Overspeed Protection System

Rotary machines are the main part of many industries. These machines are designed to work at a certain rated speed depending on the type of application. keeping machine speed, within rated limit is one of the most important roll of machine protection, if the speed exceeds the limits, serious damaged would be happened to the shaft and other parts of machine.
The overspeed protection system is responsible for speed detection of machine and comparing it with the user set value, then react and stop the machine in overspeed conditions.

The Rayan P-10 is an overspeed protection system designed based on API670 with high level of functional safety (SIL3) in accordance with IEC 61508.
High reliability and unique features of this system make it a suitable selection for protecting all types of high level rotating machines such as turbines and generators in the critical industries such as refineries, power plants, and petrochemicals.

Catalog
Datasheet

Overspeed Protection System

Rotary machines are the main part of many industries. These machines are designed to work at a certain rated speed depending on the type of application. keeping machine speed, within rated limit is one of the most important roll of machine protection, if the speed exceeds the limits, serious damaged would be happened to the shaft and other parts of machine.
The overspeed protection system is responsible for speed detection of machine and comparing it with the user set value, then react and stop the machine in overspeed conditions.

The Rayan P-10 is an overspeed protection system designed based on API670 with high level of functional safety (SIL3) in accordance with IEC 61508.
High reliability and unique features of this system make it a suitable selection for protecting all types of high level rotating machines such as turbines and generators in the critical industries such as refineries, power plants, and petrochemicals.

Catalog
Datasheet

Key Features

  • SIL3/IEC 61508 certified
  • Triple Modular Redundancy (TMR)
  • Fully Compatible with API670 standard
  • High-speed reaction (Trip < 15ms)
  • High accuracy of frequency measurement (1 Hz in all measuring range)
  • 19″ rack, standard 3U height according to IEC60297-3-100
  • The possibility of monitoring and protecting two independent rotating machines in a single rack
  • Possibility of configuration with 1oo2, 2oo3, 4oo6 arrangements
  • Automatic test during system operation
  • Online Repair with hot-pluggable modules
  • Alarm management and event logger
  • Optional Isolated analogue outputs— 4 to 20mA
  • Free-floating sensor signal repeater
  • Zero speed detection and two alarm relays outputs
  • Configuration via PC software (RayLink) and front panel LCD and keypad with password security protection
  • External trip input
  • Multiple communication platforms such as USB, ProfiBus, ModBus, OPC, and Ethernet.

Functionality

In each set of Rayan P-10, there are 3 speed modules (SM) that independently measure the speed of the machine and activate their trip output relays if the speed increases more than the limit set by the user.
Each module has 2 trip output relays that are de-energized to trip and trip condition can be latched.
Trip relays are force guided type and their contacts participate in 2 independent 2oo3 hardware voting units. A 2oo3 vote, allows the system to maintain its safe functionality in the event of an error in a module.

If the 1oo2 arrangement is required, the user just needs to remove one of the speed modules from the rack. In addition, the 4oo6 arrangement can be applied to output by inserting 2 set modules (6 speed modules) on the rack.
Each monitoring module has an independent overspeed detection and protection unit, designed completely hardware-based. This results in High reliability and software risks are avoided.
In addition, each module has a diagnostic processor for monitoring the health of protection path. All modules’ faults are announced through alarm outputs.

User Facilities

  • There are three SM modules in each set and the status of the modules is indicated by the status LEDs
  • SM modules are compatible with various sensor types such as magnetic pickups, proximity sensors, and Hall Effect sensors
  • Two independent rotating machines can be protected with one rack

Interface Module (IM)

The interface module (IM) is a bridge between the user and speed modules. The interface module can be equipped with an LCD and keypad to communicate with the user (IMP).

IM module responsibilities are :

Parameterization

IM/IMP gets the settings from the user and programs the speed modules, then shows them to the user as current values of settings. The user can enter the settings by Keypad or in RayLink software. Entering settings by the user is password protected.

Logging

Last 50 alarms and events are logged by Sequence Of Events (SOE) and they can be displayed on LCD or RayLink log window. All the user commands and inputs, outputs are logged as events and the logs can be accessible in the future.

Detection faults

Detection of some faults such as absence of speed modules, power fault of speed modules, difference between settings of speed modules in a set, etc. is done by the IM/IMP.
*when the settings of speed modules are set, the system can continue overspeed protection function without the presence of IM/IMP.

Monitoring Terminal

Each module has a precise analog output according to its input sensor frequency. The analog output is in 4 to 20mA current range. this isolated output is optional and it can be scaled in the user defined range.

There are two alarm output for each speed module. All modules’ faults are announced through ALARM outputs.

Each speed module generates a pulse out of the input sensor, which is called repeater output. The frequency of this pulse exactly equals the sensor frequency and it can be used for monitoring or control purposes. This pulse is made independent of processor with high reliability.

Zerospeed output signal monitors the stopping of shaft speed. If the shaft speed goes below the detectable limit, this output is activated. also user can define the zero detection speed, in the detectable range of module.

Beside the trip contacts which are participate in voting, another contact is available on terminals for user applications. The trip contacts can be defined to be latched.

there are independent power inputs (18–30 V DC) for each module with a variety of power protection types such as Reverse polarity- Over voltage – Under voltage – Short circuit protection. The Main power has considered for safety path and the auxiliaries included zero speed, analog output, repeater and alarms outputs, are fully independent of safety path and powered with auxiliaries supply. This power can be joined to main power supply or isolated from it.

Trip Module

the output of two 2oo3 voters, which will be opened if system trip activated. The outputs are come from independent voters and can be connected redundantly to increase safety.

This input is a dry contact for force trip function and is independent for each overspeed set. this output trips all three modules of one overspeed set, with the highest priority and independent of processing paths.

The reset command is applied to all three monitoring modules on one set but only the module in trip mode will be affected by it.

Communication

RS-485 port with Profibus for communication with upstream systems such as PLC’s, DCS’s ,etc. with Optional Modbus RTU communication All the monitoring data of modules are transferred through Profibus.

LAN Port with TCP/IP for configuring—with optional OPC/UA communication

Orderable USB Port for configuring

Configuration Software

RayLink is a programming and configuration software that is run on a PC to manage log and settings of Rayan P-10. The Rayan P-10 connected to RayLink through LAN port with TCP/IP.
This software is a user-friendly environment and provide this possibilities:
Setting management: save the settings, reload the settings or copy a system setting to another one.
Access protection: Defined access levels, protect the system from changing by unauthorized personnel.
Reset Command: this item allows the user to reset the latched alarm and trips.
Auto Test Command: this initiates an auto test process for all three modules of each set.
Log management: there is a Log window that manages events and alarms of system. All the user command and status on software is logged.

User Interface

a TFT LCD display with 480*800 resolution is orderable. This display besides the special keypad, provide the configuration, system status monitoring, instant speed of modules, alarm and event monitoring.
Several pages are displayed in the UI, including:
Home: main data of modules is displayed in this page
Settings: in this page current settings of modules are displayed and user can change the settings too.
Sys Info: in this page product data displayed.
Alarms and Events: active alarms and events log are displayed.

Rayan P-10 Protects Your Machine Completely Reliably

SIL3/IEC61508 – 2010 Certified
The average probability of dangerous failure on demand or PFD_avg = 7.13×10^−5 (Once in every 14,025 times that overspeed occurs, Rayan P-10 will fail to react correctly!!)
Proof Test Interval = 5 years (Rayan P-10 has a 5-year performance guarantee with no testing required!!)
Safe Failure Fraction or SFF = 99.2% (In the Rayan P-10, 99.2% of errors do not lead to a dangerous state!!)

Overspeed Protection Unit Based On Reliable Hardware
In the Rayan P-10, safety is very important and critical, so using a high reliable hardware is considered a principle.
Therefore, the safety path of Rayan P-10 is completely hardware-based, by using a CPLD of mature technology MAX V, Altera design. This chip has a hardware basis and is safe from common programming errors in processors. The compliance documents of all peripherals of this chip with IEC 61508 have been provided by the manufacturer, so it has a good place in safety products.

Use Of Mature Technologies
The use of new technologies increases the risk of safety product design because they are still being tested and their defects have not been identified. Therefore, in safety products, instead of using new technologies, mature technologies should be used. In the design of Rayan P-10 products, this important principle has been included in the selection of used parts and technologies.

Independent Fault Detection and Diagnostic Unit
By using a processor unit independent of the safety path, sensor and measurement path errors and other faults are detected and notified to the user in the shortest possible time.

Force Guided Mechanical Relays
The trip relay of each module that participates in 2oo3 voting and issues the trip command is a force-guided type. The mechanical structure of these types of relays provides the possibility to read the correct feedback of the state of the contacts. As a result, any defect in the relay function during system operation can be identified and the user is notified in case of a defect.

Auto Test Based On DDS
To ensure the correct functioning of the modules during operation, the measuring and protection path are tested by a variable frequency generation based on DDS and the trip relay status is read. Therefore the main function is tested and alarm will be initiated if a fault is detected. This test is done for each module in specific time intervals that can be adjusted by users and is coordinated with other modules.

Online Replacement and Repair with Hot Plug Capability
Rayan P-10 is hot pluggable. With this feature, in case of a module failure, the faulty module can be replaced with a healthy one without the need to turn off the system.

Fully Compliant with Multiple Standards

Safety (IEC61508- SIL3)

  • System Type: B
  • HFT: 1
  • Architecture: 2oo3
  • Service Time: 5 Years
  • PFD avg: 7.13×10−5

EMC Standards (IEC 61000-6-2)

  • Fast Transient (Burst) | IEC61000-4-4, ±1kV, 5/50ns, 5Khz
  • Surge immunity | IEC61000-4-5, ±0.5kV, 1.2/50 µs
  • Electrostatic discharge | IEC61000-4-2, ±4kV contact, ±8kV Air
  • RF Conducted immunity | IEC61000-4-6, 0.15 to 80 MHz,10V, 80% AM
  • EMS radiated | IEC61000-4-3, 10V/m, 80MHz to 1GHz 3V/m, 1.4GHz to 6 GHz
  • Power frequency magnetic field | IEC61000-4-8, 50Hz, 30A/m, 10 min

Temperature

  • IEC60068-2-1 (0°C)
  • IEC60068-2-2 (55°C)

Damp heat

  • IEC60068-30, 55°C and 95%, 24h cycle 

We Support Rayan Products

Rayan Safety Group in Ahar Company supports this product
Rayan Safety Group, in addition to designing and manufacturing safety products, also provides support services for these products. Whenever and wherever you need our support, you get it…

Ahar is proud to provide customer service
At Ahar Company, we have experienced professional experts to provide all the services needed by the customer, including the purchase and installation of speed sensors, the installation and commissioning of the Rayan P-10 and providing all after-sales services and support for this product.

Customer training is Ahar’s priority
After installing and setting up Rayan P-10, you will receive all necessary training to work with this system and its accessories. We believe that proper customer training, ensures Rayan’s continued operation.

Safe Packing and
Shipping Services

Repair Services

Installation and
Commissioning 
Services

Remote Support

If you want more information, enter your email