ITT i-ALERT2 User guide

Application Guide

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TABLE OF CONTENTS
INTRODUCTION................................................................................................................................................ 5
HOW I-ALERT2 MONITOR AUGMENTS A CONDITION MONITORING PROGRAM.................................................................... 7
Improved Program Efficiency .............................................................................................................................................................. 7
Improved Program Effectiveness......................................................................................................................................................... 7
Improved Worker Safety ..................................................................................................................................................................... 7
RELIABILITY OVERVIEW .................................................................................................................................... 8
INTRODUCTION TO CONDITION MONITORING................................................................................................................... 9
Step 1.NOTICE: Detection of Problems............................................................................................................. 10
Step 2.INVESTIGATE: Analyze the problem ...................................................................................................... 10
Step 3.RESOLVE: Correction and Improvement................................................................................................ 11
Step 4.DOCUMENT ........................................................................................................................................... 11
SYSTEM OVERVIEW........................................................................................................................................ 12
DEVICE TECHNOLOGY BACKGROUND ........................................................................................................................... 12
Device Overview ............................................................................................................................................... 13
Vibration and Temperature Specifications........................................................................................................................................ 13
Trending Specifications ..................................................................................................................................................................... 13
Hardware Specifications.................................................................................................................................................................... 14
APPLICATION BEST PRACTICES ....................................................................................................................... 14
CHOOSING THE CORRECT MEASURES AND ASSETS ......................................................................................................... 14
Equipment Criticality ........................................................................................................................................ 14
Machine selection criteria ................................................................................................................................ 15
Where to Start? ................................................................................................................................................................................. 16
Condition Monitoring Measures ...................................................................................................................... 18
Temperature...................................................................................................................................................................................... 18
Vibration – RMS Velocity ................................................................................................................................................................... 18
Kurtosis.............................................................................................................................................................................................. 19
INSTALLATION BEST PRACTICES...................................................................................................................... 20
MOUNTING LOCATIONS............................................................................................................................................. 20
General Guidelines ........................................................................................................................................... 20
i-frame pump.................................................................................................................................................... 21
End suction pump ............................................................................................................................................. 22
Horizontal Electric Motors................................................................................................................................ 23
Between Bearings pump .................................................................................................................................. 24
Vertical Electric Motors .................................................................................................................................... 25
Vertical Pump ................................................................................................................................................... 26
Mixers............................................................................................................................................................... 26
Vacuum Pumps................................................................................................................................................. 26
MOUNTING METHODS .............................................................................................................................................. 27
COMMISSIONING........................................................................................................................................... 27
STEPS TO ACTIVATE THE I-ALERT2 EQUIPMENT HEALTH MONITOR: ................................................................................. 27

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TO RESET THE I-ALERT2:........................................................................................................................................... 28
I-ALERT2 EQUIPMENT HEALTH MONITOR ROUTINE OPERATION ...................................................................................... 29
I-ALERT2 EQUIPMENT HEALTH MONITOR TROUBLESHOOTING........................................................................................ 29
I-ALERT2®MOBILE APP OPERATION................................................................................................................ 30
INSTALLING THE APP ................................................................................................................................................. 30
CONNECTING TO I-ALERT2 DEVICES............................................................................................................................ 30
DASHBOARD............................................................................................................................................................ 34
TRENDING ............................................................................................................................................................... 35
Weekly View ..................................................................................................................................................... 40
Kurtosis............................................................................................................................................................. 41
ADVANCED TOOLS .................................................................................................................................................... 42
FFT and TWF Data ............................................................................................................................................ 43
Stored and Alarm Generated FFT Data ............................................................................................................ 44
EQUIPMENT INFORMATION ........................................................................................................................................ 45
Alarms / Warnings ........................................................................................................................................... 45
Equipment Details ............................................................................................................................................ 47
Parts List / BOM ............................................................................................................................................... 48
Pump Curve ...................................................................................................................................................... 49
Commands........................................................................................................................................................ 50
REPORT GENERATOR................................................................................................................................................. 51
HELP/FAQ.............................................................................................................................................................. 60
SERVICE LOCATOR .................................................................................................................................................... 61
USER SETTINGS ........................................................................................................................................................ 62
TECHNICAL REFERENCES................................................................................................................................. 62

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INTRODUCTION
This guide is designed to assist reliability practitioners in optimizing the performance of their rotating equipment assets
using modern condition monitoring technologies.
Traditional condition monitoring techniques and budget constraints force practitioners to make difficult choices as to which
pieces of equipment they can focus on while relegating many of the less critical assets to a suboptimal time based
maintenance regime or a “fix it when it breaks” mentality. Even in those plants that do perform periodic predictive
maintenance (PdM) inspections, the frequency or time between inspections is a month or more, sometimes up to a year.
Many failure mechanisms can develop and progress into catastrophic failure well before the next inspection, rendering the
PdM program ineffectual for “balance of plant” equipment.
Continuous monitoring of machinery health is an ideal solution to prevent unplanned downtime, but has historically come
with a big price tag that couldn’t be justified except on the most critical assets. 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. Leveraging new technology allows the i-ALERT2 condition monitor to offer improved utility and
reduced cost compared to a typical “walk-around” monthly vibration program.
Using the latest Micro-
Electromechanical Sensors (MEMS) and Bluetooth® wireless communications
technologies ITT has created a tool that better fits the needs of reliability practitioners.

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Enables
ODR
Improves
Safety
Optimizes
Equipment
Reliability
Operators can collect high quality,
repeatable, vibration and
temperature data with no training.
Wireless communication allows a user to collect data a
safe distance from rotating equipment hazards.
Allows your highly skilled vibration analysts to focus on
solving chronic problems instead of routine monitoring.
Figure 1: Condition Monitoring Technology Comparison

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HOW I-ALERT2 MONITOR AUGMENTS A CONDITION MONITORING PROGRAM
IMPROVED PROGRAM EFFICIENCY
•Faster data collection and less time spent walking routes because the need to physically mount a temporary
sensor is eliminated.
•Easily visible indication of equipment condition during data collection through the device’s onboard LEDs.
•Data collection can be easily integrated into existing operator rounds.
•Allows your highly skilled vibration analysts to focus on solving chronic problems instead of routine monitoring.
This is becoming increasingly more important as these skill sets are in short supply.
•Users can simultaneously view any machine’s current overall condition for any device in range. No need to
actually touch each machine to get the data.
IMPROVED PROGRAM EFFECTIVENESS
•Continuous data collection allows for diagnosis of transient and process related problems which are traditionally
very hard if not impossible to spot with monthly or quarterly data collection cycles. Especially effective for batch
process equipment.
•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.
•Changes in machine state automatically trigger the device to capture spectral and time waveform data. The ability
to capture this diagnostic data in conjunction with the trend and timestamp information improves a reliability
practitioner’s ability to troubleshoot process related problems.
•Temperature and Kurtosis trending enhance the traditional overall vibration dataset, yielding more accurate
condition assessment than overall RMS vibration alone.
IMPROVED WORKER SAFETY
•No need to get close to dangerous rotating equipment hazards to collect the data. Just be in the same room with
it.

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RELIABILITY OVERVIEW
Maintenance and Reliability (M&R) practices including condition monitoring are largely governed by the type of assets
being maintained and the associated failure patterns of those assets. Numerous studies have been conducted in both the
Industrial and Aeronautical / Military markets that show the relative frequency or “probability” of failure of equipment. This
data is summarized in Figure 2. What should immediately become apparent is that very few failures are attributable to
“wearing out” or what might be termed an “age-related” failure1pattern.
1Those that are age-related are almost all corrosion in seawater applications with a relatively predictable lifecycle.
UAL 1968 Bromberg
1973
US Navy
1982
4% 3% 3%
2% 1% 17%
5% 4% 3%
7% 11% 6%
14% 15% 42%
68% 66% 29%
Conditional Probability of Failure
Time
Failure Curves
Figure 2: Failure curves

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The majority of industrial equipment will tend to have a failure probability distribution similar to that of Figure 3, where the
risk of failure for equipment is highest upon startup, sometimes termed “infant mortality” and will decrease to some
relatively constant probability of failure over time.
Knowing that most equipment will follow the failure pattern of Figure 3 should guide M&R practitioners to select condition
monitoring equipment that can:
1. Quickly identify defects or problems when new equipment is started before they cause severe damage
2. Help establish confidence that a newly commissioned machine is operating within specific limits
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. Implementing new technology just for the sake of saying you have the latest and
greatest technology will lead to a lot of wasted money and effort.
INTRODUCTION TO CONDITION MONITORING
CM and PdM tools available today are great enhancements to the traditional visual / audible Inspections and augment
regular operators’ inspections. Whether performing a simple visual inspection or using the most sophisticated tools
available the process is fundamentally the same. There are 4 Steps:
oNOTICE
•We have to notice or detect that we have a problem with a piece of equipment.
oINVESTIGATE
•Once detected, we can investigate and analyze the problem to determine the root cause.
oRESOLVE
•After determining the root cause, we can correct the problem and, if possible, improve the machine by leaving
it in a precise state.
oDOCUMENT
•By documenting our results, we are able to verify that the problem has been solved and communicate our
successes to others.
It is important to thoroughly understand each of these steps. Valuable time is often wasted when too much emphasis is
placed on any one component.
Figure 3: Most common failure probability pattern for industrial equipment
Random
Higher risk at startup
Time

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STEP 1.NOTICE: DETECTION OF PROBLEMS
Since analysis of machine problems is a time consuming process and there are many
machines in a typical plant, it is important NOT to try to analyze all machines. The
first step in an effective condition monitoring program is to identify the problem
machines. This is the purpose of the detection phase of the program. Measurements
and machines are organized into a series of logical routes and data is collected on
them in a routine manner. 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. After the data has been collected, it is reviewed and
exceptions are noted and reported.
After identifying machines in need of further analysis using detection, the next step is
to determine the root cause of the problem. This is
achieved during the INVESTIGATE or ANALYSIS phase.
STEP 2.INVESTIGATE: ANALYZE THE PROBLEM
The analysis phase involves gathering more detailed diagnostic data which can include process conditions, flows, pressures,
FFT, TWF, Timestamps and Trend data. Performing such analysis is a time consuming process and should NOT be
attempted on all machines, only the ones that have exceeded alarm limits.
Figure 4: Simultaneously view
states of all devices in range
Process change
Figure 5: Process data related to
condition monitoring data