86497

Interface
Module
User Guide
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iii
Bently Nevada Corporation has attempted to identify areas of risk created
by improper installation and/or operation of this product. These areas of
information are noted as CAUTION for your protection and for the safe
and effective operation of this equipment. Read all instructions before
installing or operating this product. Pay particular attention to those areas
designated by the following symbol:
CAUTION
Bently Nevada Part No. 86947-01 M M First Printing: April 1990
Revision E M M December 1999
Copyright 1990, 1991, 1993, 1999 Bently Nevada
Corporation
All Rights Reserved
REBAM, Keyphasor, and ADRE 3 registered trademarks
of Bently Nevada Corporation.
No part of this publication may be reproduced, transmitted, stored in a
retrieval system, nor translated into any human or computer language, in
any form or by any means, electronic, mechanical, magnetic, optical,
chemical, manual or otherwise without prior written permission of the
copyright owner.
Bently Nevada Corporation
P.O. Box 157
Minden, Nevada 89423 USA
Telephone 800-227-5514 or 775-782-3611
Fax 775-782-9259
Copyright infringement is a serious matter under
United States of America and foreign copyrightlaws.
iii
FOREWORD
This manual describes installation, maintenance, and
specifications of the 86497 Interface Module. This manual is
addressed to plant engineers, plant operators, service
engineers, and technicians.
CAUTION
If seismic measurements are being made
for overall protection of a machine,
thought should be given to the usefulness
of the measurement for each application.
Most common machine malfunctions,
such as unbalance and misalignment,
occur on the rotor and originate as an
increase or change in rotor vibration. In
order for any seismic measurement alone
to be effective for overall machine
protection, a significant amount of rotor
vibration must be faithfully transmitted to
the machine casing or mounting location
of the transducer.
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CONTENTS
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Section 1
System Overview
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Electrical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Materials List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 2
Installation
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Input Signal Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Output Signal Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power Input Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GSI 122 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Section 3
Maintenance
Corner Frequency Selection . . . . . . . . . . . . . . . . . . . . . . . 14
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Appendix A
Monitor Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Appendix B
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Appendix C
Specifications
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Physical Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Ok Circuit Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Appendix D
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Machinery Considerations . . . . . . . . . . . . . . . . . . . . . . . . . 18
Measurements Considerations . . . . . . . . . . . . . . . . . . . . . 19
Direct Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Section 1
SystemOverview
General
The 86497 Interface Module provides monitoring of two Rolls Royce
aeroderivative engines by interfacing the Rolls Royce specified
accelerometer system with the Bently Nevada 3300 Monitoring
System. One 86497 Interface Module will condition three channels
of acceleration in accordance with current Rolls Royce monitoring
specifications for the RB211 and AVON engines.
The standard Rolls Royce monitoring specifications require a
bandpass velocity signal with corners at 40 Hz and 350 Hz. The
86497 Interface Module has highpass velocity signal outputs and
buffered acceleration signal outputs for each channel. The additional
outputs let you measure the vibration signal with diagnostic
equipment such as an oscilloscope or ADRE 3. These signals give
you machinery information but do not replace the monitored
bandpass velocity signal.
Electrical Description
The 86497 Interface Module powers each transducer with +24 Vdc
and detects OK limits for the input acceleration signal. Figure 1
shows the signal flow for one channel. The following paragraphs
describe this flow.
The differential input provides high common mode rejection which is
needed for noise immunity.
The highpass filter has a 40 Hz (35 Hz option) corner frequency with
a 48 db /octave rolloff. This corner is the same filter for both the
highpass velocity (H/P VEL) output and the bandpass velocity (B/P
VEL) output.
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Figure 1. Block Diagram
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The integrator converts the 5 mV/g (0.51 mV/m/s ) acceleration
2
signal to 100 mV/in/s (4 mV/mm/s) velocity signal.
The lowpass filter has a 350 Hz (400 Hz option) corner frequency
with a 24 db/octave rolloff.
The buffer amplifies the input signal sensitivity from 5 mV/g (0.51
mV/m/s ) to 10 mV/g (1.02 mV/m/s ).
2 2
Materials List
The 86497 Interface Module is shipped with the following accessory:
1 - 86947-01 Interface Module Manual.
System Description
Two system configurations are possible depending on the engines
being monitored. The AVON engine requires two channels of
monitoring, and the RB211 engine requires three. Figure 2 shows
the typical system configuration for an RB211 engine. For the
appropriate 3300/15 monitor modification refer to Appendix A.
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Figure 2. Typical System Configuration
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Section 2
Installation
Mounting
Determine the mounting location for the 86497 Interface
Module and the necessary hardware (see figure 3 for
mounting dimensions). It is preferable to mount the 86497
Interface Module within ten feet (3 metres) of the monitor(s)
and GSI 122 for minimum signal degradation.
Input Signal Cabling
The input signal originates from the Rolls Royce specified
acceleration system which consists of the CE 134
accelerometer and the GSI 122 galvanic separation interface.
The manual for this system shows how to connect the CE 134
to the GSI 122. Figure 4 shows how to connect the GSI 122
to the 86497 Interface Module. The recommended cable is 18
awg twisted pair shielded.
Output Signal Cabling
The output signal cabling connects the 86497 Interface
Module to the Signal Input Relay Module behind the 3300/15
Monitor. Figure 5 shows the proper connection between the
two instruments. Again, the recommended cable is 18 awg
twisted pair shielded.
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Figure 3. Mounting Dimensions
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Figure 4. Cabling Example
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Figure 5. Cabling Example
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Figure 6. Power Connections Examples
Power Input Cabling
Power cables are not specified. Figure 6 shows the
appropriate connections on the 86497 Interface Module.
CAUTION
To prevent safety violations from
improper wiring, be sure to follow all
applicable electrical codes when
power connections are made.
CAUTION
If the D.C. power supply is being used,
input voltages over +40 Vdc may
cause permanent damage to the
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Figure 7. Potentiometer Locations (P1,P2)
GSI 122 Adjustment
The 86497 Interface Module requires an output signal from the
GSI 122 of between 7 and 8 Vdc. Use a voltmeter to measure
the voltage between terminal 1 (Signal) and 2 (0V) on the GSI
122. If the voltage is not between 7 and 8 Vdc, use
potentiometer P2 on the rear panel of the GSI 122 to adjust
the voltage. This adjustment is not always required. P1 is
factory set and should not be adjusted. (Refer to figure 7).
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Verification
Use this procedure to verify operation of the 86497 Interface
Module. This test uses a function generator to simulate a
vibration signal input and a true rms voltmeter or oscilloscope
to measure the output of the 86497 Interface Module.
1. Disconnect the transducer wiring from channel 1.
2. Connect the test equipment as shown in Figure 8.
3. Set up the function generator with a +7.5 Vdc offset
and a 200 Hz sine wave. Choose a vibration level from
Table 1 and input the appropriate rms or peak
amplitude.
4. Verify that the output on the voltmeter or oscilloscope
is within 5% of that shown in Table 1.
Note: The highpass velocity output should be the same as
the bandpass velocity output. The acceleration output should
be 2 times the signal input.
5. Repeat steps 1 through 4 for channels 2 and 3.
Note: Vpk = Vpp/2 = V rms/.707
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Table 1
Verification Signal Levels
Vibration
Level
Input Output
rms(mV) peak(mV) rms(mV) peak(mV)
2 in/s pk 23.0 32.6 141 200
3 in/s pk 34.5 48.9 212 300
50 mm/s pk 22.6 32.0 139 197
75 mm/s pk 34.0 48.1 209 295
2 in/s rms 32.6 46.0 200 283
3 in/s rms 48.9 69.1 300 424
50 mm/s 32.0 45.3 197 278
rms
75 mm/s 48.1 68.0 295 418
rms
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Figure 8. Verification Example
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Section 3
Maintenance
Corner FrequencySelection
CAUTION
To prevent electrical shock,
disconnect power from the 86497
Interface Module before performing
maintenance.
Select, as required, the highpass and lowpass corner
frequencies by setting jumpers on the 86498-01 board. The
highpass options are 40 Hz (standard) and 35 Hz, and the
lowpass options are 350 Hz (standard) and 400 Hz. To select
the different options install the white header across the
appropriate jumper, indicated by letter A or B. Refer to Table
2:
Table2. Corner FrequencyOptions
OPTION CHANNEL 1 CHANNEL 2 CHANNEL 3
Highpass W100B W200B W300B
35 Hz W108B W208B W308B
to to to
Highpass W100A W200A W300A
40 Hz W108A W208A W308A
to to to
Lowpass W109B W209B W309B
350 Hz W112B W212B W312B
to to to
Lowpass W109A W209A W309A
400 Hz W112A W212A W312A
to to to
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Appendix A
MonitorModifications
The following are the modification numbers to the 3300
Monitor with a brief description:
Table3. Peak Readout Options
Modification Description
156497-01 Dual Channel 3300/16 monitor with English
meter scales from 0 to 3 in/s pk
156501-01 Dual Channel 3300/16 monitor with English
meter scales from 0 to 3 in/s pk
156499-01 Single channel 3300/16 monitor with Metric
meter scales from 0 to 75 mm/s pk
156503-01 Single channel 3300/16 monitor with Metric
meter scales from 0 to 75 mm/s pk
Table4. RMS Readout Options
Modification Description
156328-01 Dual channel 3300/26 monitor with English
meter scales from 0 to 2 in/s rms
156332-01 Single channel 3300/26 monitor with English
meter scales from 0 to 2 in/s rms
156330-01 Dual channel 3300/26 monitor with Metric
meter scales from 0 to 50 mm/s rms
156333-01 Singe channel 3300/26 monitor with Metric
meter scales from 0 to 50 mm/s rms
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Appendix B
SpareParts
Bently Nevada recommends ordering identical units for spare
parts; however, the manual can be purchased separately if
needed. Part number 86947-01 is the 86497 Interface Module
Manual.
AppendixC
Specifications
Environmental
Temperature
Storage: -4 to +158EF
(-20 to +70 EC)
Operating: +32 to +140EF
(0 to +60 EC)
Humidity: 5% to 90%
noncondensing
Electrostatic Discharge: 10k through 1000 S
PhysicalInterface
Mounting Size: 12.48 x 7.6 x 3.12 in
(317 x 193 x 79.2 mm)
Overall Size: 12.06 x 9.12 x 3.75 in
(306 x 232 x 95.3 mm)
Weight: less than 5 lbs (2.27 kg)
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Electrical
Power Input
A.C. option: 85 to 265 Vac,
at 47 to 440 Hz
D.C. option: +20 to +34 Vdc
Transducer power input: -23 to -24.5 Vdc
Power Output +22 to +25.5 Vdc,
per Channel: at 80 mA
Sensitivity
Input: 5 mV/g (0.51 mV/m/s )
2
Output
B/P VEL and
H/P VEL: 100 mV/in/s (4 mV/mm/s)
ACC: 10 mV/g (1.02 mV/m/s )
2
Corner Frequencies
High Pass: 35 and 40 Hz,
at 48 db/octave rolloff
Low Pass: 350 and 400 Hz,
at 24 db/octave rolloff
OK Circuit Detect
The OK circuit detect defines a window of OK operation for the
transducer. If the input to the interface module is outside of
the OK window listed below, the output will be driven to 0 Vdc
which is not OK for a 3300 monitor. To return to an OK
condition the input to the interface module must be within the
OK Recover window listed below.
OK: 5.03 V to 11.87 V nominal
OK Recover: 5.53 V to 11.86 V nominal
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Appendix D
Considerations When Using Aeroderivative Gas Turbine
Monitoring Systems
Introduction
Bently Nevada aeroderivative gas turbine monitoring systems
are designed using specifications established by the engine
manufacturers. These specifications require seismic vibration
transducers which have limitations. Monitoring systems which
are based solely on casing or bearing housing seismic
measurements cannot provide information to protect against
certain types of engine malfunctions. This appendix lists these
limitations and describes options that can enhance the
seismic based systems.
MachineryConsiderations
Most common machine malfunctions, including unbalance
and misalignment, originate at the rotor and cause a change
in shaft vibration. The extent to which this vibration may be
transmitted to the bearing housings and machine casing
depends upon the machine's transfer ratio. Using seismic
transducers to monitor the effects of shaft vibration requires
that the transfer ratio be large and relatively constant with
varying machine speed. Experience has shown that
transmission of shaft vibration is not constant along the rotor
span or machine frame and may vary due to the nature of the
vibration source and machine speed.
Seismic measurements, although useful for detecting some
machine problems, provide only an indirect indication of shaft
vibration. They are not ideal for rotor monitoring purposes
and offer limited information for rotor behavior diagnostics.
Rotor vibration occurs typically in the frequency range of 25
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Hz (1500 cpm) to 400 Hz (24,000 cpm). Turbine blade
passage vibration exists at much higher frequencies, typically
5 kHz (300,000 cpm) to 15 kHz (900,000 cpm). Blade passage
vibration routinely causes very high acceleration amplitudes,
typically 10 to 100 times higher than the levels from rotor
vibration sources.
MeasurementConsiderations
When seismic transducers are specified, the high temperature
accelerometer is the type that has demonstrated the best
ability to survive the temperature and vibration environment of
aeroderivative gas turbines. This transducer, however, has its
own set of limitations.
As stated, blade passage vibration acceleration amplitudes
are typically 10 to 100 times higher than those from rotor
vibration sources. Reliably extracting the small rotor vibration
signals from the high amplitude blade vibration signals is not
easy. The monitoring system must have a wide dynamic range
to prevent saturation by blade passing frequency vibration.
Both signal integration and special filtering are needed which
makes the monitoring system complex. Because of this
complexity, the system is more susceptible to false alarms
and/or missed detection of a real machine malfunction.
To achieve reliable machine information, a vibration
monitoring system must be simple. Direct measurement of
rotor vibration can play an important role in achieving this
reliability because it allows the monitor to be simple and thus
more reliable.
Direct Measurements
Bently Nevada offers vibration monitoring systems for
aeroderivative gas turbines that use displacement transducers
to observe the shaft or the outer ring of the bearing. These
systems provide more complete machinery vibration
information than seismic transducer based monitoring
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systems. These monitoring systems do not need the wide
dynamic range, special filtering, and electronic integration
required by seismic systems. As a result, they are simpler and
more reliable.
Direct measurements do not depend on a transfer ratio which
is seldom constant. Since displacement is being measured, a
wide dynamic range is not required to prevent saturation by
blade passing frequency vibration. This is because blade
passing frequency vibration, even though it has high
acceleration amplitudes, has low displacement amplitudes. As
an example, 50 g (490 m/s ) acceleration at 10 kHz (600,000
2
cpm) is only 9.78 Fin (0.248 Fm) displacement.
These displacement systems are based on proximity probes
specially developed for this application. The probe tip and
body operate at temperatures up to 500EF (260 EC).
Probe cables are available in two types. One is a flexible cable
that will operate at temperatures up to 482 EF (250 EC). This
withstands the temperatures normally encountered exiting the
compressor portion of the turbine. The other is a semirigid
cable that operates at temperatures up to 1800EF (982EC).
This withstands the temperatures often encountered when
exiting the turbine through the hot gas path. These
transducers overcome most of the temperature problems that
are encountered with installation of proximity probes in
aeroderivative gas turbines.
Rotor support in aeroderivative gas turbines is provided by
rolling element bearings. Many gas turbines utilize squeeze
film dampers. Standard sensitivity proximity probes are very
effective in measuring shaft vibration in these cases. A
proximity probe can observe either the shaft near the bearing
or the outer ring of the bearing. The motion of the outer ring
of a squeeze film damped bearing is essentially the motion of
the shaft because virtually all of the shaft motion appears
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across the damper.
Direct shaft relative measurements with standard sensitivity
proximity probes are also useful with rigidly mounted
bearings, especially when made several shaft diameters away
from the bearings.
In the case of rigidly mounted rolling element bearings, a
monitoring system is available that uses a special high
sensitivity proximity probe transducer system called REBAM
(Rolling Element Bearing Activity Monitor). The REBAM
proximity probe directly measures the small deflections in the
outer ring of a rolling element bearing. In addition to providing
rotor related information, REBAM is useful in detecting bearing
failure.
Proximity probes can also be used to provide a
once-per-revolution (Keyphasor) signal. This is very useful
in balancing and rotor diagnostics.
Summary
Seismic transducers have limitations. One must understand
and consider these limitations when specifying seismic
transducers exclusively for monitoring aeroderivative gas
turbines. Direct reading shaft or REBAM probes overcome
many of these limitations and can provide superior
performance. Bently Nevada Corporation is ready to help you
engineer and install the proper combination of vibration
measurements to provide a reliable and effective monitoring
system for your aeroderivative gas turbine.
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