1 Introduction

 

Introduction of SY3000 on-line monitoring and protection system 

★Long time on-line monitoring and failure diagnose for varies rotary machines
★Break the tradition, SY3000 system is the first one which integrates TSI with TDM in the same system.
★Fully compatible with NT6000 DCS system for control of turbine.
★In line with the American Petroleum Institute API670 standard, it has passed the CE certification.
 
SY3000 on-line monitoring and protection system provides online parameter measuring, safeguard, vibration failure analysis for rotary machine, especially for field application of electricity, metallurgy, petrochemical etc. Integrate TSI and TDM as a whole, with combination of the most advanced computer and communication technology, using advanced production process, SY3000 system is a most secure protective device for rotary machine which is fully compatible with NT6000DCS system for control of turbine. Sciyon Group provides DEH, ETS and TSI complete solution for you, effectively improves the industrial automation level and informatization level.

1.1 System structure
 
SY3000 system absorbed many advantages of monitoring and vibration analysis system from both home and abroad. With combining TSI with TDM in a same system as its innovation, SY3000 system seamless connects with the latest generation of DCS system of Sciyon and becomes its subsystem with TSI function. SY3000 system not only realizes TSI and TDM function on its own engineer station, but also conducts system configuration and data monitor in TSI as a subsystem of DCS system.
 
TSI system in SY3000 system is consists of sensor, monitor, communication network, computer and configuration software. TDM consists of transmission control module which has transient data collection and management function, transient data acquisition I / O module, vibration monitoring and fault diagnosis software package on the basis of TSI system.

1.2 Features of the system
 
●Modules and monitors are few, the cost of spare parts is reduced.
 
SY3000 on-line monitoring and protection system consists of power, transmission control module and varies monitors with a standard 19-inch cabinet, the design cuts module and monitor as much as possible to reduce the cost. 

●Power and transmission control modules are redundant designed, each monitor work independently, to maximum ensure the safe running of  the  unit.
 
Both power and transmission control modules of SY3000 on-line monitoring and protection system are redundant designed. Each monitor works independently, the transmission control module does not effects the monitor after configuration. Transient data acquisition, real-time data display, parameter configuration, and data communication functions can be completed by transmission control module, it also real-time monitors whether the running status of modules and parameters maintain normal. The reliability of the system has been improved by this mode of centralized management and distributed control.
 
●Industrial chip, multi-layer printed circuit board and SMT are adopted by all modules and monitors.
 
The dual-core RISC POWERPC processor with industrial-grade and low power consumption has been adopted by transmission control module and all monitors adopt 32-bit industrial-grade processor. All monitors and modules are designed with standard plug-in structure, support hot plug, in line with ISO / DIN standard, have strong electromagnetic compatibility and anti-interference capability.
 
●Compatible with sensors from different manufacturers at home and abroad, linearity correction of sensor and channel self-diagnose function can be achieved.
 
SY3000 on-line monitoring and protection system compatible with sensors from different manufacturers at home and abroad. Targets and sensor parameters can be configured and linear calibration function of LVDT and eddy current sensor can be achieved. Each channel of SY3000 system has self-diagnose function, the sensor inputs failure and alarm automatic bypass for malfunction preventing.
 
●Intelligent relay management for various logic alarm output

Logic alarm output of various channels can be realized by management of relay output status of SY3000 system by unique relay output module.

●Integrate with NT6000 DCS system, provides online vibration monitor and fault diagnosis.

SY3000 online monitoring and protection system is the first one which integrates TSI and TDM in a same system in China. At most 32 channels transient data can be collected synchronous with high-speed and provided to engineer station through redundant 100M Ethernet. After processed by vibration monitoring and fault diagnosis software, the real-line vibration monitoring and fault diagnosis function can be achieved. Meanwhile, SY3000 system works as a distributed data acquisition station of Sciyon NT6000 DCS system, which completes the configuration, centralized monitoring and recording function of TSI.

Main technical parameters

 

 

1.3 List of main modules, monitors for the whole System 

Name

Main functions

Size and location

Remarks

System framework

Applied for installation of power, communication control modules and all monitoring modules. Provides backplane bus for communication between modules and power.

Width 19 inches (84Te), height 6U, at most eleven monitor modules.

Mandatory

Power module

Supply for the system, redundant configuration is available. Input :90-260VAC

It is a half-height module, installs on the front of power slot at left side of the frame only, redundant installation is available.

Mandatory

Terminal Control Module TCM

It is not only the gateway communication module for condition monitoring and protection system of SY3000, but also the control unit of the whole system. At most 32 channels of transient data can be collected simultaneously. Redundant configuration is available.

It is a half-height module, installs on front of power slot at left side of the frame only, redundant installation is available.

Mandatory

Over-speed Protective Monitor

Single-channel monitor, fast acquisition of turbine revolution signal for over-speed protection while running.

Height 6U, width 6Te

Two over-speed protection modes optional:

1.       One out of two protection mode.

2.       Two out of three protection mode.

Vibration / displacement Monitor

4-channel monitor for monitoring shaft vibration, bearing vibration, differential expansion, valve position, axial displacement and other displacement signals.

Height 6U, width 6Te

 

Key phase / eccentricity / zero speed monitor

4-channel monitor for turbine key phase, eccentricity, zero-speed signal.

Height 6U, width 6Te

 

Relay output module

16-channel relay outputs, provides relay output normal open (close) node for the whole system.

Height 6U, width 6Te

 

I/O module

Provides input / output wiring terminal for various modules and monitors, analog signal regulating.

Height 6U, width 6Te, installs on I / O module slot at the back of the cabinet.

 

Note: 1U = 44.45mm
1Te = 5.08mm

1.4 Main electrical index

◆Output and interface
Alarm output: normal open node of relay output, capacity 5A / 30VDC or 5A / 250VAC.
Communication interface: Modbus, 100M Ethernet.
BNC Output: Each functional module has sensor original signal buffer output (designed 50 ohm impedance).  
Analog Output: Each functional module has current (4 ~ 20) mA output.

 ◆Ambient temperature
Operating temperature: (-20 ~ +50) ℃
Storage temperature: (-30 ~ +65) ℃
Humidity: RH (20 ~ 95)%, no condensation

◆Electromagnetic compatibility
IEC 61000-6-2 2005 Electromagnetic compatibility (EMC) –Immunity for industrial environments    
IEC 61000-6-4:1997 Electromagnetic compatibility (EMC) – Emission standard for industrial environments
IEC 61000-4-11:2004 Electromagnetic compatibility (EMC) Testing and measurement techniques- Voltage Dips, Short interruptions and voltage variations immunity test
IEC 61000-4-2:2001 Electromagnetic compatibility (EMC) Testing and measurement techniques - Electrostatic Discharge Immunity Test
IEC 61000-4-3:2006 Electromagnetic compatibility (EMC) Testing and measurement techniques - Radiated, radio-frequency, electromagnetic field immunity test
IEC 61000-4-4:2004 Electromagnetic compatibility (EMC) Testing and measurement techniques - Electrical fast transient/burst immunity test
IEC 61000-4-5:2005 Electromagnetic compatibility (EMC) Testing and measurement techniques - Surge immunity test
IEC 61000-4-6:2006 Electromagnetic compatibility (EMC) Testing and measurement techniques - Immunity to conducted disturbances, induced by radio-frequency fields
IEC 61000-4-8:2001  Electromagnetic compatibility (EMC) Testing and measurement techniques -  Power frequency Magnetic Immunity Test

◆Insulation
Insulation resistance: greater than 50MΩ.
Insulation strength: Maximum 1500V, lasts for 1 minute, leakage current not exceed 5 mA.
Power output: (90~264)VAC,(47~63)Hz. 
Power: 160 × 2 (W).

◆Body size 
Standard body: Width 483.3mm ×height 266.5 mm × depth 300 mm. 
Weight: about 25Kg.
Installation mode: Disc or cabinet install. 
Outline: refer to chapter 2 system framework.
 
2 System framework
 
The framework used for installation of all modules and monitors including system body and backplane, is particularly suitable for industrial environments. The body is assembled according to EIA (Electronic Industries Association) standard. The body with width of 19 inches and height of 6U can be configured with power module and terminal control module and eleven monitors. There are slots in cabinet, the power module and transmission control module are installed at left side, varies monitors can be installed on other slots. The module is inserted in the slot at backplane of the body along with the bottom plate, there are input and output signal terminals for I/O modules at the back of cabinet, wiring inside the cabinet is unnecessary.
 
The framework is powered by a power supply module named SY3210, two power supply modules are available as redundant power supply. Different I / O modules are installed at the back of the framework, which is equipped with senor/ wiring terminals and other signal terminals.
 
The framework is usually configured at factory and can be used directly. The monitor and module can also be configured at site by user. The slot without module is covered by bland flange.
 
2.1 Cabinet
 
The body is assembled according to EIA (Electronic Industries Association) standard. Width: 19 inches, height: 6U.
 
 
 
Front view 
Back view
 
2.2 System backplane

The backplane is installed in the middle of the cabinet, which provides power and communication bus for SY3000 system. The slot of power and transmission control module is fixed. SO1-SO8 is a transient data acquisition slot, at most eight channels of transient data can be collected by TCM when the system is equipped with TDM.
 
 
Slot distribution diagram
 

Order instruction:

System framework (body + backplane):
 
Model:SY3000

3 Main modules and monitors

3.1 Power module
 
The power SY3210 is a half-height module which must be installed in the specially designed power slot at the left side of the framework. One or two such modules can be installed on SY3000 framework, each one can supply for the whole system. The operation of the system will not be affected if there is only one power or the second power is under the condition of remove or install.

Main parameters:

Power input : AC (90 ~ 264) VAC, frequency (47 ~ 63) Hz, Fuse 2A
Power: maximum output is 160W each module
Output indication: when the power supply is normal, OK lights.

Order instruction:

■Power module: Model:SY3210  
Power I/O module: power supply module is required to use with power I / O module

Model:SY3211
Recommended: redundant power installation, SY3210 * 2 + SY3211
 
 
3.2 Transmission Control Module (TCM)

Transmission control module communicates with all the monitors and integrates with NT6000 DCS system through redundant Ethernet, to make SY3000 system sub-station of DCS system. Transmission control module is not only the gateway communication module for monitoring and protection module of SY3000, but also the control unit of the whole system. Alarm value, risk value, measuring range, measuring spot name etc. can be configured by TCM, which will not affect the independent operation of each monitor.

TCM must be used with I / O module and inserted in its slot, varies I / O modules can be selected according to users requirement. At most 32 channels of vibration transient data can be collected by TCM simultaneously, these data can be uploads to client end through redundant Ethernet for on-line fault analysis. The sampling frequency of each TCM channel reaches up to 100KHz for ensuring  the high-speed sampling of (0 ~ 40) KHz vibration signal. 
 
Main functions:
 
■Alarm value, risk value, measuring range, measuring spot name etc. can be configured by TCM, which will not affect the independent operation of each monitor.
■Redundant configuration is available, TCM communicates with different monitors which real-time monitor whether the running status and working parameters stay normal.
■With transient data acquisition function, at most 32 channels vibration transient data can be collected, the sampling frequency reaches up to 100KHz for each channel. Synchronous waveform sampling frequency can be configured by user, non-synchronous data sampling supports 800-line spectrum when the bandwidth is 30K.
 
1024 sampling point/revolution*2 revolutions
720 sampling point/revolution*2 revolutions
512 sampling point/revolution*4 revolutions
360 sampling point/revolution*4 revolutions
256 sampling point/revolution*8 revolutions
128 sampling point/revolution*16 revolutions
64 sampling point/revolution*32 revolutions
32 sampling point/revolution*64 revolutions
16 sampling point/revolution*128 revolutions
 
■With standard ModBus interface, redundant Ethernet interface, the system is fully compatible with NT6000 DCS.
■Setup of monitor configuration lock. All relays reset buttons.
■9 LEDs respectively indicates the working status of communication module (power 1 / power 2, master / slave\, E-net1/E-net2, initialization, synchronization, configuration).
 
Technical parameters

Input

Single-channel key phase pulse inputs, receives signals from eddy current sensor and photoelectric sensor. During the transient data collection, the key phase pulse can be taken as multi-channel synchronization signal, the key phase pulse inside the system framework can also be regarded as synchronization signal.
 
Output

Standard Modbus interface, redundant 100M Ethernet interface.

Display

PS1/PS2           LED: Power 1 / Power 2 working indication light
Pri / Standby     LED: TCM master / slave working indicating light
Net1/Net2         LED: E-net1/E-net2 indication light
Initial                  LED:     TCM initial indication light
Duplex               LED:    TCM synchronization indication light
Config.               LED:    System configuration indication light

Power consumption

Less than 10W

Order instruction:

Transmission control module (TCM)
■Model:SY3000
Transmission control I/O module:
Transmission control I/O module is a full height module, which can maximum connects with two transmission control modules for providing them with input and output wiring terminals. I / O modules can be selected according to users requirement.
(1) General I / O module provides input and output wiring terminal for transmission control module without transient data acquisition function.
■Model:SY3311
(2) 16-channel transient data acquisition I / O modules collect 16-channel transient data synchronously with high-speed.
■Model:SY3312
(3) 32-channel transient data acquisition I / O modules collect 32-channel transient data synchronously with high-speed.
■Model:SY3313
Recommended configuration: if transient data acquisition function is not required, transmission control module independently runs: SY3310 * 1 + SY3311
if transient data acquisition function is required, transmission control module redundant runs:SY3310*2+SY3312(SY3313)
 

IO module diagram


3.3 Over-speed protective monitor
 
This over-speed protective monitor collects revolution signal of turbine, provides over-speed protection with high reliability and quick response while running. There are two over-speed modes available in SY3000 system: one out of two over-speed protective mode or two out of three over-speed protective mode, the former needs to install two adjacent over-speed protective monitors and the latter needs to install three adjacent protective monitors. Over-speed protective monitor can be installed on any monitor slots are long as they are next to each other, only one voting system can be installed in a SY3000 system.
 
Main functions:
 
■Each revolution channel independently responds to different active or passive sensors, -24V DC power is provided to proximitor by monitor when the input is eddy current sensor.
■There are two loops as alarm and risk relay output for each channel, the range of alarm delay time is (0 ~ 60) s.
■Configuration of the monitor in operation or when the sensor fault diagnosis. In order to avoid relay malfunction, automatic bypass all the output relays.
■Outputs current signal (4-20mA) which is proportional to revolution with short circuit protection.
■Alarm value, risk value, measuring scale, measuring point name and other parameters can be set via configuration software. The operation is instructed by graph, which is convenient to use.
■There are seven LEDs on the panel which respectively indicates the current work status of the channel (normal, communication, bypass, over-speed alarm and risk alarm, over-speed alarm and risk alarm after logic vote).
■BNC plug at front panel outputs buffered sensor signal.

 

Main parameters:

Input

Type of input sensor: eddy current sensor, LVDT, magnetoresistive velocity sensor (The output voltage is related to turbine revolution and the installation space)
Monitor threshold voltage: 500mV peak value

Detection range

Revolution monitoring range: (0 ~ 15000) r / min

Output

Proximitor power output: (-23.2 ~ -24) VDC, 50mA, output short circuit protection
(4 ~ 20) mA output: 1 ‰ FS, maximum load 500 ohms
Relay output: 5A/30VDC,5A/250VAC

Display

OK          LED: indicates the module works normal.
TX / RX   LED: indicates the module is communicating with other modules of SY3000 system.
Bypass   LED: indicates the module is in bypass status
RL1         LED: indicates the alarm has occurred, the RL1 relay has operated.
RL2         LED: indicates the risk has occurred, the RL2 relay has operated.
RL3         LED: indicates over-speed voter alarm has occurred, the RL3 relay has operated.
RL4         LED: indicates over-speed voter alarm has occurred, the RL3 relay has operated.  
 
Alarm

Alarm setting: risk value greater alarm value is recommend for every two point alarm (alarm and risk) of the full measuring scale.
Alarm delay: any integer from 0 to 60, default 3 seconds.
Alarm output: relay normal open, normal close node mode output, contact capacity is 30VDC/5A or 250VAC/5A.

Action time for over-speed protection system

Less than 30ms (including relay actuation time) when the frequency is higher than 2000Hz

Power consumption

Less than 7W

Order instruction:

Over-speed protective monitor
■Model:SY3410
I / O modules for over-speed protective monitor
Over-speed protective monitor must be used with corresponding I / O modules.                  
■Model:SY3411
 (2) General I / O module, single-channel signal alarm and risk relay output with two out of three logic voter for over-speed protection system. There is only one I / O module in a SY3000 system.
■Model:SY3412
Recommend configuration: two out of three over-speed protective mode, SY3410 * 3 + SY3411 * 2 + SY3412
 
 
I / O panel diagram


3.4 Vibration / Displacement monitor
 
Vibration / displacement monitor is a 4-channel monitor, receives signals from displacement sensor and velocity sensor, after processing signals from these devices, varies vibration and position measurement can be done, then compare those processed signals with alarm values of user programmed.
 
The main objects under measurement of vibration / displacement monitor are: shaft vibration, bearing vibration, axial displacement, differential expansion, absolute expansion.
 
Main functions:

■Monitor 4-channel sensor signal, -24V DC is supplied to proximitor by monitor when input eddy current sensor.
■Measuring objects and sensor parameters can be configured by software and linear calibration of LVDT and eddy current sensor can be done.
■When configuration of the monitor and diagnose the sensor failure, automatic bypass all the output relays in order to avoid malfunction of the relay. 
■ Each channel outputs current signal (4-20mA) which is proportional to vibration / displacement, current output has short circuit protection function.                                                                                                                                                                
■ Alarm value, risk value, measuring scale, measuring point name and other parameter can be set via configuration software. The operation is instructed by graph, which is convenient to use.
■ There are eleven LEDs on panel, each LED respectively indicates the current work status of the channel (normal, transmission, bypass and the status of each relay).
■ There are two loops as alarm and risk relay output for each channel, also, logical combination alarm output between channels can be set, the range of alarm delay time is (0 ~ 60) s.
■ BNC plug at front panel outputs buffered sensor signal.
 
Main parameters:

Input

Type of input sensor: eddy current sensor, LVDT, magnetoresistive velocity sensor

Detection range

Shaft vibration detection range: maximum 1000μm
Bearing vibration detection range: maximum 500μm
Displacement monitoring range: depends on measuring range of the sensor.  
 
Output

Proximitor voltage output: (-23.2 ~ -24) VDC, 50mA, output short circuit protection
(4 ~ 20) mA output: 1 ‰ FS, maximum load 500 ohms
Relay output: 5 A / 30 VDC, 5 A / 250 VAC
 
Display

OK              LED: indicates the module works normal.
TX / RX      LED: indicates the module is communicating with other modules of SY3000 system.
Bypass     LED: indicates the module is in bypass status.
RL1-RL8  LED: indicates the alarm has occurred, the RL1 relay has operated.

Alarm

Alarm setting: risk value greater alarm value is recommend for every two point alarm (alarm and risk) of the full measuring scale.
Alarm delay: any integer from 0 to 60, default 3 seconds.
Alarm output: relay normal open node mode output, contact capacity is 30VDC/5A or 250VAC/5A.

Power consumption

Less than 10W

Order instruction:

Vibration / Displacement monitor:

■Model:SY3420
Vibration / Displacement monitor I / O modules:
Over-speed protective monitor must be used together with corresponding I / O modules.
(1) I / O module for eddy current sensor, access 4-channel eddy current sensor signal, used for turbine shaft vibration monitoring, axial displacement, differential expansion.
■Model:SY3421
(2) I / O module for magnetoresistive velocity sensor, access 4-channel eddy current sensor signal, used for turbine bearing vibration monitoring.
■Model:SY3422
(3) LVDT sensor I / O Module, access 4-channel LVDT signal, used for turbine absolute expansion, servomotor valve position and oil tank level.
■Model:SY3423
(4) 2-channel LVDT signal and 2-channel eddy current sensor signal accessed to 2-channel LVDT and 2-channel eddy current sensor I / O module for monitoring absolute expansion of axial displacement.
■Model:SY3424
Recommend configuration: varies I / O modules are available according to object to be measured.
 
 
I / O panel diagram


3.5 Key phase / eccentricity / zero speed monitor

Key phase / eccentric / zero speed monitor detects four-channel eddy current sensor signal, monitor one loop key way signal, one loop eccentricity and two loops zero speed signal. The monitor occupies one slot, can be installed on any slot for monitor.
 
The cycle and phase position are detected by key phase signal of the rotary machine. The key phase signal can be considered as synchronization signal collected by multi-channel transient data or trigger signal collected by eccentricity testing and vibration testing.

The peak value of eccentricity of rotor in running, start and stop are continuously monitored and measured by eccentricity signal.
 
Zero speed signal detection is used for measuring and monitoring of rotary machine, alarm or shutdown will happen when the speed of rotary machine is lower than the alarm value.
 
Main functions:

■Monitor signals of 4-channel eddy current sensor, -24VDC is supplied to Proximitor.
■Measuring objects and sensor parameters can be configured by software and linear calibration of eddy current sensor can be done.
■When configuration of the monitor or sensor failure, automatic bypass all the output relays in order to avoid malfunction of the relay.
■Output (4 ~ 20mA) current which is proportional to all the eccentricity / zero speed signal range. Current output has short circuit protection function.                                                         
■Alarm value, risk value, measuring scale, measuring point name and other parameter can be set via configuration software. The operation is instructed by graph, which is convenient to use.
■There are nine LEDs on panel, each LED respectively indicates the current work status of the channel (normal, transmission, bypass and the status of each relay).
■There are two loops as alarm and risk relay output for each channel, also, logical combination alarm output between channels can be set, the range of alarm delay time is (0 ~ 60) s.
■BNC plug at front panel outputs buffered sensor signal.
 
Main parameters:

Input

Type of input sensor: eddy current sensor

Detection range

Eccentricity detection range: maximum 1000μm
Revolution monitoring range: (0 ~ 9999) r / min
 
Output

Proximitor power output: (-23.2 ~ -24) VDC, 50mA, output short circuit protection
(4 ~ 20) mA output: 1 ‰ FS, maximum load 550 ohms
Relay output: 5 A / 30 VDC, 5 A / 250 VAC   
 
Display

OK       LED: indicates the module works normal.
TX / RX   LED: indicates the module is communicating with other modules of SY3000 system.
Bypass    LED: indicates the module is in bypass status.
RL1-RL6   LED: indicates the alarm has occurred, the RL1 relay has operated.
 
Alarm

Alarm setting: risk value greater alarm value is recommend for every two point alarm (alarm and risk) of the full measuring scale.
Alarm delay: any integer from 0 to 60, default 3 seconds.
Alarm output: relay normal open node mode output, contact capacity is 5A/30VDC, 5A/250VAC.

Power consumption

Less than 7W
 
Order instruction:

Key phase / eccentricity / zero speed monitor:
■Model:SY3430
Key phase / eccentricity / zero speed monitor must be used together with I/O module.
Key phase / eccentricity / zero speed monitor I/O module
■Model:SY3431
Recommend configuration: key phase / eccentricity / zero speed monitor, SY3430 + SY3431

 

I / O panel diagram
 
3.6 Relay Output Module

 Relay module provides relay output normal open node for the entire framework, all alarm signals of monitor can be logic output by varies configurations by user. There are sixteen relays, eight of which is relay normal open node mode output, the other eight is normal open, normal close output. The relay module occupies a slot, which can be installed on any slot for monitor.
 
Main functions:

■Provides relay output normal open (close) node for the whole system.
■Alarm signal of monitor can be logical combination output via configuration.
■There are 19 LEDs for relay output module, the status indicating light of the first three modules respectively (normal, communication, system), and the remaining 16 LEDs are relay status indicating light.
 
Main parameters:

Output

Relay output: 5A/30VDC,5A/250VAC
 
Display

OK          LED: normal working indicating light.
TX / TR   LED: communication indicating light
1-16        LED: indicates the alarm has occurred, the relay has operated.
 
Alarm setup

Alarm delay: any integer from 0 to 60, default 3 seconds.
Alarm output: relay normal open, normal close node mode output.
 
Power consumption

Less than 7W
 
Order instruction:

Relay output module:
■Model:SY3510
Relay output I/O module:
Relay output module must be used with relay output I / O module.
■Model:SY3511
Recommend configuration: SY3510+ SY3511  
 
 
I / O panel diagram
 
4.Sensor
 
 4.1 SY-T03 magnetoresistive sensor
 
 Product overview:

The rotary unit under induction by SY-T03 magnetoresistive sensor must be gear or orifice, the modulus of gear greater than 2, the sensor can be installed in the radial or axial direction, the sensor face is 1mm away from the air gap, the farther the distance is, the greater the sensor output signal, the sensor output is dual-core shielded cable. SY-T03 magnetoresistive sensor adopts new technology and special material, the sensitivity is better than similar domestic sensor.  
 
Working principle:

 There is permanent magnet in SY-T03 magnetoresistive sensor which formed magnetic field at the head, the coil inside senses the changes of AC voltage signal if reluctance changes.
 
Technical index:

(1) Coil resistance: about 380 ohms

(2) Output voltage:
In order to obtain a larger output and approximate sinusoidal wave form, involute gear must meet: tooth length ≥ φ (φ is the diameter of sensor probe), pitch ≥ 3φ, tooth ≥ pitch, the distance between sensor end and addendum <1mm. In addition, the output value will increase if the diameter and the number of teeth are large. Output voltage waveform: involute gear output is similar to sinusoidal wave, orifice outputs positive and negative pulse.

Revolution rpm

10

20

50

100

200

500

1000

 2000

5000

Output voltage (RMS) ≥

50mV

100mV

250mV

500mV

1V

2.5V

5V

8V

10V


(3)  Dimension:
The shell is made of M16 × 100 stainless steel and the front is made of φ4 pure iron.
Lead socket:×12K4P
Lead plug:×12K4P

Sensor outline:
 
 
Order instruction:

SY-T03: indicates magnetoresistive sensor.
 
4.2 SY-MT speed sensor

Product overview:

SY-MT series speed sensor used for inducing of absolute vibration between bear base, shell or structure and free space. The measuring frequency range is generally 15Hz ~ 1000Hz, standard sensitivity is 30mV/mm/s. It can be vertically or horizontally installed. With high anti-interference ability, it is able to work in harsh environment with reliability and stability.   
 
Working principle:

SY-MT series speed sensor mainly consists of magnetic system, inertial mass, spring damper etc. It changes vibration signal into voltage signal on the basis of electromagnetic induction principle, this voltage signal is in proportion to vibration value of the object under measurement, displacement signal can be obtained after integrating and amplification of this signal, thus, overall condition of rotary machine or reciprocating machine can be evaluated.
 
Main technical parameters: 
 

 

5.2 System features
 
On-line vibration monitoring and turbine diagnosis system results from absorbing international advanced technology, it is a product particularly for running condition and parameters of large rotary machines such as turbine in coal fired power plant, the system based on windows operating system integrates expert system, neural network system for achieving online monitoring of running status, vibration monitoring, historical data storage and management and fault diagnosis etc. With English interface, abundant functions, convenient use, SY3000 system provides a powerful technology tool for turbine vibration monitoring and fault diagnosis, represents domestic leading level. The functions are as follows:

●Windows operating platform with English menu
●Real-time monitors and storages varies status signals of unit such as shaft vibration, bearing vibration, axial displacement, differential expansion, revolution, vector etc.
●High capacity of historical database management
●Powerful analysis function, rich real-time charts in the condition of transient, steady state and alarm state.
  Time domain analysis: general diagram, time domain waveform, data list, bar graph, amplitude trend graph, axis orbit
  Frequency domain analysis: spectrum, phase, waterfall plot, two dimensional holographic spectrum
  Variable speed and trend analysis: cascade diagram, bode diagram, polar coordinates, trend analysis chart
● Advanced failure diagnosis package, expert system, online / offline failure diagnosis
● Dynamic balance calculating
● Flexible on-line configuration of system parameter, rich report and graphic printing function
● Post disturbance review (PDR) and storage of alarm file

 

Model

MT2/MT3

Measuring direction

Horizontal, vertical

Sensitivity

30mV/mm/s

20mV/mm/s

Measuring range

±1mm

Frequency Response range (-3dB)

12Hz~1000Hz

Linear error

±3%

Maximum output voltage (half-peak)

3V(MT3)

 

2V(MT2)

Environment temperature range

(-20~80)

Dimension

Φ32×85mm

Installation Method

Screw \ magnet \ stylus

 
Order instruction:

 

5.2 System features
 
On-line vibration monitoring and turbine diagnosis system results from absorbing international advanced technology, it is a product particularly for running condition and parameters of large rotary machines such as turbine in coal fired power plant, the system based on windows operating system integrates expert system, neural network system for achieving online monitoring of running status, vibration monitoring, historical data storage and management and fault diagnosis etc. With English interface, abundant functions, convenient use, SY3000 system provides a powerful technology tool for turbine vibration monitoring and fault diagnosis, represents domestic leading level. The functions are as follows:

●Windows operating platform with English menu
●Real-time monitors and storages varies status signals of unit such as shaft vibration, bearing vibration, axial displacement, differential expansion, revolution, vector etc.
●High capacity of historical database management
●Powerful analysis function, rich real-time charts in the condition of transient, steady state and alarm state.
  Time domain analysis: general diagram, time domain waveform, data list, bar graph, amplitude trend graph, axis orbit
  Frequency domain analysis: spectrum, phase, waterfall plot, two dimensional holographic spectrum
  Variable speed and trend analysis: cascade diagram, bode diagram, polar coordinates, trend analysis chart
● Advanced failure diagnosis package, expert system, online / offline failure diagnosis
● Dynamic balance calculating
● Flexible on-line configuration of system parameter, rich report and graphic printing function
● Post disturbance review (PDR) and storage of alarm file

SY¬¬¬¬¬    —    MT   —    A:□□
Manufacturer    Type       Series
A:□□Series
Example:MT2    0 0
                  MT3    0 1
Example:
SY¬¬¬¬¬—MT—01:indicates the selected type is MT3.

Sensor outline:
 
 
4.3 SY¬¬¬¬¬-SE series eddy current sensor
 
Product overview:

Eddy current sensor is a non-contact sensor used for measuring relative static and dynamic displacement between probe and the measured object. It is mainly consists of probe and proximitor. SY-SE series sensor is supplied with -24VDC, -4 ~-20VDC output, the probe diameter, length etc. which can be selected according to measuring requirement by user. There are many sorts of SY-SE sensors which have advantages such as high sensitivity, wide measurement range, anti-interference ability, immune to oil etc., it is able to work under severe environment such as oil, gas, water etc. Therefore, eddy current sensor system is widely used in electric power, petroleum, chemical, metallurgy industries and some research institutes. It online measures and protects radial vibration, axial displacement, key phase detector, shaft revolution, differential expansion, eccentricity, and rotor dynamics and components size for large rotary machines such as turbine, blower, compressor, air blower, gear boxes, large cooling pump. 
 
Working principle:

Q value of coil inside of probe changes while the distance between the metal under measurement and the sensor changes. The amplitude of oscillating voltage changes while Q value changes, it converts into voltage (current) change after detection, filter, linear compensation and amplification process, for final converting mechanical displacement (gap) into voltage (current).
 
Technical index:
  
Order instruction:

Model

SY-SE08

SY-SE11

SY-SE16

SY-SE25

Probe diameter (mm)

Φ8

Φ11

Φ16

Φ25

Measuring range mm

2

4

8

16

Sensitivity (v / mm)

8

4

2

1

Frequency response range (Hz)

0~5000(-3dB)

Sensitivity error (%)

≤±3.0

Linearity %F.S

≤±2.0

zero error %F.S

≤±1.0

Temperature drift%F.S

≤±0.1

Probe temperature ()

-10~100

Proximitor temperature ()

-10~60

Working voltage (VDC)

-22~-26

Working current (mA)

25

Mounting thread (mm)

M10×1

M14×1.5

M22×1.5

M30×1.5

Note: If there is special requirement for temperature, -20 ~ 200 can be customized

       

 

 

 

SY¬¬¬¬¬    —    SE    —    A:□□
Manufacturer    Type        Probe diameter
A:□□ Probe diameter
Example:  Φ8    0 0
                      Φ11   0 1
                      Φ16   0 2
                      Φ25   0 3
 
Example:

SY-SE-0 1: indicates the sensor probe diameter is Φ11.
 
4.4 SY-TDM-1 displacement sensor
 
Product overview

SY-TDM-1 series displacement sensor has the features of small size, high accuracy, stable performance, excellent reliability, long lifetime etc. Under the condition that the temperature of power plant is 80 ℃ ~ 120 ℃, (higher temperature reaches up to 250 ℃), it is able to run continuously for an overhaul cycle without maintenance. It is applied for servomotor stroke, monitor and protection of valve position. Transmitter order instruction is available before leave factory.
 
Working principle:

 SY-TDM-1 series displacement sensor converts mechanical of linear displacement into power with differential inductance principle for automatic monitor and control of displacement, it has been widely applied in mechanical, electricity, automotive, aerospace, metallurgy, energy, water , national defense project and research institute etc.

Technical index:

(1) Linear measuring range: (0 ~ 1000) mm, twelve kinds of specifications (refers to technical index and dimension figure).
(2) Accuracy: 0.25%.
(3) Working temperature: normal type - (40 ~ 140) ℃; high temperature type :-( 40 ~ 250) ℃.
(4)Sensitivity affected by temperature: less than 0.03% of the full scale output / ℃.
(5) Lead: three Teflon insulated sheathed wire, outside is Φ5mm stainless steel sheath hose.
(6) Withstand vibration: 20g (up to 2kHz).
(7) Withstand shock: 1000g (within 5 ms).
 

Model size

Unidirectionalmm

Bidirectionalmm

Shell length (mm)

SY—TDM—1—50

0—50

±25

120

SY—TDM—1—100

0—100

±50

200

SY—TDM—1—150

0—150

±75

250

SY—TDM—1—200

0—200

±100

300

SY—TDM—1—250

0—250

±125

350

SY—TDM—1—300

0—300

±150

470

SY—TDM—1—350

0—350

±175

470

SY—TDM—1—400

0—400

±200

620

SY—TDM—1—500

0—500

±250

770

SY—TDM—1—600

0—600

±300

770

SY—TDM—1—800

0—800

±400

950

SY—TDM—1—1000

0—1000

±500

1240


Model size Unidirectional(mm) Bidirectional(mm) Shell length (mm)

SY—TDM—1—50 0—50 ±25 120
SY—TDM—1—100 0—100 ±50 200
SY—TDM—1—150 0—150 ±75 250
SY—TDM—1—200 0—200 ±100 300
SY—TDM—1—250 0—250 ±125 350
SY—TDM—1—300 0—300 ±150 470
SY—TDM—1—350 0—350 ±175 470
SY—TDM—1—400 0—400 ±200 620
SY—TDM—1—500 0—500 ±250 770
SY—TDM—1—600 0—600 ±300 770
SY—TDM—1—800 0—800 ±400 950
SY—TDM—1—1000 0—1000 ±500 1240

Order instruction:

Order depends on specification, which is defined as follows:
SY-TDM-1 -  A:□□□□ -  B:□□ -  C:□ -  D:□□
Manufacturer, Type   Sensor stroke    Lead length   Lead mode     Transmitter selection
A:□□□□Sensor stroke
Example: 100mm       0 1 0 0
B:□□Sensor lead length
Example: 1m       1   0              
2.5m     2   5
C:□Lead mode
Example: Straight lead 0            
Aerial plug  1
D:□□
Example: DC24V transmitter
AC220V Single loop output 0      1
AC220V Double loop output 0       2
Without transmitter 0       3
 
Example: 

SY-TDM-1-0150-10-1-03 indicates the stroke is 150mm, lead line 1m, aerial plug is equipped at output end, without transmitter.
 
Sensor outline:
 
 
SY-TDM-1 sensor outline:
 
 
Bracket mounting diagram
 
4.5 SY-TDM-2 absolute expansion sensor

 Product overview

The sensor used for measuring of absolute expansion displacement has two kinds of indication as local and remote. Local indication has broad view, which adopts frequency displacement sensor as the sensing element with characteristics of excellent linearity, high interference, simple structure, difficult to damage, excellent reliability, continuous use, the output is constant current. This product is not only adopted by large and medium sized turbine manufacturer, but also can be applied for measuring of displacement of other precision devices.
 
Working principle:

Changes mechanical of linear displacement into power based on differential inductance principle. Measuring of absolute expansion of turbine is done by automatic monitor and control of displacement.

Technical index:

(1) Linear measuring range: 0 ~ 25mm; 0 ~ 35mm; 0 ~ 50mm, 0 ~ 80mm.
(2) Accuracy: 0.5%.   
(3) Sensor working temperature: ≤ 100 ℃.
(4) Working environment humidity: ≤ 95%.
(5) Working environment vibration: ≤2.3g
(6) Work mode: continuous.

 

5.2 System features
 
On-line vibration monitoring and turbine diagnosis system results from absorbing international advanced technology, it is a product particularly for running condition and parameters of large rotary machines such as turbine in coal fired power plant, the system based on windows operating system integrates expert system, neural network system for achieving online monitoring of running status, vibration monitoring, historical data storage and management and fault diagnosis etc. With English interface, abundant functions, convenient use, SY3000 system provides a powerful technology tool for turbine vibration monitoring and fault diagnosis, represents domestic leading level. The functions are as follows:

●Windows operating platform with English menu
●Real-time monitors and storages varies status signals of unit such as shaft vibration, bearing vibration, axial displacement, differential   expansion,   revolution, vector etc.
●High capacity of historical database management
●Powerful analysis function, rich real-time charts in the condition of transient, steady state and alarm state.
  Time domain analysis: general diagram, time domain waveform, data list, bar graph, amplitude trend graph, axis orbit
  Frequency domain analysis: spectrum, phase, waterfall plot, two dimensional holographic spectrum
  Variable speed and trend analysis: cascade diagram, bode diagram, polar coordinates, trend analysis chart
● Advanced failure diagnosis package, expert system, online / offline failure diagnosis
● Dynamic balance calculating
● Flexible on-line configuration of system parameter, rich report and graphic printing function
● Post disturbance review (PDR) and storage of alarm file


 

 

Model size

Measuring range mm

A

B

C

SY—TDM—2—25

25

225

87.5

157

SY—TDM—2—35

35

225

100

170

SY—TDM—2—50

50

263

115

187

SY—TDM—2—80

80

303

115

215


Model size Measuring range (mm)
 A B C
SY—TDM—2—25 25 225 87.5 157
SY—TDM—2—35 35 225 100 170
SY—TDM—2—50 50 263 115 187
SY—TDM—2—80 80 303 115 215
 
Order instruction:

Order depends on specification,  which is defined as follows:
SY-TDM-2- A:□□
Manufacturer and type      stroke of the sensor 
A:□□stroke of the sensor 
Example: 25mm       2   5
Example:   
SY-TDM-2-25 indicates the stroke is 25mm

Sensor outline:
 
The dimension of absolute expansion sensor
 
5 Introduction of on-line monitoring and protection system for rotary machine
 
SY3000 online monitoring and protection system integrates status monitoring protection, online vibration analysis and diagnostic management system as a whole, which integrates many high-tech and intelligent products such as sensor, transient signal high-speed acquisition and processing, computer, expert system, neural network and so on, establishes a strict monitoring and protection system for unit. After continuous monitoring and on-line failure analysis, SY3000 system controls the running condition of the unit timely, provides important information for pre-diagnose of accident. Meanwhile, SY3000 system rapid diagnosis the failure which has occurred and timely finds out the cause of the failure for alerting operator to take necessary measures for the safe operation of the unit. Abnormal or fault can be detected through estimate mechanism and experts diagnose system, unit continues running time can be estimated, to maximum unit life and minimize unexpected downtime, avoid surplus maintenance. SY3000 system not only ensures the safe running of the unit, but also obtains great economic benefits.
 
5.1 System structure
 
SY3000 system integrates turbine supervisory instrument (TSI) with transient data collector. 16 or 32 channels online vibration monitoring and fault diagnosis function of each basic TSI can be achieved by selecting transmission control module which has transient data collection and management function, transient data acquisition I / O module, computer and vibration monitoring and fault diagnosis software package on the basis of TSI system. The schematic refers to figure 1.
 
 
Figure 1
 
Distributed monitoring system is composed of multiple monitoring and fault diagnosis system, the system communicates with existing MIS / SIS of power plant for data transmission which enables management / operating personnel easily monitors turbine and auxiliaries. The network is as figure 2.
 
 
Figure 2 Network diagram

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