Description
Key Technical Specifications
- Model Number: 3500/22-01-01-00 138607-01
- Manufacturer: Bently Nevada (a Baker Hughes business)
- Channel Count: 2 fully independent monitoring channels
- Measurement Parameters: Vibration velocity (RMS), displacement (peak-peak), acceleration (peak); configurable per channel
- Input Compatibility: Eddy current proximity probes (3301 series) and IEPE/charge accelerometers
- Measurement Ranges: Velocity: 0-50mm/s (0-2.0 ips); Displacement: 0-508μm (0-20 mils); Acceleration: 0-50g
- Power Supply: 24VDC ±10% (19.2-26.4VDC) from 3500 rack backplane; 0.4A typical current draw
- Operating Temperature: -40°C to +70°C (-40°F to +158°F)
- Mounting Type: Rack-mount (3500 system 19″ rack, 1U height, hot-swappable)
- Isolation Rating: 1kV AC (input circuits to backplane/power)
- Certifications: CE, ATEX Zone 2 (Ex nA IIC T4), IECEx, UL 508, SIL 2 compliant (IEC 61508)
- Compatibility: Bently 3500/15 Rack Assembly, 3500/25 Relay Module, 3500/92 Communication Module, 3301 proximity probes, industrial accelerometers
- Diagnostic Capability: Per-channel LED indicators (power, signal OK, alarm, trip), rack-level fault reporting, waveform capture
- Response Time: ≤10ms (alarm/trip trigger); 1kHz sampling rate per channel
3500/22-01-01-00 138607-01
Field Application & Problem Solved
In critical rotating machinery—refinery gas turbines, power plant steam turbines, chemical plant centrifugal compressors—the biggest challenge is reliable, high-precision vibration monitoring that integrates with the 3500 system’s safety shutdown logic. Generic monitoring modules fail to sync with 3500 racks, suffer from signal noise in harsh environments, or lack the dynamic range to detect both low and high-frequency vibrations. A Texas refinery lost $580k in an 8-hour outage when a generic module missed a 35mm/s vibration spike in a hydrocracker turbine, leading to rotor damage. A Pennsylvania power plant spent $45k annually troubleshooting false trips from modules that couldn’t filter out gear mesh noise from their generator sets.
This module solves these issues as a native 3500 system component. You’ll find it in: 3500 rack assemblies protecting main turbines, compressors, and generators—equipment where unplanned downtime costs six figures per hour. It’s the standard for facilities requiring SIL 2 compliance, as it meets IEC 61508 requirements for safety-related monitoring.
Its core value is 3500-native integration + dual-channel efficiency + noise-immune signal processing. Unlike generics, it communicates directly with the 3500 rack’s backplane, eliminating latency between vibration detection and shutdown. The dual-channel design reduces rack space requirements by 50% compared to single-channel modules, while Bently’s proprietary filtering algorithm blocks electrical and mechanical noise. For a Louisiana chemical plant, this module detected a 5mm/s increase in turbine vibration (indicative of bearing wear) 72 hours before a potential failure, allowing scheduled maintenance and avoiding a $320k outage.
Installation & Maintenance Pitfalls (Expert Tips)
- Input Type Configuration: Match to Sensor Type: Rookies leave the module set to “proximity probe” when using accelerometers, resulting in invalid readings. An Ohio steel mill’s generator monitor showed 0mm/s vibration until the input type was adjusted via 3500 Configuration Software. Always verify sensor type (proximity/accelerometer) and configure the module accordingly—use a signal generator to test input response post-installation.
- Firmware Mismatch with 3500 Rack: Outdated module firmware (pre-v5.0) causes communication failures with 3500 racks running v6.0+. A Florida refinery’s technicians spent 6 hours troubleshooting until the module was updated via the 3500 rack’s USB port. Check Bently’s compatibility matrix—firmware must align with the rack’s controller version.
- Terminal Torque: 0.6Nm for Signal Connections: Loose sensor terminals cause intermittent signal dropouts. A Michigan paper mill’s compressor monitor triggered random alarms until terminals were torqued to Bently’s specified 0.6Nm. Use a precision torque screwdriver—over-tightening damages terminal blocks; under-tightening causes arcing and signal degradation.
- Grounding: Isolate Sensor Cables: Sharing sensor cable shields with power circuits introduces 60Hz noise. A North Carolina power plant’s turbine vibration data had persistent hum until shields were grounded at the module end only. Use shielded twisted-pair cable (Bently 200350 series) and maintain 30cm separation from AC power lines.
- Ignoring Waveform Capture: Use It for Root Cause Analysis: Rookies don’t enable waveform capture, missing critical data during fault events. A Texas chemical plant’s turbine trip was traced to a 10ms vibration spike only after reviewing the module’s captured waveform. Enable continuous waveform capture (10-second buffers) via 3500 software—this is invaluable for troubleshooting.
3500/22-01-01-00 138607-01
Technical Deep Dive & Overview
The Bently Nevada 3500/22-01-01-00 138607-01 is a dual-channel vibration monitoring module engineered to be the workhorse of the 3500 Machinery Protection System. At its core, a 32-bit microprocessor samples sensor signals at 1kHz per channel, executing Bently’s proprietary signal processing algorithms to filter noise (electrical, mechanical) and convert raw data into calibrated vibration values (velocity/displacement/acceleration). The module compares these values to user-set alarm/trip thresholds (configurable via 3500 Configuration Software) and sends digital signals to 3500/25 relay modules for safety shutdown or alerts.
Unlike generic modules, it features native integration with the 3500 rack’s backplane, enabling hot-swap functionality (module replacement without rack power down) and rack-level diagnostic reporting. The dual-channel design allows monitoring two independent sensors (e.g., radial vibration on both ends of a turbine shaft) with one module, reducing rack space and installation costs. The module’s 1kV AC isolation blocks electrical interference from VFDs and motor cables, while the wide operating temperature range (-40°C to +70°C) withstands harsh industrial environments.
What sets it apart is its SIL 2 compliance and waveform capture capability. The module’s hardware and firmware meet IEC 61508 requirements for safety-related systems, making it suitable for critical applications. The waveform capture function stores 10-second buffers of raw sensor data during fault events, enabling maintenance teams to perform root cause analysis (e.g., distinguishing between unbalance, misalignment, or bearing damage). For facilities relying on the 3500 system, this module isn’t just a monitoring tool—it’s a critical component of a comprehensive machinery protection strategy, ensuring the safety of personnel and equipment while minimizing unplanned downtime.
