INTRODUCTION TO

BENTLEY NEVADA MACHINE

MONITORING SYSTEM

HARDWARE & SOFTWARE CONFIGURATION

 Introduction

• Topic: Machine Monitoring & Protection System Bentley Nevada 3500.

• Course Benefits: The course will beneficial for participants in terms of

– Knowledge of Bentley Nevada Hardware & Software System.
– Types of Vibration e.g. Radial and Axial vibration measurement.
– Study of characteristic curves and problems.
 Training Sessions
 Session-1: Introduction to Machine Monitoring
- Duration: 01 hour 30 minutes
- Objective: It will cover basic attributes of vibration measurement.

 Session-2: BN 3500 Monitoring System

- Duration: 01 hour 30 minutes
- Objective: It will cover the hardware & software of BN 3500 System.

 Session-3: Speed Measurement

- Duration: 01 hour
- Objective: It will cover the hardware & software of BN 3701/55 ADAPT PLC.

 Session-4: Wrap-Up & Assessment

- Duration: 20 minutes
- Objective: It will cover summary of important topics with Q/A Session and Quiz.
 Session-1: MACHINE MONITORING
Topics

Introduction to Vibration Monitoring

Vibration Measurement Principles

Types of Vibration Measurement

BN 3500 Vibration System

Linear Range & Scale Factor Calculation

Problems in Vibration Measurement

 INTRODUCTION TO VIBRATION MONITORING
MACHINE MONITORING:
• Monitoring of rotary equipment (pumps, compressors, turbines, fans, etc.) using set
of tools to find out equipment health continuously or at a predetermined interval.

• Includes:
– Vibration Monitoring
– Temperature Monitoring
– Speed Monitoring
– Running Hours, Etc
• Why is Machine Monitoring Important?
– Extends asset life
– Reduces maintenance cost
– Cost savings on prematurely replaced resources
– Reduces downtime
 INTRODUCTION TO VIBRATION MONITORING
WHAT IS VIBRATION?
• A mechanical phenomenon whereby oscillations occur about
an equilibrium position.
 INTRODUCTION TO VIBRATION MONITORING
UNITS OF VIBRATION:
• Displacement: m, mm, microns, mils
• Velocity: m/sec, mm/sec, in/sec
• Acceleration: m/sec2, g

CAUSES OF VIBRATION:
• Unbalance • Electrical Problems
• Misalignment • Gear Problems
• Shaft & Bearing Wear • Bearing Failure
• Mechanical Looseness • Belt Problems
 INTRODUCTION TO VIBRATION MONITORING
• Vibration in machinery is a serious problem with plant operations. Its
severity sometimes leads to plant shut down. So It must be monitored.
• Vibration monitoring systems help to detect equipment damage or
malfunction in good time.

Types of Vibration Monitoring:

• Online Monitoring:
– Non-interrupted permanent system that produces data continuously.
• Offline Monitoring:
– Periodic check using a portable (manual) or semi-automatic
equipment.
 VIBRATION MEASUREMENT PRINCIPLES
• To measure vibration, mechanical motion has to be converted into an
electrical signal.

• A Transducer is a device that performs this function.

• Electrical signal is proportional to vibration and allow diagnosis of

machinery health.

• Two Types of Transducers are available:

– Contact Type

– Non-Contact Type
 VIBRATION MEASUREMENT PRINCIPLES

CONTACT TYPE NON-CONTACT TYPE

MODE OF OPERATION Attached

machine.
to the part of the Directed to the part of
machine but not in contact

Seismic Type: Proximity Type:

• Velometer • Capacitive
TRANSDUCERS • Inductive
• Accelerometer • Eddy Current Probes
 VIBRATION MEASUREMENT PRINCIPLES
CONTACT TYPE MEASUREMENT:

VELOMETER (VELOCITY METER):

• Permanent magnet-mass suspended on a spring

and surrounded by a coil attached to the
protective housing.

• Voltage produced is proportional to vibration.

• Old technology, now replaced with piezo electric

crystals.
 VIBRATION MEASUREMENT PRINCIPLES
CONTACT TYPE MEASUREMENT:

ACCELEROMETER:

• Works on piezoelectric effect.

• Acceleration of machine is transmitted to a

seismic mass that generates a proportional force
on piezoelectric crystal.

• Piezo electric crystal generates an electrical

charge (mv) which is proportional to applied
force.
 VIBRATION MEASUREMENT PRINCIPLES
NON-CONTACT TYPE MEASUREMENT:

PROXIMITY PROBE (EDDY CURRENT):

• Also known as displacement sensor.
• Sensor consists of a coil of wire, energized with high-
frequency alternating current (AC). (Oscillator Circuit)
• Magnetic field produced by coil induces eddy
currents in metal shaft.
• The AC signal becomes loaded due to eddy currents.
• Demodulator converts the signal into DC voltage.
• DC Voltage is directly proportional to distance.
VIBRATION MEASUREMENT PRINCIPLES
 TYPES OF VIBRATION MEASUREMENT
Three Types of Vibration Measurement:
1. RADIAL VIBRATION:
• Vibration that occurs as a force applied
outward from the shaft.
2. AXIAL VIBRATION:
• Vibration that occurs along the axis of the shaft.
3. CASING VIBRATION:
• Vibration that occurs on the housing or casing
in which shaft is located.
 TYPES OF VIBRATION MEASUREMENT

STG-1 Vib Temp.png

 BENTLEY NEVADA BN3500 VIBRATION SYSTEM

• BN 3500 provides Machine Monitoring

and Protection System.

• BN3500 system uses various types of

transducers & sensors which translate
process parameters into electrical
signals.

• These signals then processed for

protection and display.
 BENTLEY NEVADA BN3500 VIBRATION SYSTEM
• PROBES:
Eddy Current Probes. 5mm, 8mm and 11mm dia
probes.

• EXTENSION CABLES:
Connecting Probes with Proximitor. Complete the
required length.

• PROXIMITOR:
Excitation and Demodulating probes signal. 1m,
5m and 9m Systems.
 BENTLEY NEVADA BN3500 VIBRATION SYSTEM
• Total length of cable from proximitor to Probe must be either 1m, 5m
or 9m.
BENTLEY NEVADA BN3500 VIBRATION SYSTEM
 LINEAR RANGE AND SCALE FACTOR CALCULATION
LINEAR RANGE:
• Range of values in which proximitor output varies linearly with probe distance
from target.
• 2 mm (80 mils). Begins at approx 0.25 mm (10 mils) to 2.3 mm (90 mils) (approx
–1 to –17 Vdc).

SCALE FACTOR:
• Average Increase in voltage output for every 1 unit increase in probe distance
from target.
• 7.87 V/mm (200 mV/mil) ± 5% for 1m and 5m system.
• 7.87 V/mm (200 mV/mil) ± 6.5% for 9m system.
LINEAR RANGE AND SCALE FACTOR CALCULATION
LINEAR RANGE AND SCALE FACTOR CALCULATION

-24V
 PROBLEMS IN VIBRATION MEASUREMENT
Verifying The Resistance of Proximitor Transducer System.
• For 8mm Probe and Extension Cable together
– 5 Meter System 8.72 ± 0.70 Ω
– 9 Meter System 9.87 ± 0.90 Ω
• For 11mm Probe and Extension Cable together
– 5 Meter System 7.20 ± 0.80 Ω
– 9 Meter System 8.50 ± 1.10 Ω
 PROBLEMS IN VIBRATION MEASUREMENT
Verifying The Resistance of 8mm Probes.
 PROBLEMS IN VIBRATION MEASUREMENT
Verifying The Resistance of Extension Cables.
 Session-2: BN 3500 MONITORING SYSTEM
Topics

BN3500 Monitoring System Modules

Hardware Loop of Vibration / Temperature Monitoring

BN3500 Software Configuration Tool

Voting Logic of Steam Turbines

Relay Logic
 BN3500 MONITORING SYSTEM MODULES

Power Key Phasor Proximitor / Temperature Modbus

TDI Relay Proximitor
Supply Module Seismic Module Module Comm Module
Module Module
 BN3500 MONITORING SYSTEM MODULES
• Redundant Power Supplies (PIM)
• 3500/22M TDI Comm. Module
• 3500/25 Key Phasor
• 3500/42M Proximitor/Seismic monitor
• 3500/40M Proximitor Module
• 3500/65 16-Channel Temperature Module
• 3500/33 16-Channel Relay Module
• 3500/92 MODBUS Comm Module
• 94/94M/93 VGA & LCD display
 BN3500 MONITORING SYSTEM MODULES

• To measure vibration we use Proximitor

Module 3500/42M & 3500/40M.

• The transducer is connected to Proximitor

module through a I/O module to read
values.

• These Modules have 4 configurable

Channels.
 BN3500 MONITORING SYSTEM MODULES
• Hot swappable is only monitors and power
supplies

• TDI & key phasor can be swapped during

machine running.

• I/O’s modules are not hot swappable

required power shutdown for replacing.

• Care should be taken while connecting any

portable device to BN3500 rack.
HARDWARE LOOP OF VIBRATION / TEMPERATURE
HARDWARE LOOP OF VIBRATION / TEMPERATURE
 BN3500 SYSTEM CONFIGURATION TOOL

• Software tool is a GUI platform.

• Allows user to interact with the

hardware components to perform.
– Programming
– Modification
– Forcing
– Diagnostic Check
 VOTING LOGIC OF STEAM TURBINE

• BN 3500 sends High vibration / temperature alarm to PLC.

• In case of High High vibration / temperature, a direct trip command is

initiated by BN 3500.

• High High Vibration / Temperature output is based on:

– HIGH HIGH RADIAL VIBRATION
– HIGH HIGH THRUST DISPLACEMENT
– HIGH HIGH BEARING TEMPERATURES
VOTING LOGIC OF STEAM TURBINE (STG-1)
VOTING LOGIC OF STEAM TURBINE (STG-1)
 VOTING LOGIC OF STEAM TURBINE (STG-1)
SOV Trip
Valve

Safety
Relay
BN 3500

SOV Gov
Valve
PLC
 RELAY LOGIC
• Two relay modules 3500/33 16 Channels
installed in BN3500 system

• Relays in BN3500 can be configured in

following ways.
– SPDT (Single Pole Double Throw) or DPDT (Double
Pole Double Throw)
– NE (Normally Energized) or NDE (Normally De-
Energized)
– Latching or Non Latching
RELAY LOGIC
 Session-3: SPEED MEASUREMENT
Topics

Speed Measurement

BN 3701/55 ADAPT PLC

STG Over-Speed Logic and Tripping

 SPEED MEASUREMENT
• BN 3500 Measures speed of turbine
using key phasor probes and zero
speed probes.

• All these probes are proximitor based.

• Only Over Speed probes are used for

tripping purposes.

• ADAPT 3701 / 55 PLC is used for Over-

Speed detection and tripping.
 SPEED MEASUREMENT
• Two purposes of keyphasor signal:
• To provide a reference point in the
machine’s rotation to correlate other
vibration signals.
• To provide a means of measuring shaft
speed.
• The location in time of pulse represents
shaft position.
• The frequency of pulse signal
represents shaft speed.
 BN 3701/55 ADAPT PLC
• The 3701/55 ADAPT Emergency Shutdown Device (ESD) is a stand-alone,
triple-redundant system.

• Design for emergency shutdown and overspeed detection on critical and

highly critical rotating machinery.

• Consists of three redundant processor modules (CPUs) and three Relay

Modules.

• Supports sensor interfaces for speed inputs, Discrete and Analog Inputs
and 4 - 20 mA Analog Outputs.
BN 3701/55 ADAPT PLC
 STG OVER-SPEED LOGIC AND TRIPPING
• 2oo3 Over Speed Probes used for tripping of Steam Turbines.
• Overspeed Set-points are 110% of rated speed.
• Set-points of Overspeed are as follows:

S.NO STEAM TURBINE OVERSPEED SET-POINT RATED SPEED

1 STG-1 7425 RPM 6776 RPM

2 STG-2 7425 RPM 6776 RPM

3 STG-3 7700 RPM 7000 RPM

4 STG-4 4655 RPM 4232 RPM

 STG OVER-SPEED LOGIC AND TRIPPING
SOV Trip
Valve

Safety
Relay
ADAPT PLC

SOV Gov
Valve
PLC
THANK YOU