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ITT i-ALERT2 Application Manual

Equipment health monitor
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Application Guide

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Summary of Contents for ITT i-ALERT2

  • Page 1 Application Guide...
  • Page 2 Application Guide 2 of 64...

  • Page 3: Table Of Contents

    Vertical Electric Motors ............................ 25 Vertical Pump ..............................26 Mixers ................................26 Vacuum Pumps ..............................26 .............................. 27 OUNTING ETHODS COMMISSIONING ............................27 -ALERT2 E : ................. 27 TEPS TO ACTIVATE THE I QUIPMENT EALTH ONITOR i-ALERT2 Application Guide 3 of 64...
  • Page 4 Equipment Details ............................47 Parts List / BOM ............................... 48 Pump Curve ..............................49 Commands ................................ 50 ..............................51 EPORT ENERATOR /FAQ ................................60 ..............................61 ERVICE OCATOR ................................ 62 ETTINGS TECHNICAL REFERENCES ..........................62 i-ALERT2 Application Guide 4 of 64...

  • Page 5: Introduction

    Using the latest Micro-Electromechanical Sensors (MEMS) and Bluetooth® wireless communications technologies ITT has created a tool to better fit the needs of reliability practitioners. The i-ALERT2 Equipment Health Monitor is a low cost alternative that continuously trends key machinery health parameters including overall vibration and temperature and allows users to access that trend data during routine inspections.
  • Page 6 Operators can collect high quality, Optimizes repeatable, vibration and Equipment temperature data with no training. Improves Reliability Safety Enables Wireless communication allows a user to collect data a safe distance from rotating equipment hazards. i-ALERT2 Application Guide 6 of 64...

  • Page 7: How I-Alert2 Monitor Augments A Condition Monitoring Program

    Traditional monthly walk around monitoring with a portable data collector requires at least 2 months to generate 2 points or a “trend” upon which a baseline condition can be established. In 2 months, the i-ALERT2 monitor can measure and store 720 points, giving the PdM practitioner a superior level of confidence and understanding of the equipment’s behavior.

  • Page 8: Reliability Overview

    “wearing out” or what might be termed an “age-related” failure pattern. Bromberg US Navy UAL 1968 Failure Curves 1973 1982 Time Figure 2: Failure curves Those that are age-related are almost all corrosion in seawater applications with a relatively predictable lifecycle. i-ALERT2 Application Guide 8 of 64...

  • Page 9: Introduction To Condition Monitoring

    3. Maximize the ability to detect randomly occurring failures after a successful startup. The i-ALERT2 Equipment Health Monitor is designed to provide all of these functions while still maintaining cost effectiveness. Always consider the benefits a new condition monitoring technology will provide against these proven failure curves to ensure it will be effective.

  • Page 10: Step 1.Notice: Detection Of Problems

    Route functionality is a cornerstone of the i-ALERT2 condition monitor’s value. One of the strengths of the i-ALERT2 monitor is the ability to broadcast the machine’s condition without having to wirelessly connect to it. The data collected is designed to indicate when a change has occurred or when a preset limit has been exceeded.

  • Page 11: Step 3.Resolve: Correction And Improvement

    “precision state” levels after it has been repaired. This will extend the life of the machine. Figure 6: Precision repair at an ITT PRO Service center STEP 4.DOCUMENT After determining the root cause of the problem, correcting the problem and improving the machine, it is important to verify that the correction/improvement has occurred and document the findings.

  • Page 12: System Overview

    ITT is free from this commercial constraint and will continue to utilize the best and latest technology that allows our customers to optimize the reliability of their rotating equipment assets.

  • Page 13: Device Overview

    Privacy Policy. The i-Alert2 may use Version 1 or Version 2 firmware. To determine which version you have, in the App go to “Equipment Info, i-ALERT Information” where the device version number will be shown., Alternatively, for the Version 2 units, the sticker on the back of the device will have a manufacturing date after 8/22/2016.

  • Page 14: Hardware Specifications

    For systems deemed critical, a full Reliability Centered Maintenance (RCM) analysis should be performed. One approach to determine criticality is to use tables similar to those below to assess consequence and probability. i-ALERT2 Application Guide 14 of 64...

  • Page 15: Machine Selection Criteria

    In order to maximize the return on investment for any given CM system, it has to be applied to the correct machinery. The following tables and comments help illustrate the best fits for the i-ALERT2 condition monitoring system. i-ALERT2 Application Guide...

  • Page 16: Where To Start

    • The upper and lower frequency cutoffs for the i-ALERT2 devices are 1000 Hz and 10 Hz respectively. Just as with any condition monitoring instrumentation, it is recommended that the machinery shaft speed and primary potential fault frequencies fall within this range.
  • Page 17 However these systems are generally very expensive and cannot be applied to all assets in a plant. The low cost and ease of installation of the i-ALERT2 monitor make it a perfect device to bridge the gap between machinery protection systems and periodic inspections. In fact, the i-ALERT2 monitor can completely supplant the use of portable data collectors for monthly inspections.

  • Page 18: Condition Monitoring Measures

    ISO 10816 standard. These limits can and should be modified based on the equipment’s actual vibration data and user’s experience. Remember, a doubling of the overall vibration is almost always related to a change in machine condition. i-ALERT2 Application Guide 18 of 64...

  • Page 19: Kurtosis

    KURTOSIS Monitoring of Kurtosis is a somewhat unique feature in condition monitoring equipment that separates the i-ALERT2 monitor from traditional overall vibration meters. Kurtosis is a mathematical function that indicates how “peaky” a data set is. It is related to Crest Factor which is another commonly used vibration parameter used to assess machine condition.

  • Page 20: Installation Best Practices

    GENERAL GUIDELINES In general the ideal place to mount the i-ALERT2 device is as close as possible to the machines bearings in a place where the LEDs can be easily observed. Since the primary function of the i-ALERT2 device is to monitor for changes in condition, it is not critical that the device be placed in the “load zone”...

  • Page 21: I-Frame Pump

    I-FRAME PUMP On any ITT Goulds Pumps that come equipped with the i-ALERT2 device, a slot will be machined in the bearing housing to mount the device within close proximity to both bearings. See figure 12. Figure 12: ITT Goulds 3196 i-FRAME contains milled slot for mounting the monitor...

  • Page 22: End Suction Pump

    On end-suction (overhung) style pumps where the thrust and radial bearings are contained within the same bearing housing, ITT Goulds Pumps recommends mounting the i-ALERT2 device centrally on the bearing housing in an area where the LEDs can easily be observed.

  • Page 23: Horizontal Electric Motors

    HORIZONTAL ELECTRIC MOTORS Mount the i-ALERT2 monitor directly over the bearing housing on the drive-end bearing. A second monitor can be mounted over the non-drive end bearing if desired. Never mount a monitor on a fan cover! Figure 15: Horizontal motor, mounted over drive end bearing housing...

  • Page 24: Between Bearings Pump

    BETWEEN BEARINGS PUMP On between bearings pumps, it is recommended to mount i-ALERT2 monitors to both bearing housings. If only one device is to be installed on a pump, then it should be installed on the bearing housing that contains the thrust bearing. Note, that this is not always the drive end bearing housing.

  • Page 25: Vertical Electric Motors

    VERTICAL ELECTRIC MOTORS The best mounting location for the i-ALERT2 device will depend on which class of vertical motor is being monitored. For vertical solid shaft motors with 2 rigid bearings, instrument the upper thrust bearing housing first since this is the primary bearing absorbing thrust loads.

  • Page 26: Vertical Pump

    VERTICAL PUMP Vertical pumps can be instrumented with the i-ALERT2 device at the pump discharge head. See image below. Mount the device at the top of the discharge head where the LEDs are clearly visible. Figure 21: Arrows show recommended mounting location for vertical pumps (On Discharge Head) MIXERS Mixer configurations can vary widely so ITT does not recommend any single best location.

  • Page 27: Mounting Methods

    MOUNTING METHODS There are three methods that can be used to mount the i-ALERT2 device to a machine. They are shown in the figure below. On new pumps and pumps repaired through ITT PRO Services, a slot will be milled into an appropriate location on the bearing housing and the device will be secured with a screw.

  • Page 28: To Reset The I-Alert2

    TO RESET THE I-ALERT2: Figure 24: Using a magnet to reset an i-ALERT2 *Using a magnet to reset a Version 1 i-Alert2 will permanently erase stored trend and FFT data; a Version 2 device will retain all data after a magnetic reset.

  • Page 29: I-Alert2 Equipment Health Monitor Routine Operation

    I-ALERT2 EQUIPMENT HEALTH MONITOR ROUTINE OPERATION Measurement interval The measurement interval for the condition monitor during normal and alarm operation is 5 minutes. When the monitor measures a reading beyond the specified temperature and vibration limits, the appropriate red LED flashes (after 2 consecutive readings).

  • Page 30: I-Alert2 ® Mobile App Operation

    On version 2 units the last alarm status is located below the tag name in red, on the Scan for Devices screen or Active Routes screen. If the message is present, it will indicate if the i-Alert2 has been in alarm in the last 2, 7, or 30 days. Once the device has been out of alarm for 30 days, the message will disappear.
  • Page 31 Figure 26: Scan for devices Devices that are no longer in range will have a grey icon next to their names. See Figure 27. i-ALERT2 Application Guide 31 of 64...
  • Page 32 Figure 27: Devices in range and out of range i-ALERT2 Application Guide 32 of 64...
  • Page 33 After clicking on the device’s name, the screen shown in figure 28 will come up as the phone and i-ALERT2 device begin to communicate. Once all 4 steps are completed and green checkmarks are shown you will be taken to the device dashboard showing the latest data.

  • Page 34: Dashboard

    The Dashboard page (Figure 29) shows the latest overall vibration amplitudes and temperature measurements as well as the total Runtime hours and Battery Status. To refresh the dashboard and request the latest reading, tap the circular arrow icon on the top right hand portion of the screen. Figure 29: Dashboard i-ALERT2 Application Guide 34 of 64...

  • Page 35: Trending

    Figure 30: Trending The Trend page shows the historical values of each individual measurement. You can overlay or remove measurement trends by clicking the radio buttons on the bottom of the screen. See Figure 31. i-ALERT2 Application Guide 35 of 64...
  • Page 36 See figure 32. You will have a choice to print it directly to a local printer, or attach it to an email in the CSV file format. CSV files are universal and can be imported to plant historians or opened with a spreadsheet processing program. i-ALERT2 Application Guide 36 of 64...
  • Page 37 DEVICE NAME Figure 32: Tap the upward facing arrow to view numerical data, tap the icon again on the subsequent page to export the data i-ALERT2 Application Guide 37 of 64...
  • Page 38 Figure 33: Export trend data by printing or attaching to email i-ALERT2 Application Guide 38 of 64...
  • Page 39 To reset the zoom to the default setting, you will have to leave this screen by either going into the Kurtosis trend or switching to “Weekly” and back. DEVICE NAME Zoom In Zoom Out Figure 34: Trend graph zoomed in i-ALERT2 Application Guide 39 of 64...

  • Page 40: Weekly View

    Average value but there is also a colored region accompanying the trend. The colored region shows the maximim and minimum values measured during that time period. (Note that non run hours are dropped from the average measurement calculation) Figure 35: Export trend data by printing or attaching to email i-ALERT2 Application Guide 40 of 64...

  • Page 41: Kurtosis

    KURTOSIS Kurtosis is a measure of how “peaky” a data set is. (i.e. The many vibration data points recorded by the i-ALERT2 monitor for a given sensor axis would constitute a data set) Higher values of kurtosis generally indicate increased crest factor of the vibration signal.

  • Page 42: Advanced Tools

    ADVANCED TOOLS The i-ALERT2 device offers some advanced tools that can help in troubleshooting equipment. To access these tools, tap the icon in the upper left that looks like 3 horizontal lines again and then tap “Advanced Tools”. See figure 37.

  • Page 43: Fft And Twf Data

    This will bring up a new menu with several options to choose from. These options are; request new FFT, download stored FFT, and download alarm FFT’s. (The i-Alert2 can store up to eight alarm FFT’s, and one user requested FFT).

  • Page 44: Stored And Alarm Generated Fft Data

    After requesting an FFT, the LED on the i-Alert2 will stop flashing for 10-30 seconds while the FFT is being computed. Once complete, the user will be prompted to download the FFT immediately or at a later time. By selecting Download Alarm FFT’s, the user can download all alarm FFT’s.

  • Page 45: Equipment Information

    “Equipment Information” page also includes functionality that allows a user to adjust alarm and warning limits as well as send commands to the i-ALERT2 monitor to reset the device. To access the Equipment information page, tap the icon in the upper left that looks like three horizontal lines and then choose “Equipment Info.”...
  • Page 46 DEVICE Figure 43: Use the + and – buttons to adjust values. Tap “Send” to program the new device settings. i-ALERT2 Application Guide 46 of 64...

  • Page 47: Equipment Details

    Figure 45: Entering a Goulds S/N enables additional functions Note: Once a valid ITT Goulds Pumps S/N is entered into the “Equipment Details” page, there is no need to manually enter any other data. The next time it connects to the internet the mobile app will communicate with the ITT servers and pull down this information, auto-populating it within the app.

  • Page 48: Parts List / Bom

    PARTS LIST / BOM The “Parts List / BOM” is not user editable and only applies to ITT Goulds Pumps products. If a valid ITT Goulds Pumps S/N is entered into the Equipment Details page the user should be able to view all the parts on the bill of material. The user can also choose to send part information via email to their purchasing department or local ITT Goulds Pumps sales representative.

  • Page 49: Pump Curve

    The “Pump Curve” page allows users to easily download, view and save/send a PDF version of the pumps performance curve. This feature is only available for valid ITT Goulds Pumps S/Ns. To view the curve, simply select “Pump Curve” under the Product Information Heading.

  • Page 50: Commands

    COMMANDS Occasionally the need may arise to refresh the i-ALERT2 devices stored data. For instance after a machine is repaired or if a device is moved to another piece of equipment. The “Commands” page contains commands that can be sent to update or refresh the i-ALERT2 monitor as necessary.

  • Page 51: Report Generator

    The Report Generator function allows the user to export several condition monitoring reports. Currently, reports can be created that show 30 day and 90 day trends of the vibration/temperature as well as the stored FFTs on that i-ALERT2 device. See figure 49.
  • Page 52 Once a report has been generated it can be sent or saved using the upwards arrow icon in the upper right hand corner of the page. Figure 50: Export standard reports in PDF i-ALERT2 Application Guide 52 of 64...
  • Page 53 Trends are downloaded for units in Alarm/Warning, or units with > 60 days since last trend download FFTs are downloaded for units in Alarm Traditional: Trend and FFTs are downloaded every time the route is run. i-ALERT2 Application Guide 53 of 64...
  • Page 54 After the route settings are completed select “Next” in the upper right. This brings you to the device list, where you can add or remove equipment from the route. A gray checkmark indicates the equipment has been added to your route; a clear icon shows equipment that can be added. i-ALERT2 Application Guide 54 of 64...
  • Page 55 5. Followed by a listing of the “Checked Devices” (meaning there are no remaining download actions or no actions required for that device.) Figure 54: Main Route Screen i-ALERT2 Application Guide 55 of 64...
  • Page 56 RMS vibration for each axis and current temperature. The equipment type can be edited from the Equipment Details. In the tabular data columns any values in red font indicate an alarm condition. i-ALERT2 Application Guide 56 of 64...
  • Page 57 Figure 56: Route Report Summary Page After the Summary, the remaining pages of the report contain any trend data and FFT’s acquired during the most recent route. i-ALERT2 Application Guide 57 of 64...
  • Page 58 Figure 57:Route Report Trend Details Screen i-ALERT2 Application Guide 58 of 64...
  • Page 59 At the top of each page a summary of equipment details is found followed by either trends or FFT’s for that device. The timestamp for each FFT is found in the upper right corner of each graph. i-ALERT2 Application Guide 59 of 64...

  • Page 60: Help /Faq

    The Help/FAQ section provides useful tools In the event you encounter a problem or need additional assistance with the i- ALERT2 or mobile application. Within the Help/FAQ menu you can access the FAQ or Troubleshooting documentation for the product. (Internet connection is required). You also access ITT’s website, contact us via email, or view the software policy information.

  • Page 61: Service Locator

    SERVICE LOCATOR ITT makes it easy to get in touch with local resources that can assist with equipment repairs, spare parts, and field service. Upon tapping the “Service Locator” tag in the main menu, you will be prompted to allow access to you location in order for the application to locate the nearest service center or sales office.

  • Page 62: User Settings

    The FFT display can also be adjusted to display in Hz, CPM (Cycles per Minute) or Orders (multiples of shaft speed). FFT Chart smart zoom: This feature minimizes white space on the FFT chart. ITT Recommends leaving it enabled. Figure 61: Adjust units in user settings TECHNICAL REFERENCES 1.
  • Page 63 Application Guide 63 of 64...
  • Page 64 G.iALERT2AppGuide.en-US.2016-10 i-ALERT2 Application Guide 64 of 64...

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