Bently Nevada 3500/25 User Manual

3500 series

Machinery protection system

Bently Nevada Asset Condition Monitoring

Why protect
and monitor?

Whether generating power, compressing and pumping
fluids, or driving process equipment, industries rely on
critical machinery every hour of every day. In these
settings, machinery failure isn’t just inconvenient, it can be
catastrophic. While repair costs alone can be staggering,
the partial or even total loss of production resulting from
critical machinery failure – sometimes worth millions per
day – can mean the difference between profit and loss
for the entire year. With so much at stake, mechanical
condition monitoring is more than just a good idea, it’s a
necessity.

Continuously monitoring critical asset parameters such as
vibration, temperature, speed, and numerous other condition
indicators is a proven method for anticipating and preventing
mechanical failures – proven in tens of thousands of industrial
facilities around the world by delivering tangible benefits such
as:

Improved protection from catastrophic failures

Better machinery reliability/availability

Fewer process interruptions

Enhanced maintenance/outage planning

Lower maintenance and repair costs

Longer intervals between outages

Reduced insurance premiums

And when it comes to protecting and monitoring critical
machinery, one name has proven itself above all others:
Bently Nevada

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Why Bently Nevada Condition Monitoring?

Bently Nevada machinery protection and monitoring systems
span more than a dozen different models deployed during the
last 60 years. Combined, they comprise the largest installed
base of permanently installed transducers and monitoring
channels in the world. It’s a position of trust that has been
earned over more than six decades of learning, refining,
and improving our solutions to meet the industry’s most
demanding applications. Applications that require the highest
integrity. Applications where false trips or missed trips simply
cannot be tolerated.

It’s not just our products, it’s our people. Our reputation for
the highest quality, best value in the industry is born of a
culture that “takes excellent care of our customers.” When
you choose our condition monitoring solutions, you get it all:
the best people, the best products; the best service; the best
solutions - together generating the best value.

For more than half a century, Bently Nevada products have
been world-renowned as the standard by which all others
are measured. Because after all, with so much riding on your
machinery, why trust anyone else?

Experience

With more than six million transducers and monitoring
channels installed worldwide, more end users trust their
machinery to Bently Nevada’s continuous monitoring
systems than anyone else. We are also the supplier of choice
to nearly every major machinery manufacturer in the world.

Technology

Today, although our products number in the thousands, we
never rest. Each year, tens of millions of dollars are invested in
expanding and improving our technology with the purpose of
better serving our customers. Better technology that creates
better value is our passion.

Technical support

Behind everything we deliver, you’ll find our unwavering
commitment to provide the best technical support to our
customers. No matter where in the world you are, or what
time of the day, a knowledgeable professional with technical
experience is standing by 24/7 to assist you with answers to
your technical questions. We also have the ability to supply
many emergency parts and services after traditional working
hours. Additionally, our state-of-the-art knowledge database
tracks every support call, every question, and every answer,
allowing our global team to deliver faster, more complete
support than ever before.

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3500 – Simply the best

Monitor modules

Beginning with the 5000 Series in the 1960s, we’ve introduced
seven successive generations of highly successful
monitoring platforms. Today, that experience is embodied
in the most advanced, powerful, and reliable system we
have ever offered: The Bently Nevada 3500 Series Machinery
Protection System.

Certified

The 3500 is designed to fully comply with the American
Petroleum Institute’s Standard API 670, the world’s most
widely used specification for machinery protection systems.
For reciprocating compressor applications, the 3500 meets
API 618 requirements as well. It can also be ordered with DNV
and Class NK certifications for maritime applications such as
offshore platforms and ship propulsion. And, when used as
part of a safety instrumented system, third party Functional
Safety Certification can be supplied for applications requiring
up to Safety Integrity Level (SIL) 2. In addition, the 3500 is
approved to meet relevant Canadian Standards Association
(CSA), Factory Mutual (FM), GOST, ATEX, and CE requirements.

Bently Nevada follows closely the development and changes
in these standards and continually demonstrates our
capacity and commitment to be in sync with them as they
change and evolve. This continued focus and investment
in regulatory excellence ensures our customers don’t have
to worry about deploying a non-compliant solution that
may later require significant update or replacement. A
compliance miss has the potential for exposure to not only
catastrophic consequences, but also can lead to fines from
governments and inspection agencies as well as impact on
insurance rates and reputation. Baker Hughes Bently Nevada
is committed to continued compliance leadership and full
regulatory excellence.

Reliable

We understand that our systems are routinely used not just
for indication, but to provide auto-shutdown protection.
That’s why – even in simplex mode – the 3500 is the most
reliable monitoring system we have ever offered with
extensive self-checking and fault tolerant design features.

Connected

Connecting to condition monitoring and diagnostic software
has never been easier. With the 3500 there are no bulky
external modules, no additional wiring, and no extra rack
slots required. Simply use the Ethernet port in the 3500/22M
Transient Data Interface Module and a single network cable
to communicate with our System 1
to plant control and automation systems is straightforward
as well. Simply add a communication gateway module.
You can even add multiple gateways when communication
redundancy is required or when multiple systems must be
supported with differing protocols.

Flexible

The 3500 Series features the industry’s most extensive
selection of machinery measurement parameters combined
with software configuration for virtually all monitor options.
Local or remote mounted displays are available, or you can
operate the 3500 without a display. The result is unparalleled
flexibility to address almost any application.

Field-proven

The 3500 Series system has proven its value and
dependability with customers everywhere, year after year,
with more than 100,000 racks installed globally.

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software. Connecting

3500 Series

measurement and

output capabilities

Phase reference

Radial vibration (proximity probes)

Radial position (proximity probes)

Axial position (proximity probes)

Eccentricity (proximity probes)

Seismic vibration (velocity
transducers/accelerometers)

Shaft absolute (proximity and seismic)

Aeroderivative gas turbine
casing vibration

Differential expansion

Ramp differential expansion

Complementary differential expansion

Case expansion

Valve position

Hydro turbine/generator vibration

Measurements

Hydro generator air gap

Machine operating state (discrete input)

Rotor speed

3500/25

3500/32/33

3500/42M

3500/44M

3500/45

3500/46M

3500/50

3500/60/61/65

3500/62

3500/64M

3500/70M

3500/72M

3500/77M

3500/91/92

Rotor speed rate-of-change (acceleration)

Rotor zero speed (turning gear engagement)

Reverse rotation

Relays

Temperature (direct/average/differential)

Process variable signals
(4-20 mA, 1-5 Vdc, etc.)

Gas turbine combustor instabilities

Reciprocating compressor impulse/velocity

Reciprocating compressor rod position

Reciprocating compressor cylinder pressure

Communication gateway

1. The 3500/60 and /61 are 6-channel monitors. The 3500/65 is a 16-channel monitor.

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Buffered outputs – every
dynamic input signal is
conveniently available at
the front panel via buffered
output connectors for easy
connection to portable and
test instrumentation.

3500/15 Power supply –
accepts worldwide AC/DC
voltages and frequencies
and can be supplied fully
redundant to assure
uninterrupted performance.

Keylock security – all
monitor modules are
software configurable via
the 3500’s Transient Data
Interface Module – key
lockable to prevent
unauthorized tampering.

Analog communications –
monitor module channels
are available with analog
4-20 mA proportional
outputs for process control
systems and other
instrumentation.

Transient Data Interface
(TDI) – provides

configuration interface as
well as single-cable
connection to System 1
software via conventional
wired or wireless Ethernet
networks. The 3500’s
advanced design ensures
that simultaneous data
acquisition occurs for all
channels in the rack.

Digital communications – the 3500/92
Communications Gateway supports
Modbus® and Modbus/TCP protocols via
serial (RS232/422/485) or Ethernet links
for digital communications with PLCs,
DCSs, and other instrument and
automation platforms. Multiple gateways
can be installed in a single rack for link
redundancy or when multiple protocols
are needed.

Multiple parameters from each channel
– radial vibration channels can provide
eight individual parameters (overall, gap,
1X amplitude/phase, 2X amplitude/phase,
Not 1X, Smax), meaning a 4-channel
monitor actually provides up to 32
channels of measurements. Alarms can
be set on any or all 8 parameters from
each channel.

Keyphasor module – accepts
single- and ulti-event-per-turn
signals from proximity probes
and magnetic pickups. A
standard rack can
accommodate up to four
Keyphasor
modules), and special
modifications are available when
more than four Keyphasor
signals are required.

Hot-swappable
modules – for ease

of maintenance and
maximum uptime,
modules can be
removed and
reinserted without
removing rack power

Built-in Intrinsic Safety (I.S.)
barriers – I/O modules can be

ordered with or without internally
mounted I.S. barriers to decrease
wiring, increase accuracy, and reduce

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signals (two 3500/25

installation costs when hazardous
environments require intrinsically safe
installation practices

.

Industry-standard 19” rack size –
provides more than twice the
channel density of previous
systems. Available in both EIA rack
and bulkhead mounting versions,
along with integral (standard) or
external field wiring termination
blocks (optional) for maximum
installation flexibility.

VGA display module – The 3500/94M
VGA module displays all 3500
machinery protection system
information, including:

• System event list

• Alarm event list

• All module and channel data

• Alarm and OK status

• Nine Custom display options

Supports either the 10" or 15" Advantech
VGA touch screen displays. These
compact, durable displays are
designed for excellent viewing quality
in industrial applications. The 10"
Advantech display is certified for
hazardous environments

Relay modules –
software-programmabl
e voting logic provides
unmatched flexibility. 4­and 16-channel
versions available.

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Applications and industries

Service and support

The table on page 5 summarizes the enormous selection
of measurement types available in the 3500. This allows it
to be applied to an extremely wide-range of rotating and
reciprocating machinery in many industries. Below are just
a few of the more common applications that can be easily
addressed by the 3500 System.

• Steam turbines

• Hydraulic turbines

• Industrial gas turbines

• Aeroderivative gas turbines

• Reciprocating compressors

• Centrifugal compressors

• Axial compressors

• Screw compressors

• Gears

• Turbo-expanders

• Horizontal and vertical centrifugal pumps

• Reciprocating pumps

• Electric motors

If your specific machine doesn’t appear on the list, just
ask us. Chances are, our applications engineers have
already developed a solution that’s right for you. And,
with our extensive custom applications capabilities, we
can easily modify off-the-shelf 3500 solutions to handle
your nonstandard applications and signal processing
requirements.

• Generators

• Fans

• Blowers

• Agitators

• Mixers

• Centrifuges

• Pulp refiners

• Ball mills

• Crushers/pulverizers

• Extruders

• Pelletizers

• Cooling tower/heat exchanger fans

We design and manufacture the 3500 system so there’s
nobody better equipped than Bently Nevada to professionally
install and support these products.

Bently Nevada Services offer complete lifecycle support
coverage from initial design, commissioning and integration
with your operating processes, and continue throughout
the operational life of your facility with available upgrades,
replacements, and retrofits. This enables you to get the most
out of your investment. Our service offerings are carefully
developed to ensure you realize the maximum benefits our

Bently Nevada service menu

Get it right the 1st time

• Ensure your assets are protected and monitored when you’re ready to startup

Implementation services

Proactive support

• Avoid costly delays and rework

• One source to design, plan, manage, and execute the installation

• Avoid startup trips due to improper installation and configuration

Keep your System healthy and optimized

• Prevent instrumentation related false trips

• Prevent and minimize potential data loss events

• Keep up to date and compliant with the best technologies available

• Access the expert support you need when you need it most

solutions have on your operation. Bently Nevada service
professionals undergo rigorous training and certification
processes developed through our 60+ years of machinery
protection and conditioning monitoring experience. This
ensures we provide the highest quality and most expert
services in the industry. With more than 500 service and
support professionals in over 50 countries we have the global
reach and local presence to be there with expert support
when and where you need us.

Actionable insights you can trust

• Understand your asset health to optimize outage and maintenance planning

Asset Health and consulting

• Plug in to our global network of machinery experts with remote monitoring

• Professional OEM agnostic machinery diagnostics when and where you need it

• Custom analytic development and tuning to pinpoint specific conditions

Stay ahead of evolving cyber threats

• Ensure your system is up to date and protected as threats continually evolve

Cybersecurity

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• Identify and mitigate cybersecurity risks to your operation

• Keep your system both secure and accessible with advanced security
technologies and architectures leveraging data diodes and database replication

Critical skills that amplify your machinery management capabilities

Training and education

1. https://www.us-cert.gov/sites/default/files/documents/Seven%20Steps%20to%20Effectively%20
Defend%20Industrial%20Control%20Systems_S508C.pdf

• Enable your personnel to operate and maintain your monitoring and protection system

• Enable your operation to maximize the value of your system leveraging expert product
and application training and knowledge

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System 1

Plant-wide data with context and clarity

System 1†, connected to your 3500 Monitoring System,
delivers the comprehensive machinery wide diagnostic HMI
capability users need to make informed decisions on how to
proactively manage their machinery.

Connectivity

Seamless connectivity to Bently Nevada’s 3500 machinery
protection system with full access to available trend,
waveform, and event data. Standard integration to control
system PLCs through OPC DA protocol with full access to
applicable process data, first-outs, permissives, surge
control, and set points.

Visualization and management

Complete Diagnostic HMI desktop-based application,
designed to enable rich HMI overviews, extensive trend
diagnostics, vibration analysis, and proactive condition
monitoring.

Plant-wide scalability

Ability to scale connectivity beyond 3500 and the control
system to monitor more machinery leveraging other Bently
Nevada online, scanning, or portable devices in the same
System 1 platform.

Comprehensive diagnostic HMI implementation

Standardized & holistic machinery configurations based on
Bently Nevada best practices for vibration and process data.
Standard data connectivity (OPC, 3500, etc.) for overall machine
and key sub-systems (vibration, lube, seal, surge, etc.)

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Optional hosted and/or remote monitoring

Access to Bently Nevada machinery experts through
standardized remote monitoring.

Customer solution

Connectivity

S1

Analytics Visualization

Equipment

1110

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and its subsidiaries in one or more countries.

Copyright 2020 Baker Hughes Company. All rights reserved.

BHCS13965 2/2020

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