Telemetry_System_Specification.pdf

NAVAL SURFACE WARFARE CENTER PHILADELPHIA DIVISION

Multi-Channel Digital Shaft Telemetry System

Specification Number: 12412-0001

4 May 2016

NSWCPD - Multichannel Digital Shaft Telemetry System

Date: 4 May 2016

Table of Contents 1 Purpose

2 Scope of Effort

3 Telemetry Design Description

3.1 Description

3.1.1 Rotating Transmitter Assembly

3.1.2 Stationary Pickup Antenna (Integral Radio Frequency (RF) Tuning Capability)

3.1.3 Cabling (Calibrated/Tuned)

3.1.4 Receiver Unit

3.1.5 Locating Provisions

3.1.6 Anti-Rotation Provisions

3.1.7 Lifting Provisions

3.1.8 Fasteners and Tapped Holes

3.2 Dimensional Requirements

4 Performance Requirements

5 Additional Options

6 Material Prohibitions Requirements

7 Component Identification and Marking

8 Deliverables

8.1 Test Data

8.2 Drawings

8.3 Rights to Technical Data

8.4 Drawing Identification Numbers

8.5 Drawing Format

8.6 Parts List

8.7 Spare Parts

8.8 Dimensions and Tolerances

8.9 Units

8.10 Drawing Notes

Date: 4 May 2016

8.11 Marking Details

8.12 Revision to Engineering Drawings and Associated Lists

8.13 Fastener Installation Requirements

8.14 Electronic Drawing Format

8.15 Hardware Delivery

8.16 Instruction Documentation

8.17 Design Review

Date: 4 May 2016

1 Purpose This specification describes the physical and functional requirements of a Multichannel Digital Shaft Telemetry System. The system will be used to provide continuous long term wireless measurements from (24) accelerometers mounted on a shaft.

2 Scope of Effort This effort consists of the development and manufacture of a Multichannel Digital Shaft Telemetry System that meets the requirements specified in this document. The end product from this effort will be:

a. Outline engineering drawings of the design

b. Delivery of a telemetry system including spare parts

c. Technical manuals for the system and associated hardware including details of sampling, filtering, and other relevant details of the system

d. User’s manual with written text and diagrams to assist users with unit checkout, check-calibration, setup on rotating equipment, operation of shaft components and receiver, prospective errors and troubleshooting.

Naval Surface Warfare Center Philadelphia Division (NSWCPD) hereinafter is referred to as the Purchaser. The telemetry system supplier hereinafter is referred to as the Contractor.

3 Telemetry Design Description

3.1 Description

The Purchaser provides the following general description of the system arrangement.

The telemetry system shall provide wireless transmission of (24) on-shaft accelerometer signals to a stationary receiver. The system shall be mounted on both the shaft’s outer diameter and the adjacent stationary structure.

The telemetry system shall consist of four primary elements including:

• Rotating transmitter assembly including input connectors and shaft antenna coil

• Stationary pickup antenna with integral radio frequency (RF) tuning capability

• Cabling (calibrated/tuned)

• Receiver unit

Date: 4 May 2016

The rotating transmitter electronics shall electronically condition and digitize all transducer sensor signals into a single high speed digital data stream on the shaft. (The use of multiple data streams requires Purchaser approval.) The transmitter shall condition all transducer signals through precision instrumentation amplifiers, apply high-pass filtering to attenuate once-per-rev excitation, apply an anti-alias filters, and then shall digitize all the accelerometer data. The data shall then be transmitted off the shaft across an appropriately-sized air gap. The data transmission shall use non-contacting digital telemetry techniques. Slip-rings shall not be used.

The telemetry system shall allow data transmission while the shaft is rotating in either direction, or stationary. The shaft sensors and shaft transmitter electronics shall receive power through the wireless air-gap RF transformer. The transformer shall be contained in both the shaft transmitter and stationary pickup antenna assemblies. The data shall be recovered after transmission off the shaft at the pickup antenna, and cabled to the receiver unit.

3.1.1 Rotating Transmitter Assembly

The rotating transmitter assembly will include input connectors and shaft antenna coil. It shall fit within the OD of the rotating metal components.

The accelerometer signals shall all be sampled simultaneously to ensure phase coherence of all signals. Since the gravitational effect will produce a 1 G peak sinusoid at the rotational frequency, a third order high-pass or equivalent filter with a cutoff frequency at 3 Hz shall be incorporated in the accelerometer channels. The third order high-pass or equivalent filter shall attenuate the gravitational effect to allow greater signal dynamic range from the signals of interest. This filter shall be defined by the Contractor and approved by the Purchaser.

The telemetry system shall have a single full scale range of ± 10 V peak.

3.1.2 Stationary Pickup Antenna (Integral Radio Frequency (RF) Tuning Capability)

The stationary pickup antenna shall be spaced radially above the transmitter collar. The stationary and rotating antenna elements shall be axially aligned. The axis of the rotating shaft may shift in any radial direction up to 0.050” relative to its nominal position. The axial movement tolerance is expected to be about +/- 0.125”. The antenna base shall contain RF tuning components to allow optimization of the data and power signals if necessary.

3.1.3 Cabling (Calibrated/Tuned)

50 feet of cable shall be provided to connect the stationary pickup antenna to the remote receiver unit. The cabling shall be factory calibrated/tuned to ensure accuracy of the data being transmitted. Cabling shall be selected to minimize potential EMI issues.

Date: 4 May 2016

3.1.4 Receiver Unit

A radio frequency source in the receiver shall transfer power to the stationary pickup antenna and the rotating antenna coil. The radio frequency power source will provide the power required for both the transmitter’s needs and the sensor excitation.

The receiver unit shall demodulate and recover the telemetry data. The receiver will output, amplify and filter the dynamic accelerometer signals. The receiver will then provide to the end user individual analog voltage signal outputs corresponding to each of the (24) accelerometers.

Each individual accelerometer output channel shall be supplied as high level voltage signals (+/- 10 V).

The system shall be factory calibrated. No user adjustment shall be necessary to initially use the system. The receiver shall be packaged in a National Electrical Manufacturers Association (NEMA) Type 12 style industrial painted steel enclosure (similar to Ingress Protection IP65). The complete telemetry system shall be powered through the receiver unit.

3.1.5 Locating Provisions

Provisions for properly locating telemetry system parts with respect to each other shall be explained and provided by the Contractor (e.g., doweling, bolts, marking, etc.). These provisions shall ensure telemetry system parts cannot be inadvertently assembled incorrectly. .

3.1.6 Anti-Rotation Provisions

The Rotating Transmitter Assembly shall incorporate a clamping mechanism to prevent the component from rotating on the shaft. Pins or doweling that penetrates the Purchaser’s shaft cannot be used.

3.1.7 Lifting Provisions

Provisions shall be made for lifting and handling of telemetry components that weigh more than 35 pounds. Lifting points shall be identified on the Contractor drawing.

3.1.8 Fasteners and Tapped Holes

All fasteners used on or within the system shall meet the requirements of FED-STD-H28.

3.2 Dimensional Requirements

The Purchaser and Contractor shall work together to establish the final telemetry system dimensions. The system will be installed on a shafting system spool piece with the nominal dimensions shown in Figure 1. The shaft diameter is 39.370 inches (1000 mm). The telemetry system and sensor cable connectors must fit within an axial length of approximately 10 inches (254 mm). All telemetry system holes, slots, and grooves shall be free of sharp edges and of sufficient size and depth to prevent damage to wires.

Figure 1. The Telemetry System will be designed to be installed on a shaft spool piece with the nominal dimensions shown.

4 Performance Requirements The signals shall be recovered at the remote receiver without degradation or compromise in the data integrity.

The telemetry system shall be highly immune to electromagnetic interference (EMI)/RF interference/noise (from noisy variable speed drive circuitry, motors, magnets, or other sources) by use of the following:

a) Accelerometer signal filtering and sampling techniques: The telemetry system transmitter shall have both front-end anti-alias filtering and high speed sampling on the shaft for the accelerometer (dynamic) signals. The anti-alias filtering shall cut out high frequency signals (including noise) beyond the 1000 Hz third octave’s band. The high speed sampling shall allow accurate data characterization through the required bandwidth. The telemetry system will have high pass filtering to minimize 1G signal from the rotating sensors.

b) Digitizing the data: The data shall be in digital format during transmission to make it harder to corrupt, avoiding the limitations of both FM telemetry designs and slip ring designs.

Date: 4 May 2016

c) Short range data transmission: The telemetry shaft to stator air gap shall be as small as possible to eliminate the vulnerability of crosstalk from other telemetry systems or radio equipment (air gap = 0.375 ± .125”).

d) Direct connections: After the digital data telemetry is transferred off the shaft to the stationary pickup antenna, the data shall be transferred by cable connection to the receiver unit.

The telemetry system architecture shall remove problems of telemetry drift and tuning by combining all of the on-shaft digitized signals into a single high speed data stream that is transmitted to the remote receiver unit. (The use of multiple data streams requires Purchaser approval.) This is to avoid having to tune or calibrate individual transmitters and receivers and to eliminate tuning drift.

Requirements for the telemetry system are collected in Table 1.

Table 1. Telemetry System Procurement Specification

1) Rotating transmitter assembly including input connectors and shaft antenna coil

Accelerometer Inputs Channel Capacity 24 channels Sensor Type Wilcoxon Model 728T IEPE accelerometer (or alternate as suggested by Contractor and as approved by the Cable Connections BNC connectors (or alternate as suggested by Contractor and as approved by the Purchaser)

High pass filtering 3 Hz, third order (or alternate as suggested by Contractor and as approved by the Purchaser)

Sensor Excitation 4 ma with 18 V minimum compliance Sensor and Telemetry System Measurement Range

Acceleration 20 -126 dB re: 1 uG

Digitizing Sample rate Approximately 3311 samples per second for each input, simultaneous sampling Bandwidth Approximately 3 Hz to 1122.4 Hertz (-3dB points) Anti-alias filtering 8-pole elliptical filter (or alternate as suggested by

Contractor and as approved by the Purchaser) High-pass filtering Filtering to attenuate once-per-rev sensor signals as suggested by Contractor and as approved by the Purchaser

Digital resolution 18 bit (or alternate as suggested by Contractor and as approved by the Purchaser)

Transmitter Environment Mounting Friction fit ring clamped to shaft Shaft Diameter Shaft Diameter

39.37 inches (1 meter) ± .002 inch outer diameter in the area of the collar mounting location.

Shaft Speed 120 RPM maximum

Temperature/ Environment Operating temperature will range from 40-150 ⁰F, 0 to 100%

RH

Distance to nearby metal +/- 1.5 inches axially and radially from the back side of the collar (side opposite cable connections) to nearby metal to avoid detuning the RF circuitry

Axial Shift Tolerance ±1/8” minimum

2) Stationary pickup antenna with integral RF tuning capability Construction Split antenna (ring style) to be mounted to a nearby stationary structure.

Tuning Enclosure RF tuning assembly will be built into the base of the antenna.

3) Cabling Cable/Connections 50 foot length shielded cable between receiver and tuning enclosure.

Cable temperature rating 40‐150 ⁰F

4) Receiver Unit

Accelerometer Outputs Individual channels of up to +/- 10 Volt (peak) analog outputs

Accuracy <1% total telemetry error for gain drift and linearity (exclusive of sensor error)

Bandwidth Approximately 3 Hz to 1122.4 Hertz (-3dB point)

Date: 4 May 2016

5 Additional Options

The Shaft Telemetry System and Sensors may be required to cover a wide dynamic range that exceeds the capability of a typical single range telemetry system and sensor. Because of this constraint, the Shaft Telemetry System shall include options for the following capability.

Options A/D with (2) input ranges User selectable range from off-shaft. (or as suggested by

Contractor)

6 Material Prohibitions Requirements The Shaft Telemetry System shall not contain hazardous materials. Where suitable substitute for hazardous materials are not available, the Contractor shall identify the location and amount of hazardous materials to be used via letter or report to the Purchaser and provide appropriate Material Safety Data Sheets for identified materials.

7 Component Identification and Marking The Contractor shall mark each Shaft Telemetry System with a Purchaser assigned serial number using the following format: S/N XXX.

Major component parts shall be permanently marked so that they can be identified with the drawings from which they are manufactured. Parts shall also be permanently marked to aid in assembly, disassembly and inspection. After inspection, parts that are individually fitted or parts that may affect alignment if not reinstalled in their original position shall be permanently marked to ensure that they are assembled correctly. Permanent markings shall be applied in areas of essentially no stress and shall be accomplished in accordance with MIL-STD-792, as modified herein.

8 Deliverables

8.1 Test Data

The Contractor shall prepare, and submit for approval, test results demonstrating the Shaft Telemetry System performance with respect to the key accuracy and bandwidth requirements.

Date: 4 May 2016

8.2 Drawings

The Contractor shall prepare and submit for approval engineering drawings in accordance with the requirements specified herein. Product drawings and associated lists shall provide the design, engineering, manufacturing and quality support information necessary to permit the reorder of the finished product.

8.3 Rights to Technical Data

Rights to technical data shall be in accordance with the conditions forming a part of the contract or purchase order.

8.4 Drawing Identification Numbers

Drawing identification numbers shall not exceed fifteen characters including all numbers, letters and dashes. For associated lists provided separate from the base drawing, the associated list prefix (i.e., “PL”) is not applicable relative the fifteen character identification number limit. The letters “I,” “O,” “Q,” “S,” “X” and “Z” shall not be used for drawing identification numbers. Symbols and spaces shall not be used.

8.5 Drawing Format

Drawings shall be formatted in accordance with ANSI Y14.1, as modified herein.

a. Dimensional Variations – Dimensional variation associated with differences between ANSI Y14.1 format and existing Contractor format are acceptable.

b. Title Blocks - In addition to the information defined by ASME Y14.1, sheet one title blocks shall include the sheet number and total number of sheets (e.g., “1 of 1”, “1 of 5”). Subsequent sheet title blocks shall identify the sheet number and total number of sheets in a similar manner as sheet one (e.g., “2 of 5”, “3 of 5”, “5 of 5”).

c. Multi-sheet drawings shall contain a revision status of sheets table on Sheet 1, or a note that all sheets are the same revision. The current revision level may be marked on all drawing sheets.

8.6 Parts List

A parts list, where required by ASME Y14.24M, shall be provided either separate from or integral with each drawing. Where parts lists are provided separate from the base drawing, they shall be identified by the prefix “PL” followed by the drawing number to which the parts list applies. Parts lists shall include the following column information, as applicable:

a. Piece or Find Number – Component or part identifier used in the field of the drawing (in lieu of the part number) which provide a cross reference to applicable part list information.

b. Quantity Required – Number of pieces required for each item. If a piece is not used on a specific design option, “0” or “X” shall be indicated.

Date: 4 May 2016

c. CAGE Code – If different from that which is specified in the title block, the code assigned to the manufacturer of the item.

d. Material or Part Identification – As applicable, the information necessary to identify the material (e.g., drawing number, class, grade, type, condition) or the assembly (e.g., drawing number or “make from” number).

e. Part Number – To include, or be the same as, the drawing identification number and not to exceed fifteen characters including all numbers, letters, and dashes. Suffix identifiers (if used) shall be included in the fifteen character limit.

f. Nomenclature or Description – Phrase describing the referenced item.

g. Item Weight – To be provided for assemblies 35 pounds and over except where the required information is traceable through information provided in another column (e.g., where a referenced drawing provides the item weight).

h. Notes or Remarks – To provide additional information (e.g., size and dimensions of fasteners) not shown on the drawing or defined by the item name or description.

8.7 Spare Parts

The Contractor shall define and supply recommended spare parts required for a service life of ten years. The spare parts list shall be accompanied with directions for their use including replacement criteria.

8.8 Dimensions and Tolerances

Drawing dimensions and tolerances shall be in accordance with ASME Y14.5 or ANSI Y14.5M- 1982.

8.9 Units

English units shall be used as the primary reference. Metric units may be shown as secondary reference at the Contractor’s option.

8.10 Drawing Notes

Notes shall be provided on drawings where necessary to clarify requirements for the item shown. Welding and brazing fabrication and inspection documents, safety precautions, special cleaning and lubrication, and shock and vibration requirements shall be specified by drawing notes. Where notes are included for manufacturer’s use only, they shall be so designated.

8.11 Marking Details

Drawings shall specify marking details (where and how) when marking to be done by the manufacturer requires control to prevent stamping of highly stressed parts.

Date: 4 May 2016

8.12 Revision to Engineering Drawings and Associated Lists

Revisions made to engineering drawings and associated lists shall be in accordance with the requirements specified herein.

a. Revision Designators - The letters “I,” “O,” “Q,” “S”, “X” and “Z” shall not be used as revision designators on engineering drawings or associated lists. Combined letters and numbers shall not be used for revision designators.

b. Documentation of Changes – Revision blocks shall be used to provide a record of all changes made to engineering drawings and associated lists. Revision block columns shall include a description of each change and a zone at which the change appears. Each change shall be separately identified (i.e., words such as “revised extensively,” “updated,” or similar shall not be used). Reference to a separate change notice is acceptable, provided the change notice is submitted with the revised drawing.

c. Associated List Revision Status – Where revisions are made to associated lists which are integral with drawings, the revision shall be treated as a revision to the drawing. The revision status of associated lists provided separate from the base drawing may be independent of the base drawing revision status.

8.13 Fastener Installation Requirements

Drawings shall specify or reference installation procedure requirements for all fasteners.

Specified information shall include torque range, torque check and inspection requirements, thread lubricant requirements and, as necessary, requirements for treatment with a retaining anaerobic compound. Bolt tightening sequence shall be provided for sequence critical joints.

8.14 Electronic Drawing Format

Unless otherwise approved, all electronic drawing image files shall be provided on CD, DVD, or email in Adobe Acrobat (pdf) format. The format and version used shall be agreed upon between the Purchaser and the Contractor prior to submittal of any Contractor drawings. The electronic drawing files shall be converted directly to pdf format. If not possible, drawings shall be scanned where practicable in full size 100 percent scan size with a resolution of between 200 and 400 DPI oriented to be right reading with title block in the lower right hand corner. The files shall contain one file per drawing and revision, and the file name shall be the same as the drawing number and revision.

8.15 Hardware Delivery

Material certification of conformance documents shall be provided with each complete or partial shipment.

Finished parts shall be weighed and actual weight reported at the time of delivery.

Finished parts shall be preserved prior to shipment.

Date: 4 May 2016

8.16 Instruction Documentation

Installation, operating and troubleshooting instructions shall be provided in Technical and Users Manuals. The troubleshooting documentation shall list any special tools or diagnostic equipment necessary to determine possible problems with each major component of the system. Directions associated with sensor installation, including grounding requirements for accelerometers, shall also be provided.

8.17 Design Review

Prior to start of manufacturing, the Contractor shall have a Final Design Review with Purchaser representatives.

3.2 Dimensional Requirements