sensors for the modules

Module	Measurement Function	Input Sensor	No. of Channels	Measured Units	Data Sheet
M88200	Casing Vibration - It is a measurement of the Absolute Vibration of the Bearing Casing; Keyphasor - It acts as the phase reference point in Vibration Analysis	Accelerometer/Velometer for Vibration; Eddy Current Probe for Keyphasor	2 for Vibration; 1 for Keyphasor	g Pk, g RMS m/s/s Pk, m/s/s RMS mm/s Pk, mm/s RMS i/s Pk, i/s RMS microns Pk-Pk, mils Pk-Pk	Data Sheet of M88200-DC
M88210	Relative Shaft Vibration - It is a measurement of the Shaft Vibration Relative to the Bearing; Keyphasor - It acts as the phase reference point in Vibration Analysis	Eddy Current Probes for Vibration and Keyphasor	2 for Vibration; 1 for Keyphasor	Microns Pk-Pk
M88250	Casing Vibration - It is a measurement of the Absolute Vibration of the Bearing Casing; Keyphasor - It acts as the phase reference point in Vibration Analysis	Inductive Velocity for Vibration	2 for Vibration; 1 for Keyphasor	mm/s Pk, mm/s RMS, i/s Pk, i/s RMS, microns Pk-Pk
M88280	Generator End Winding Vibration - It is a measurement of the Absolute Vibration of the Stator End Winding within a Generator	Charge Amplifier with an input from high temperature charge output accelerometers	2 for Vibration	LF1 (50/60Hz), LF2(100/120Hz) mm/s Pk, mm/s RMS, i/s Pk, i/s RMS microns Pk-Pk, mils Pk-Pk
M88285	Absolute Vibration (Stator End Winding Monitoring)	Fibre-optic (FBG) vibration sensor	2 for Vibration	microns Pk-Pk
M88300	Axial Shift (Gap)	Eddy Current Probe	2 for Axial Shift	+/- mm, +/- mils	How M88300 monitors gap
M88400	Cam Valve	Rotary Potentiometer	2	%, Deg, mm, inch
M88500	Differential Expansion*	Eddy Current Probe	2	+/- mm, +/- mils
M88600	Eccentricity	Eddy Current Probe	2	microns pk-pk, mils pk-pk
M88700	Other Parameters (Pressure, PF, Load, etc)	4-20 mA DC	2	User Defined
M88750	Vibration and Temperature	IRD544M Velocity Input & RTD 3-Wire Input	2	mm/s Pk, i/s Pk, microns P-P , mils Pk-Pk Deg C or Deg F
M88800	Shell Expansion	LVDT	2	mm, inch
M88900	Speed Monitor**	ECP - User Defined	2	RPM
M88925	Reverse Rotation	Dual ECP Input Sensors	1	Direction by LEDs
M88950	Temperature	RTD (3 Wire)	4	Deg C or Deg F

Information available on MODBUS Output

The Redundant MODBUS RTU/TCP-IP Output available per Rack on the Rack Backplane provides the following information for integration in DCS/PLC/SCADA:

Trip Level Setting
Trip Hysteresis count
Trip Fail Safe Logic setting
Trip Relay Latch setting
Trip Turn ON Delay time
Process Value

Alarm Level Setting
Alarm Hysteresis count
Alarm Fail Safe Logic setting
Alarm Relay Latch setting
Alarm Turn ON Delay time
Gap Voltage

Full Scale Range
Sensitivity Unit
Sensitivity Setting
Display Unit
Low Pass Filter Selection
Relay Status

High Pass Filter Selection
Noise
Tx Fail Low Level Setting
Tx Fail High Level Setting
Startup Delay Time
Process Status

Please feel free to reach out to our Sales Team with any questions that you may have about the System and we shall be happy to answer the same. You can send us your requirements for this system using the adjacent Email Button

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