B2B_03_Monitoring_Special_Apps_R2.ppt
- 1. 1 Monitoring System Special Applications
- 3. 3 Field Cable Length What is the recommended Maximum cable length between BN Sensor and BN monitor ? - The standard recommended cable length is 1000 feet (305 meters). Can the field cable length be extended ? - Yes, but the specific customer application must be reviewed. Why does the 1000 foot limit exist? - Meets the basic requirements of the vast majority of applications for BN transducer and monitoring systems. - Achieves the best signal quality (minimal signal and frequency response degradation)
- 4. 4 Considerations – Extended Cable Length - Signal Frequency response degradation (especially at higher frequencies). - Specific capacitance limits for hazardous areas. The Key Issues that impact field wiring length are: Total cable capacitance is calculated in (pf/M) For 3-wire: (typical for Prox and Accel applications) total = (2*C core-to-core ) + C core-to-screen For 2-wire (typically for Velomitor applications): total = (C core-to-core ) + C core-to-screen The Signal frequency response of cable is affected by - Resistance - Capacitance - Inductance
- 5. 5 Extended Cable Runs May Impact: Applications • High Frequency Applications - Gearboxes, Turbine Blade Pass, Roller Element Bearing signatures, high-speed machines - Speed-sensing applications •Hazardous Areas Applications - Must limit the energy stored in the system - Hazardous area classification
- 6. 6 Considerations – Extended Cable Length Thoroughly evaluate the application to determine the desired frequency response To extend field cable length - need to know • Cable capacitance per unit length • Total cable length • Machine running speed • Any machine characteristic that could affect transducer signal response (I.e. gearmesh frequencies) • Type of transducer used in the installation • Hazardous areas
- 7. 7 Co Ccable+Ci Ccable = CUL*Lmax Co is the maximum allowable connected capacitance for Ci is the input capacitance of the transducer CUL is the capacitance per unit length of cable Solution – Extended Cable Length
- 8. 8 Solution – Extended Field Wiring Calculator
- 10. 10 What is a Hazardous Area? • An area where conditions exist for an explosion to occur • Generally associated with flammable gases or vapours mixed in air to form an explosive mixture • Combustible Dusts and Fibers
- 11. 11 Legal Requirements for Hazardous Areas • All developed and developing countries have legal regulations that require certification for equipment used in areas where explosive atmospheres may be present. • Europe: 94/9/EC ATEX Directive (and transposed into national code) • China: GB 3836.x • Brazil: INMETRO • U.S.: CFR 29 OSHA 1910.307/NEC • Canada: CEC 22.2
- 12. 12 What is a Hazardous Area Classification? • Defines the level of risk to which the personnel are exposed. • Type of hazard • Expected frequency of hazard • Determines allowable protection methods • Other parameters that may affect the safety of personnel
- 13. 13 Hazardous Area Classifications Low Risk Moderate Risk High Risk Present under failure conditions Present under normal operation <10 hrs/yr 10<hazard<1000 hrs/yr >1000 hrs/yr Gas Class I, Div 2 Zone 2 Class I, Div 1 Zone 1 Class I, Div 1 Zone 0 Dust Class II, Div 2 Zone 22 Class II, Div 1 Zone 21 Class II, Div 1 Zone 20 Fibers Class III, Div 2 No Zone designation Class III, Div 1 No Zone designation Class III, Div 1 No Zone designation
- 14. 14 Area Classification Terminology Terminology Used in Classification Class Division Groups A, B, C, D, E, F, G Zone Gas Groups IIA, IIB, IIC USA Canada * * * EU International =preferred =acceptable *= Only acceptable for existing installations
- 15. 15 Gas Groups Zone gas groups: IIA, IIB, IIC (most easily ignited) Division gas groups: D, C, B, A (most easily ignited) Groups E, F, and G are for dust Indicate the energy required in a spark to ignite a gas. Areas classified by gases present. Equipment classified available. Gas Groups do not necessarily correlate with Temperature Codes.
- 16. 16 Temperature Codes • Area Temperature Code • Ignition Temperature of the hazard • Equipment Temperature Code • T(max) at exposed surfaces during operation Deg C Deg F T1 450 852 T2 300 572 T3 200 392 T4 135 275 T5 100 212 T6 85 185
- 17. 17 Obligations GE: • Obtain the required area classification(s) • Ensure BN product has appropriate certifications. (area classification, type of protection, temperature code, certificate acceptable for nation) • In case of Zone 1/0 or Div 1 areas determine if Zener barriers or galvanic isolators are required • Determine if internal barriers or external barriers are required • Make clear any system constraints or special conditions necessary to ensure compliance and proper performance. Such as: field wiring lengths, conduit/no conduit, housings, custom transducers, field wiring type – flammability Customer: • Have an area classification map or otherwise provide the area classification for all equipment (is a legal requirement in certain nations) • Communicate what preferences they have for method of protection. Such as: Zener barriers vs. galvanic isolators, flameproof vs. intrinsic safety. • If installing – follow appropriate installation drawings. • Maintain system. Such as: intrinsic safety earth. •Customer/EPC/Contractor will get local electrical inspector sign-off in most cases.
- 18. 18 Intrinsic Safety vs. Non Incendive • In an Intrinsically safe device, the energy in the system is always low enough that ignition of the hazardous atmosphere cannot occur. • A non incendive device should not create a spark in its normal state of operation.
- 19. 19 Zener Barriers vs. Galvanic Isolators Zener Barrier • Requires an intrinsic safety earth which must meet certain specifications. This can be impractical in some cases. (ex: offshore) • 3500 internal barriers are Zener barriers • Must be certified. • Specific Zener barriers are needed for specific sensor types. • External Zener barriers usually are DIN mount in or near to monitors. • Zener barriers are passive – no power needed. Galvanic Isolator • Does not require the safety earth to meet requirements as in a Zener barrier. • BN has galvanic isolators from MTL for use with 3500. • Galvanic isolators mount separately. • Galvanic isolators (vendor dependent) can have more signal noise than Zeners. • Require external power, +24VDC • Must be certified. • May have less operational temperature range than monitor.
- 20. 20 Triple Modular Redundant (TMR) System
- 21. 21 TMR Overview • What is TMR? – Monitoring system that allows triplicated monitoring points – No single point failure of any component will disable machinery protection – Applied to most critical machinery application • TMR Application – Addresses industry requirements for safety critical monitoring – 3500 system offers over speed detection as TMR solution – Typically used for axial vibration, can be applied for any monitoring points. • Architecture – Triplicated alarming communication networks between TDI, Relay Module and TMR monitor groups. – Triplicated alarm logic solver – 2 out of 3 relay voting logic – Duplicated Power Supplies
- 22. 22 TMR Requirements •Standard rack is used with rack jumper setting to “TMR” •3500/22 TMR TDI •Two 3500/15 Power Supplies with independent power sources •TMR monitors are the same as standard 3500 monitors •3 monitors are installed in sets of 3 in adjacent slots •Can be configured as Discrete or Bussed •TMR I/O module must be used for bussed transducers •3500/34 TMR Relay module
- 23. 23 TMR Relay Features: • Requires 2 x 3500/34 TMR Relay card • Half-height cards processing alarm events from the other monitor cards in duplicate. • Triplicated relay logic solver • 2 out of 3 relay voting
- 24. 24 TMR Input Configuration •Bussed Transducer Requirements: – TMR I/O Module required – Bussed ET Block required – Not available for Intrinsic Safety Barriers Discrete Bussed (Animation) (Animation)
- 26. 26 Power Supplies in TMR Rack
- 28. 28 What to know about Overspeed Detection Systems • 3500/53 Overspeed Detection Systems “detect” an overspeed condition on a machine • It is a smaller component of the overall overspeed “protection” system • Requires FAE overview and approval • It is a very specific application (requires a complete engineered solution) • The Bently Nevada 3 channel solution can be fully TUV SIL 3 certified • Available in dual and triple channel configurations
- 29. 29
- 30. 30 Overspeed Application Information in PATLite
- 31. 31 1. GE machines must have a 2oo3 Triple Modular Redundant Overspeed Protection System. This entails 3 probes, 3 Proximitors, and 3 3500/53 channels. OR: 2. Non-GE Machines may use a 2oo2 Dual Redundant ODS system provided that the following requirements met: • The PAT-Lite ODS Spreadsheet is completed showing that the ODS meets requirements (is approved) for speed sensing signal quality and has affirmative answers to the PAT-Lite application questions. AND: • The ODS speed sensors are observing the driver machine on the main shaft – no secondary shafts or gears allowed and not on the driven side of any coupling • The 2oo2 ODS is a complete speed sensing system from probe through Proximitor to the 3500/53 ODS – one probe cannot drive two 3500 ODS channels and be a 2oo2 ODS system • The Governor speed sensors are independent of the ODS speed sensors • A second overspeed shutdown system is installed on the machine such as: • A mechanical overspeed (bolt) • An independent (non-GE) electronic overspeed • If the primary governor speed controller has overspeed alarm and shutdown, it may function as the second overspeed protection • The 4/20 mA output from the 3500 ODS is NEVER used to control the Summary of Overspeed Detection System Mandates
- 33. 33 Discovery Questions What is Safety and Functional Safety? What is SIL? Is Functional Safety or SIL required by the customer for this project? What SIL level is required for each measurement? What specific measurements require SIL? How can Bently Nevada monitoring system do to meet SIL level?
- 34. 34 IEC 61508 IEC 61511 IEC 61513 IEC 62061 Process Sector Nuclear Sector Machinery Sector General Requirements International Functional Safety (SIL) Standards
- 35. 35 BN 3500 as A Part of Overall Safety Loop Sensor/Transducer Logic Solver Fuel Valve 3500 Rack
- 36. 36 SIL Capable vs. SIL Certified Logic Solver 1 2 3 4 5 6 7 Sensors Final Elements Safety Instrumented System (SIS) Safety Loop or Safety Instrumented Function (SIF) Certified as SIL x by experts outside BN Components certified as SIL x capable BN certificates written for sensor, monitor, relay
- 37. 37 What we can have when ordering SIL version monitors? • Each monitor with SIL option will have FS approval for modified hardware • TUV Certificates/”Stickers” (SIL 1 or SIL 3) • Supporting SIL data to allow customers themselves to calculate the overall system SIL rating • SIL option for each monitor ordered will have additional $80 compared with standard ones.
- 38. 38 How to order 3500 monitors in Slot 2 have SIL 1 or SIL 3 Certificate Use FS_System instead of 3500_System when ordering SIL version monitors
- 39. 39 Bently Nevada vibration example Probe/Cable Proximitor 3500/42 Monitor 3500/32 Relay Module Customer’s final elements Certified by TUV as capable of being part of a SIL 1 SIF Cert number: 968EL226.02/04 To achieve this certificate TUV performed: •FMEDA to the component level •In house audits of manufacturing processes •Evaluation of our design processes to 250± requirements of IEC61508 Evaluation shows that after 1 year (proof test) 50% of the SIL 1 window (0.1) for PFD has been reached. Customer wants SIL 1 vibration SIF Must also be evaluated to IEC61508 PFD for 1 year proof test interval cannot exceed 50% of SIL 1 window (0.1). PFD for entire SIL 1 SIF cannot exceed 0.1 Evaluated on site by Certified Functional Safety Engineer Sensing element Logic solver
- 40. 40 Bently Systems with SIL certificates Probe/Cable Proximitor 3500/53 Monitor 3500/53 SIL 3 Overspeed Detection System TMR (triple modular redundant) 3 channels of speed across 3 speed monitors (system has dedicated relays) Transducer options: 3300 XL 5/8mm 330180 330101, 330102, 330103, 330104, 330105, 330106, 330140, 330141, 330171, 330172, 330173, 330174, 3500/53 options: AA=03 Three channel system Probe/Cable Proximitor 3500/53 Monitor Probe/Cable Proximitor 3500/53 Monitor Dedicated Relay Outputs
- 41. 41 Bently Systems with SIL certificates Probe/Cable Proximitor 3500/40 or 42 Monitor 3500/34 TMR Relay Module 3500/40 or 42 SIL 3 vibration system TMR (triple modular redundant) 3 channels of vibration across 3 vibration monitors and one 3500/34 TMR relay module Transducer options: 3300 XL 5/8mm 330180 330101, 330102, 330103, 330104, 330105, 330106, 330140, 330141, 330171, 330172, 330173, 330174, 3500/40 I/O options: 01, 02, 03 3500/42 I/O options: 01, 02, 04, 05, 06, 09 Probe/Cable Proximitor 3500/40 or 42 Monitor Probe/Cable Proximitor 3500/40 or 42 Monitor
- 42. 42 Bently Systems with SIL certificates Probe/Cable Proximitor 3500/40 or 42 Monitor 3500/32 Relay Module 3500/40 or 42 SIL 1 vibration system Single channel of vibration Transducer options: 3300 XL 5/8mm 330180 330101, 330102, 330103, 330104, 330105, 330106, 330140, 330141, 330171, 330172, 330173, 330174, 3500/40 I/O options: 01, 02, 03 3500/42 I/O options: 01, 02, 04, 05, 06, 09
- 43. 43 Bently Systems with SIL certificates RTD or TC 3500/60 or 61 Monitor 3500/33 Relay Module 3500/60 or 61 SIL 1 temperature measurement system Single channel of temperature 3500/60 I/O options: 01, 02, 05 3500/61 I/O options: 01, 02, 05,
- 44. 44 Bently Systems with SIL certificates Process Variable Sensor 3500/62 Monitor 3500/33 Relay Module 3500/62 SIL 1 process variable system Single channel of process variable measurement 3500/62 I/O options: 01, 02, 05 Thermocouple Voltage -10V to +10V 4-20mA Current
- 45. 45 Bently Systems with SIL certificates Haz Gas Sensor 3500/63 Monitor 3500/33 Relay Module 3500/63 SIL 2 Hazardous Gas Detection System Single channel of haz gas measurement 3500/63 I/O options: All options 350800 All options or 3500/63 4-20mA outputs
- 46. 46 SIL Levels Safety Integrity Level (SIL) Average Probability of Failure on Demand per year (low demand mode of operation) Reduction Risk Factor (RRF) SIL4 10-5 to 10-4 10000 to 100000 SIL 3 10-4 to 10-3 1000 to 10000 SIL 2 10-3 to 10-2 100 to 1000 SIL 1 10-2 to 10-1 10 to 100