Faults generally grow by fatigue action, which are difficult to predict.

As machines deteriorate
performance reduces, unplanned breakdowns will happen and thousands of dollars will be loosed.
In spite of similar effects of different faults, 90% of machinery malfunctions are predictable and
controllable. Automated trending of condition of individual machine elements such as shafts, gears
and bearings will provide the planning time to restrict the damage of a particular element, and
optimize the time to perform repairs. Just it’s needed to know machinery condition at all the times.
The solution is TS-2 online monitoring system. By TS-2, equipment is protected by detecting
faults, predicting defects and preventing catastrophic failures.

TS-2 Online Condition Monitoring System

Features: Automated fault detection:
 Measuring vibration, speed, load, metallic  Imbalance, misalignment, looseness and other
particle and water in oil shaft related faults
 An hourly complete data acquisition to identify  Separating shaft related, bearing and gear faults
growing faults and trending individually
 Recognizing, individually trending installation,  Bearing faults, from the beginning to end of life
shaft, bearing, gear, oil and electrical faults  Gear faults beginning and approaching end of life
 Protection (alarm and trip) according to API670,  Single tooth faults detection for every tooth in all
ISO10816 and user defined criteria the gearbox
 Sending alarms by SMS and E-mail
 Easy to access software (Alarms, Trends, FFT
spectrum, Cepstrum, Kurtosis and …)
 Remote monitoring, analysis and support in all
over the world by qualified and experienced
engineers in Australia 10 Pigeon Bank Lank
 Applicable to slow and variable speed machines Warrandyte Vic 3113
Australia
 Very low costs for hardware and supports www.tensorsystems.com

Sells Representative
Client Site PCs
Remote analysis and support:
Tensor System’s specialists in
Australia or representatives experts in
the world can remotely analyze and
trend your equipment condition with
the lowest costs.
 Rapid response to fast changing of
machine condition
 24/7 consulting and practical
condition monitoring advice from
qualified and experienced engineers
 Monthly report and repair planning
Technology:
The critical part of an Online Condition
Monitoring System is automated fault
identification, and reliably separating and
trending shaft, bearing, gear and
electrical related faults, to minimize the
analyst time and coming to correct
conclusions.
TS-2 uses tachometer to very accurately
measure one or more shafts speeds
during the measurement period, and
using gear tooth numbers, calculates the
exact speed of every shaft even in
varying speed or low speed machines. So
it calculates harmonics of each shaft
across the whole spectrum, and measures
synchronous and nonsynchronous
vibration in each spectral band.
Rolling element bearings produce ball
pass frequencies which are non-sync
whereas shafts and gears produce sync
vibrations with shaft speed. So rolling
bearings faults are identified and trended
as non-sync vibration in the band and
shaft related faults produce sync
harmonics up to about 8x shaft speed.
Gear profile faults produce harmonics of
the meshing frequency which are sync
with shaft speed, and are identified and
trended as sync vibration in the band.
Gear single tooth faults produce low
TS-2 Online Condition Monitoring System
TS-2 hardware
Sending data via
RS485
LAN
Wireless
Sensors
and
Cables
Tensor System
analysis center in Australia
Gear single tooth faults produce low Why TS-2?
level harmonics of shaft speed and
In compare with the other monitoring
sidebands of the meshing frequency.
systems, there are some important benefits
Using Turns Synchronized Averaging in
in TS-2 monitoring system, which are
waveform domain and NASA developed
mentioned below.
algorithms such as NA4, FM4, SI and
Phase demodulation, subtle changes in It supplies a complete system including
the waveform can be highlighted and hardwares and software with a data base
trended. that made for the client’s machines and
specified alarm settings.
This systematic data processing allows
automated separation and trending of Lowest costs for hardware, software,
shaft, gear profile, single tooth faults and database setup, and remote support, with
bearing faults, without knowing any buy and hire options.
bearing numbers.
It is applicable to high and very low speed
Online oil analysis is also used to detect machines, like mining mills, steel rolling
Fe and Non Fe particles in 5 size ranges mills, wind turbines and so on.
(equivalent spheres) from 40 to 1500
Also it can use wide range of sensors,
microns. Oil humidity is also measured
tachometers, motor load, accelerometers,
to prevent water levels rising to
AE sensors, proximity probes, temperature
destructive levels, thus actually
with 24 bit accuracy from DC to 32 KHz.
preventing damage from occurring.
TS-2 monitoring system automatically
TS-2 Software supplies various trends,
separates and trends bearing faults in the
spectrum, cepstrum, kurtosis, orbit and
presence of much larger gear vibration.
other functions for a complete analysis.
In TS-2 software, Traffic Lights display
The data base is designed with all shaft
machine condition, click for trends, click
speeds defined by cumulative
trends to see waveform & spectra.
(numerator/denominator) integer values
to allow for cubic spine fitting, orders In TS-2 software, alarm conditions
resampling and Turns Sync Averaging of reported immediately by SMS and daily
every shaft from a single tachometer. email summary to the clients personnel list.