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Entry-level, Online Machinery Condition Monitoring Using
Your Process Control System (PCS) and Bently Nevada® Trendmaster® Pro
DSM Getting started with an online condition monitoring system does not have to be complex or expensive! Now, there is a simple, cost-effective approach for entry-level on-line machinery condition monitoring that allows you to...
  • automate your portable equipment surveillance program for more effective use of personnel time and more reliable, repeatable information
  • stop wasting money manually gathering data on well-running equipment
  • take advantage of your existing PCS investment
  • encourage Operator Driven Reliability by displaying asset condition monitoring information within the PCS screens
  • start with small system for 'bad actor' equipment and then expand to other equipment
  • begin reducing maintenance costs today by running your plant in a proactive manner – know the condition of your equipment 24x7
Bently Nevada® Trendmaster® Pro is a unique, patented data acquisition system capable of bringing hundreds of vibration, temperature, or other process variables into your PCS very cost-effectively. The unique design allows up to 255 sensors on a single trunk line cable that runs throughout the plant. For hazardous areas a single galvanic isolator can be used on a line with up to 254 sensors making all points on that line safe. The Trendmaster® Pro Dynamic Scanning Module (DSM) approach provides information about the plant equipment by scanning the sensors on a pre-defined schedule. The frequency is a function of the type and number of sensors to be scanned. Data from the DSM can be directly connected to a PCS or Programmable Logic Controller (PLC) via Modbus*. Ethernet wireless can be used for longer distances, removing wiring requirements for further cost reduction. The figure below illustrates the difference between a typical Trendmaster® Pro system and a conventional, continuous monitoring system:

Trendmaster Pro vs Conventional Monitoring System


All DSMs are shipped with Modbus* capability today. The only additional requirement to use this interface is the DSM Modbus* Exporter Software P/N 3010/56-AA where AA is the number of monitored points required. This software configures all the DSM inputs and defines the Modbus* interface.

In the past, some customers used transmitters to gather data for condition monitoring of plant equipment. This can be very expensive: transmitters require wiring to be connected from each transmitter back to the PCS; multiple housings are required to protect these devices from the environment; and the monitored data is very elementary in that the 4-20 mA signal is proportional to an overall level.

With the Trendmaster® Pro DSM approach, several parameters for each sensor can be monitored via communication to the PCS. The rich data set from the Trendmaster DSM provides the capability to alarm and/or trend parameters that are key to a certain equipment asset's health. For example, on certain equipment a specific frequency band of vibration may be more representative of the machine's health than an overall vibration level. Having the additional information is very advantageous when trying to further diagnose or send Actionable Information® to operations in an effort to remove stress from equipment.

The DSM can be configured to provide alarming of the monitored points over the Modbus*. In this situation the alarm statuses as well as the variable's value are provided via the Modbus* registers. Another configuration would be to configure alarm setpoints in the PCS for comparison against the variable values received from the monitored points over the Modbus* interface. This flexibility allows the DSM to meet various customer needs for alarming.

For machines that require quicker surveillance than a scanning system, a low-cost continuous monitor such as one of the Bently Nevada® 1900 Series Monitors can be installed locally and connected to Trendmaster® Pro for communications back to the PCS, having the best of both worlds.

When equipment trends from the PCS indicate problems and further information is needed, portable data collectors or other analysis or test equipment can be used to zero in on root cause. For those that want to start off with a more comprehensive system that collects dynamic data, System 1® should be considered.

Get started automating your plant with an online condition monitoring system today!