Vibro-Meter CA202 144-202-000-135 Piezoelectric Accelerometer

The CA202 144-202-000-135 is the explosion-proof ultra-long cable version within the Vibro-Meter (now part of Meggitt Group) CA200 series of piezoelectric accelerometers, representing the technological pinnacle of this series in intrinsic safety protection and long-distance monitoring applications. This model features Ex ia intrinsically safe explosion-proof design and is equipped with a 20-meter integrated stainless steel hose cable, specifically designed for large-scale industrial facilities requiring long-distance distributed vibration monitoring in explosive hazardous environments. As the highest safety level monitoring equipment certified by multiple global authorities, it can operate safely and reliably in complex hazardous areas (Zone 0/1/2) such as petrochemical plants, liquefied natural gas facilities, and large-scale refining-chemical complexes, providing a complete intrinsic safety solution for predictive maintenance of super-large critical process equipment.

Building on the core technical advantages of the CA200 series, this product achieves, through precise intrinsic safety circuit design and strict manufacturing process control, that the electrical spark or thermal energy generated by the sensor and its associated circuit under normal operating conditions and specified dual fault conditions is below the minimum energy required to ignite a specific explosive gas mixture. The 20-meter cable length design fully considers the actual wiring requirements for distributed measurement points in large-scale facilities, providing unprecedented flexibility for constructing multi-platform, multi-level, long-distance monitoring systems while ensuring system intrinsic safety and long-term reliability.

This model not only possesses top-level performance characteristics for industrial vibration measurement but also serves as a core front-end component of a complete intrinsic safety monitoring system. The product strictly complies with the highest requirements of ATEX Directive 2014/34/EU, IECEx international standard system, cCSAus North American standards, and multiple regional explosion-proof certifications, providing users with a technologically leading, safe, reliable, and highly compliant professional solution for equipment condition monitoring in super-large hazardous areas worldwide.

2. Core Design Features and Technical Advantages

2.1 Intrinsically Safe Explosion Protection System

• Highest Level Intrinsic Safety Certification: Achieves Ex ia level certification, suitable for gas explosive environments in Zones 0, 1, and 2, providing the highest safety protection under dual fault conditions

• Comprehensive Gas Group Coverage: Certified for Group IIC, can be safely used in all explosive gas environments including hydrogen and acetylene, offering the widest coverage range

• Wide Temperature Adaptability Design: Temperature classes cover T6 to T2 range, adapting to extreme operating environment temperatures from -55°C to +260°C

• Global Compliance System: Holds multiple international certifications including ATEX, IECEx, cCSAus, UKEX, ensuring compliance for access to major global industrial markets

2.2 Ultra-Long Cable Professional Design

• 20-Meter Professional Length Optimization: Optimized design for long-distance monitoring needs of large-scale facilities, reducing intermediate connections and improving system reliability

• Precise Cable Parameter Control: Strict control of cable distribution parameters ensures accuracy of intrinsic safety loop calculations

• Professional Routing Guidance: Provides complete ultra-long cable routing guidance solutions to ensure installation quality

• Stress Distribution Optimization: Specially designed cable structure optimizes stress distribution and extends service life

2.3 Rugged Industrial Construction

• Full-Path Sealed Welding Technology: Sensor housing made of austenitic stainless steel (1.4441), cable hose made of heat-resistant stainless steel (1.4541), forming a complete leak-proof unit through hermetic welding

• Excellent Environmental Resistance: Protection level reaches IP68 equivalent standard, can withstand extreme industrial environments such as 100% relative humidity, high-pressure water washdown, steam, oil contamination, salt spray, and chemical corrosion

• High Mechanical Strength Design: Can withstand 1000g peak shock load and continuous vibration environments, ensuring long-term stable operation under severe mechanical conditions

• Optimized Thermal Management Design: Wide temperature operating range and low temperature coefficient characteristics ensure measurement consistency under different environmental temperatures

2.4 Superior Electrical and Measurement Performance

• High-Precision Vibration Measurement: Standard sensitivity of 100 pC/g with ±5% tolerance range, providing precise vibration signal acquisition capability

• Wide Dynamic Frequency Response: Flat frequency response range of 0.5 Hz to 6 kHz, covering full spectrum vibration characteristics from low-speed rotating equipment to high-speed gearboxes

• Complete Electrical Isolation Design: Complete electrical insulation between signal terminals and metal housing, insulation resistance ≥1×10⁹Ω, completely eliminating ground loop interference

• Ultra-Long Distance Signal Fidelity: Optimized twisted-pair shielded low-noise cable design combined with stainless steel hose protection ensures 20-meter ultra-long distance signal transmission quality

• Precise Temperature Compensation: Provides sensitivity temperature compensation characteristics across the full temperature range, ensuring measurement accuracy in wide temperature environments

2.5 Professional Safety System Integration Characteristics

• Clear Safety Parameter Definition: Provides complete intrinsic safety parameters including Ui, Ii, Pi, Ci, Li, facilitating system engineers in complex loop calculations and verification

• Optimized Ultra-Long Cable Design: 20-meter cable length adapts to actual distance requirements for distributed monitoring in large-scale facilities

• Standardized Installation Interface: Uses industry-standard installation dimensions and interface specifications, facilitating system integration and equipment replacement

• Complete Technical Documentation Support: Provides complete technical documentation including explosion-proof certificates, installation guides, safety parameter tables, and cable parameter tables

3. Typical Application Scenarios and Industry Solutions

3.1 Ultra-Large Petrochemical Complexes

• Ten-Million-Ton Refining-Chemical Integration Units: Plant-wide critical equipment vibration monitoring network for atmospheric and vacuum units, catalytic cracking units, hydrocracking units

• Million-Ton Ethylene Complexes: Distributed monitoring systems for cracked gas compressor series, propylene refrigeration units, ethylene refrigeration units, process water pump groups

• Aromatics-PX Large Complexes: Full-process equipment condition monitoring for continuous reforming units, aromatics extraction units, xylene fractionation units

• Large Refining-Chemical Integrated Control Centers: Front-end sensing network for plant-wide equipment condition monitoring systems, 20-meter cable adapts to long-distance wiring between units

3.2 Mega-Scale LNG Liquefaction and Receiving Terminals

• 5+ Million Tons/Year LNG Production Lines: Ultra-long distance monitoring of mixed refrigerant compressors, refrigeration compressors, critical pumps in liquefaction lines

• Large LNG Receiving Terminals: Station-wide equipment condition monitoring systems for unloading arms, storage tank pumps, high-pressure export pumps, vaporizers

• Transnational Natural Gas Pipeline Compressor Stations: Distributed vibration monitoring networks for multiple compressor units, drivers, and auxiliary systems

• Floating LNG Facilities (FLNG): Equipment condition monitoring for offshore floating production facilities, 20-meter cable adapts to complex space wiring

3.3 Large Coal Chemical and New Coal-to-Liquid Facilities

• Million-Ton Coal-to-Liquid Demonstration Projects: Critical equipment monitoring for Fischer-Tropsch synthesis reactors, recycle compressors, product separation units

• Large Coal-to-Olefins Units: Distributed monitoring for methanol-to-olefins reactors, olefin separation compressors, product refining units

• Coal-to-Natural Gas Mega Projects: Full-process equipment condition monitoring for coal gasification units, shift units, methanation reactors

• Modern Coal Chemical Complexes: Front-end sensing for plant-wide equipment health management systems with multiple interconnected process units

3.4 Mega Offshore Platforms and FPSOs

• Deepwater Semi-Submersible Production Platforms: Full-platform monitoring network for main power generation sets, oil and gas processing compressors, water injection pump groups

• Large Floating Production Storage and Offloading Units: Equipment condition monitoring for crude oil processing systems, natural gas compression systems, water treatment systems

• Offshore Engineering Equipment Comprehensive Monitoring: Online vibration condition monitoring for propulsion systems, positioning systems, lifting equipment

• Offshore Wind-Power and Oil-Gas Joint Development: Equipment health management systems for integrated energy platforms

3.5 Other Ultra-Large Industrial Facilities

• Large Air Separation Units: Critical equipment monitoring for air compressors, expanders, liquid oxygen pumps

• Ultra-Large Thermal Power Generation Units: Auxiliary system monitoring for million-kilowatt ultra-supercritical units

• Large Metallurgical Complexes: Condition monitoring for blast furnace blowers, oxygen plants, main rolling mill drive systems

• Large Paper Production Lines: Vibration monitoring networks for paper machine drive systems, coaters, calenders

4. Intrinsic Safety System Design and Installation Guide

4.1 Ultra-Long Distance Intrinsic Safety Loop Architecture Design

1. Energy Layered Limitation Principle: Design multiple safety barrier levels to limit electrical energy entering hazardous areas in layers

2. Parameter Precise Matching Principle: Sensor safety parameters must precisely match safety barrier output parameters, considering 20-meter cable distribution parameters

3. System Overall Certification Principle: The entire ultra-long distance measurement loop must be certified or strictly validated as an integrated system

4. Redundancy Reliability Principle: Consider redundant design for critical monitoring points to ensure system reliability

5. Documentation Integrity Principle: All design calculations, parameter selections, and installation records must form complete traceable technical documentation

4.2 20-Meter Cable Intrinsic Safety Loop Precise Calculation

4.2.1 Cable Distribution Parameter Precise Calculation

• Total Distribution Capacitance Calculation: Cc_total = 20m × (105 pF/m) = 2100 pF (inter-pole capacitance)

• Cable Shield Capacitance Calculation: Cc_shield = 20m × (210 pF/m) = 4200 pF (pole-housing capacitance)

• Total Distribution Inductance Calculation: Lc_total = 20m × Lc_per_meter (needs to be determined based on actual cable specifications)

• System Total Energy Storage Verification: ½×Cc_total×Uo² + ½×Lc_total×Io² ≤ Safety Limit

4.2.2 Safety Barrier Selection and Parameter Verification

1. Voltage Safety Verification: Uo (safety barrier maximum output voltage) ≤ Ui (sensor maximum input voltage) × Safety Factor

2. Current Safety Verification: Io (safety barrier maximum output current) ≤ Ii (sensor maximum input current) × Safety Factor

3. Power Safety Verification: Po (safety barrier maximum output power) ≤ Pi (sensor maximum input power) × Safety Factor

4. Capacitance Matching Verification: Cc_total + Ci ≤ Co (safety barrier maximum allowed external capacitance) × 0.8

5. Inductance Matching Verification: Lc_total + Li ≤ Lo (safety barrier maximum allowed external inductance) × 0.8

4.2.3 Loop Safety Analysis

• Worst-Case Analysis: Consider extreme environmental temperatures, cable aging, connection loosening, and other worst-case scenarios

• Fault Mode Analysis: Analyze safety under various fault modes such as open circuit, short circuit, and grounding

• Temperature Impact Analysis: Analyze impact of environmental temperature changes on cable parameters and safety performance

• Installation Error Analysis: Consider parameter errors and deviations during installation process

4.3 20-Meter Cable Professional Routing Engineering Specifications

4.3.1 Cable Path Planning and Design

1. Path Optimization Principles:

• Minimization Principle: Select shortest path while meeting safety requirements

• Avoidance Principle: Avoid high-temperature zones, strong vibration zones, corrosion zones, and mechanical damage risk zones

• Layering Principle: Route cables of different safety levels in separate layers

• Maintenance Principle: Consider convenience for later maintenance and inspection

2. Professional Routing Design Points:

• Establish 3D routing models to optimize spatial paths

• Design dedicated cable trays and support systems

• Plan stress relief zones and expansion compensation zones

• Design waterproof, dustproof, and corrosion protection measures

4.3.2 Cable Fixation and Support System

1. Fixation Point Professional Design:

• Horizontal Routing: One fixation point every 1.0 meter, increase to 0.8 meter in critical areas

• Vertical Routing: One fixation point every 0.8 meter, strengthen fixation at top and bottom

• Bend Areas: Increase fixation points within 0.3 meters on both sides of bends

• Connection Points: Special fixation within 0.2 meters of sensor exit and junction box entry

2. Professional Fixation Equipment:

• Stainless steel anti-corrosion cable clamps, temperature resistant to 260°C

• Vibration-resistant cable clamps with buffer pads to reduce vibration transmission

• Universal adjustable-angle fixation clamps to adapt to complex paths

• Special chemical-resistant fixation components for harsh environments

3. Stress Management System:

• Set up professional stress relief loops, diameter 300-400mm

• Design thermal expansion compensation bends to compensate for length changes

• Install vibration damping devices to reduce vibration stress

• Set tension monitoring points to monitor cable tension status

4.3.3 Environmental Protection Professional Measures

1. High-Temperature Protection System:

• Use double-layer thermal insulation sleeves in high-temperature areas

• Install heat radiation shielding plates

• Use high-temperature resistant special fixation components

• Install temperature monitoring sensors

2. Mechanical Protection System:

• Use protective conduits when passing through active areas

• Install anti-collision guardrails

• Install anti-tread protective covers

• Use wear-resistant surface treatments

3. Chemical Protection System:

• Use Teflon-coated cable clamps in corrosive areas

• Install chemical splash shields

• Conduct regular chemical protection inspections

• Establish corrosion monitoring systems

4. Climate Protection System:

• Consider UV protection for outdoor routing

• Strengthen sealing protection in humid environments

• Consider thermal expansion and contraction in areas with large temperature variations

• Strengthen fixation protection in windy areas

4.4 Professional-Level Electrical Connection and Wiring Engineering

4.4.1 Explosion-Proof Junction Box System Design

1. Multi-Level Junction Box Layout:

• Primary Junction Box: Close to sensor, processes raw signals

• Secondary Junction Box: Regional concentration, preliminary signal processing

• Tertiary Junction Box: Backbone network, signal aggregation and transmission

• Terminal Junction Box: Safe area interface, connects to safety barriers

2. Junction Box Professional Selection:

• Explosion-Proof Rating: Ex e or Ex d, adapted to area requirements

• Protection Rating: IP66 or higher, ensuring sealing integrity

• Material Specifications: 316L stainless steel, corrosion resistant

• Internal Space: Sufficient space for wiring and maintenance

• Heat Dissipation Design: Good heat dissipation to prevent overheating

4.4.2 Professional Wiring Process

1. Terminal Connection Process:

• Use silver-plated copper terminals to ensure good conductivity

• Apply crimping plus welding dual assurance process

• Install insulation sleeves to prevent accidental short circuits

• Clear marking for easy identification and maintenance

2. Shielding Treatment Process:

• Strictly implement single-point grounding principle

• Use shield connectors to ensure continuity

• Apply insulation treatment to shield layer to prevent multiple grounding points

• Regularly test ground resistance to ensure effectiveness

3. Sealing Protection Process:

• Multi-layer sealing structure to ensure protection rating

• Regular sealing inspection to prevent aging failure

• Use special sealing compounds adapted to temperature changes

• Establish sealing maintenance records to track status

4.5 Safe Area Professional Integration System

4.5.1 Safety Barrier System Design

1. Safety Barrier Selection Principles:

• Precise parameter matching with safety margin consideration

• Redundant design to improve reliability

• Modular design for easy maintenance

• Complete diagnostic functions for easy troubleshooting

2. Safety Barrier Installation Specifications:

• Install in dedicated cabinets with good heat dissipation

• Vibration-resistant installation to reduce vibration impact

• Clear labeling for easy operation and maintenance

• Regular calibration to ensure accuracy

4.5.2 System Grounding Engineering

1. Grounding System Design:

• Independent grounding system to avoid interference

• Multi-point grounding monitoring to ensure reliability

• Real-time grounding resistance monitoring

• Regular grounding system testing

2. Equipotential Bonding:

• Equipotential bonding between equipment

• Lightning protection equipotential bonding

• Electrostatic protection equipotential bonding

• EMC equipotential bonding

5. Professional Operation, Maintenance and Safety Assurance System

5.1 Full Lifecycle Management System

5.1.1 Design Phase Management

• Establish complete design documentation system

• Implement design review and verification procedures

• Conduct risk analysis and safety assessment

• Develop emergency plans and handling solutions

5.1.2 Installation Phase Management

• Establish installation quality control system

• Implement installation process supervision and recording

• Conduct post-installation testing and verification

• Establish installation archives and database

5.1.3 Operation Phase Management

• Establish daily inspection and maintenance system

• Implement regular testing and calibration

• Conduct performance evaluation and optimization

• Establish operational data analysis and early warning

5.2 Professional Testing and Calibration System

5.2.1 Regular Testing Plan

1. Daily Testing Items:

• Visual Inspection: Integrity, corrosion, damage

• Connection Check: Tightness, sealing, grounding

• Signal Check: Noise, drift, abnormalities

• Environmental Check: Temperature, humidity, corrosion

2. Monthly Testing Items:

• Electrical Performance Testing: Insulation, continuity, shielding

• Mechanical Performance Testing: Tightness, vibration, displacement

• Environmental Adaptability Testing: Sealing, protection, corrosion

• System Performance Testing: Response, accuracy, stability

3. Annual Testing Items:

• Comprehensive Performance Testing: Full parameter testing

• Safety System Verification: Intrinsic safety system verification

• Calibration Traceability Testing: Comparison with standard systems

• Life Assessment Testing: Remaining life evaluation

5.2.2 Professional Calibration Services

• Establish on-site calibration capabilities

• Implement regular calibration plans

• Use standard calibration equipment

• Establish calibration traceability system

5.3 Safety Management and Compliance System

5.3.1 "X" Special Conditions for Use Management
This model's explosion-proof certificate carries "X" marking, requiring establishment of professional management system:

1. Environmental Monitoring System:

• Establish temperature monitoring network

• Implement gas environment monitoring

• Conduct corrosion environment assessment

• Establish environmental database

2. Personnel Management System:

• Establish personnel qualification archives

• Implement regular training and assessment

• Conduct safety behavior supervision

• Establish responsibility traceability system

3. Document Management System:

• Establish technical document library

• Implement document version control

• Conduct regular document review

• Establish document traceability system

5.3.2 Change Management System

• Establish change management procedures

• Implement change risk assessment

• Conduct change verification and confirmation

• Establish change record archives

5.4 Emergency Response and Maintenance System

5.4.1 Emergency Response System

• Establish emergency plan system

• Implement emergency drill plans

• Establish emergency resource reserves

• Conduct emergency capability assessment

5.4.2 Professional Maintenance System

1. Preventive Maintenance:

• Develop preventive maintenance plans

• Implement regular maintenance operations

• Conduct maintenance effectiveness evaluation

• Optimize maintenance strategies

2. Predictive Maintenance:

• Establish equipment health models

• Implement condition monitoring analysis

• Conduct fault prediction and early warning

• Optimize maintenance timing

3. Corrective Maintenance:

• Establish rapid response mechanisms

• Implement professional repair operations

• Conduct repair quality verification

• Analyze root causes of faults

6. Technical Advantages and Comprehensive Value

6.1 Intrinsic Safety Technical Advantages

• Highest Safety Level Assurance: Ex ia intrinsic safety design provides highest level safety protection for ultra-large hazardous facilities

• Global Compliance Certification: Passes major global explosion-proof certification systems, meeting international large project requirements

• Ultra-Long Distance Safe Transmission: 20-meter cable achieves long-distance signal transmission while ensuring intrinsic safety

• Complete Safety Parameter System: Provides complete intrinsic safety parameters supporting complex system design

6.2 Professional Technical Performance Advantages

• Ultra-Wide Temperature Operating Capability: Extreme temperature adaptability from -55°C to +260°C

• High-Precision Vibration Measurement: 100 pC/g high sensitivity combined with wide frequency response range

• Ultra-Long Distance Signal Fidelity: Optimized cable design and signal processing technology

• Long-Term Stability and Reliability: Fully welded construction and professional protection design

6.3 Engineering Application Advantages

• Ultra-Long Cable Reduces Connections: 20-meter cable reduces intermediate connections, improving system reliability

• Professional Routing Guidance: Provides complete ultra-long cable routing engineering guidance

• System Integration Convenience: Standardized interfaces and complete parameter support

• Full Lifecycle Support: Full-process technical support from design to decommissioning

6.4 Economic Benefit Advantages

• Reduced Installation Engineering Costs: Ultra-long cable reduces junction box and connection quantities

• Lower Maintenance Costs: High reliability design reduces maintenance frequency and costs

• Avoid Accident Losses: Intrinsic safety design prevents explosion accident losses

• Improve Operational Efficiency: Accurate monitoring improves equipment operational efficiency

• Extend Equipment Life: Effective monitoring extends critical equipment service life

7. Technical Support and Service Commitment

7.1 Professional Technical Support System

• Application Engineering Design Support: Provides intrinsic safety loop design and calculation support

• Installation Engineering Guidance Service: Provides on-site installation guidance and technical briefing

• System Integration Technical Support: Provides system integration solutions and technical support

• Fault Diagnosis Expert Support: Provides expert-level fault diagnosis and analysis

7.2 Professional Training Service System

• Intrinsic Safety Technology Training: Intrinsic safety principles and application training

• Product Technology Training: CA202 series product technology training

• Installation Engineering Training: Ultra-long cable routing and installation training

• Maintenance Technology Training: Operation and maintenance technology training

• Safety Management Training: Hazardous area safety management training

7.3 Full Lifecycle Services

• Design Phase Services: Solution design, parameter calculation, safety assessment

• Installation Phase Services: Installation guidance, quality supervision, commissioning support

• Operation Phase Services: Regular testing, performance optimization, fault handling

• Upgrade and Modification Services: Technical upgrades, system modifications, function expansion

7.4 Service Response Commitment

• Rapid Response Mechanism: Establish 24-hour rapid response mechanism

• On-Site Service Support: Provide on-site technical service support

• Spare Parts Supply Assurance: Establish spare parts inventory and supply system

• Technical Update Services: Regularly provide technical updates and upgrade services