Rockwell Automation System Introductionucc.colorado.edu/allen-bradley/3_JBLee-ICM_EPC.pdfanalysis and intelligent advisory software Sensors/Software • Enpac connects to Emonitor

3/15/2010 1

Copyright © 2008 Rockwell Automation, Inc. All rights reserved.

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Rockwell Automation Condition Monitoring System Introduction

ICM Business LeadJong Bae Lee

Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 2

Agenda

1. 통합 솔루션

2. 경쟁력 분석

3. 주요실적

4. 신개념 통합솔루션 – Dynamix 1000

5. Dynamix 1000 Application

Allen-Bradley PLCs

https://industrialautomation.co/product-category/allen-bradley/page/1816/

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Agenda

1. 통합 솔루션


Then & Now: Strong Heritage of Quality, Innovation and Customer Service in:Condition Monitoring & Protection

1980

1972

FoundationFoundation

1985

1994

2003

TodayToday

More than 550 years0 years of experience, innovation, and

customer serviceThe XM Series of Protection and Monitoring Modules

1200 & Unicell Series

5800 Series

5900 Series

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Condition Monitoring Overview


Rockwell Automation Condition Monitoring

• Integrated Systems andProcesses that:

– Apply multiple technologies (vibration, oil,thermography, process data, etc.).

– Implement multiple collection strategies(portable, online surveillance, real time)

– Provide connectivity with the enterprise(CMMS, Control System, etc.)

– Effectively supports a Condition-based Maintenance Program

An integrated approach to Condition Monitoring is the key to asuccessful Condition-based Maintenance strategy

An integrated approach to Condition Monitoring is the key to asuccessful Condition-based Maintenance strategy

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Experience Delivering TSI, MPS, and VMS solutions for the Entire Plant

Turbine & GeneratorFD FansID Fans

Boiler Feed PumpsCondensate PumpsPulverizersPA FansCooling Tower FansCirculating Water PumpsScrubber Fans

Protection Production Assurance Predictive Maintenance

Real Time XM Surveillance XM / Enwatch Portable1 2 3

11 21 21 2

1

2 3

2 32 3

2 3

1 2

2


• Complete solution for TSI

• Stand Alone or easily Integrated

• Cost effective solutions for general purpose and Balance of Plant monitoring and protection

• Software for visual display/analysis and historical data collection/trending

ProtectionProtectionProtection

• Sequential or fixed system leveraging CompactLogix, XM, EtherNet/IP and DeviceNet

• Operator Interface faceplates included

• FTView diagnostics and alarms

• Track and trend data for all machines

• RSLogix5000 Add-On-Instructions

SurveillanceSurveillanceSurveillance Walk-AroundWalkWalk--AroundAround

• Accelerometers• Non-contact probes• Full range of

options• Frequency

response• Environmental• Mounting/exit

• Historical data collection, trending, analysis and intelligent advisory software

Sensors/SoftwareSensors/SoftwareSensors/Software

• Enpac connects to Emonitor

• 2 Channels, 12,800 lines of resolution

• Software centered Intelligent advisory

• Flexible, variable collection options

• Enpac Kit provides collector, sensor and software

• Typically for BoP applications

Dynamix Family of Integrated Condition Monitoring (ICM) Products

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Dynamic• XM-120 Standard Dynamic

– XM-120E Eccentricity• XM-121 Low Frequency Dynamic

– XM-121A Absolute Shaft Vibration• XM-122 gSE Vibration• XM-123 Aeroderivative

• XM-160 Overall Vibration• XM-161 OA Vibration w/4-20mA Outputs• XM-162 OA Vibration w/ Prox Probe Power

Speed• XM-220 Dual Speed

Process• XM-320 Position• XM-360 Process• XM-361 Universal Temperature• XM-362 Isolated TC Temperature

Relays• XM-440 Master Relay • XM-441 Expansion Relay• XM-442 Voted EODS Relay

Packaged Products• XM-720 Machine Monitor

Gateways• 1788-EN2DN Ethernet to DeviceNet

Intelligent I/O for Machinery Monitoring and Protection

XM® Machinery Protection System


Intelligent Dynamic Measurement Module(I/O)

Single Relay

Tach InputDual Input(Dynamic)

Buffered Output

DeviceNetCommunications

Redundant Power Input

Serial Interface

LED Indicators•Module Status•Network Status•Ch1, Ch2, Tach Status•Set Point Multiplier•Relay Status

Dual 4-20mA Outputs

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Surveillance Condition Monitoring System

• Sequential or fixed XM system– Sequential uses a single set of XM modules,

CompactLogix connects sensors to XM– For each machine, CompactLogix loads new

configuration and retrieves data set via DeviceNet– Problem analysis rules sets executed

• Operator Interface faceplates included– View diagnostics and alarms– Track and trend data for all machines– Configured by Add-On-Instructions

Operations-centered; Process-centric analysis

Accelerometers wired to CompactLogix for sequencing to XM-122

DeviceNet controlsXM module andretrieves all data

PanelView PlusFactoryTalk View ME

EtherNet/IP*Custom-made/Configured surveillance panels are designed and delivered by SSB


Enpac 2500 Portable Hardware

• Portable Data Collector and Analyzer– Important part of a Condition-based Maintenance program– A cost effective way to collect periodic data on rotating

machinery – Advanced analysis capabilities that can be used in conjunction

with real time protection monitoring strategies on critical assets• Truly Portable but rugged, literally!

– Light Weight (less than 2 pounds!)– True Hand Held Package (186mm tall x 93mm wide x 36mm deep)– Larger ¼ VGA Color LCD display– Intuitive Menu and Icon Navigation

• 2 Channel option allows you to take 2 simultaneous measurements in a route

• IP65 dust & waterproof; Hazardous Area Certification• Patented Built-in Laser Tachometer

Key to A Successful Predictive Maintenance Program

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The vast majority of bearings are one of two types:

bearing

bearing housing

bearing

bearing housing

Oil Wedge (load zone)Soft Metal (Babbitt)

Eddy Current Probe Accelerometer

Fluid Film (sleeve)Capable of supporting very high loads, high temperatures, high speed. Expensive and associated rotor dynamics are very complex.

Rolling Element (anti-friction)Low cost, simple to apply. But are capable of only moderate speeds and relatively light loads. Rotor dynamics aren’t bad but diagnostics can be complex due to all those spinning balls!

A Word About Bearings


Shaft Displacement MonitoringIncludes onboard power supply for non-contact eddy current displacement probes.

Shaft Displacement MonitoringIncludes onboard power supply for non-contact eddy current displacement probes.

Casing Vibration MonitoringIncludes onboard 4mA excitation for piezoelectric transducers with integrated circuits.

Casing Vibration MonitoringIncludes onboard 4mA excitation for piezoelectric transducers with integrated circuits.

Accelerometers & Probes

Voltage Input MonitorSupports almost any externally powered or self powering voltage output sensor that produces a calibrated linear signal.

Voltage Input MonitorSupports almost any externally powered or self powering voltage output sensor that produces a calibrated linear signal.

Any voltage input will work, almost any manufacturer’s sensor

Allen-Bradley PLCs


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Measurements Radial Shaft Absolute Thrust / Eccentricity Speed / Temperature Vibration Relative Shaft Expansion / Overspeed

Position

Monitors XM - 120 XM - 120E XM -121 XM - 121A XM - 220 XM - 320 XM - 361 XM - 362

HMI Versa View PanelView Strip Chart LED Indicator RSVIEW

Reliability Emonitor RSMACC EOL ROL

Services Design Installation / Configuration, Startup & Drawings &Project Management Testing, Acceptance Commissioning Documentation

To Build a Complete Steam Turbine Instrumentation System begin with Measurements and work up to Services

Control PLC / DCS OPC Gateway Relay Logic 4-20 mA I/ODeviceNet Interface (XM – 440)

Complete Steam Turbine Instrumentation System


Turbine Supervisory Instrumentation

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Rockwell Automation API-670 Complince


Condition Monitoring truly supports RA’s Integrated Architecture Platform

OPC to Other System

Asset Center- Condition Monitoring

View ME / SE

• Complete solution for critical TSI application

• Balance of Plant (BoP) monitoring & protection

• Data available throughDeviceNet ControlNetEtherNet /IP

Complex DataXM Polled / COS Data

Typical Steam Turbine

Typical BoP - Fan XM-12x

XM-DYN

Allen-Bradley PLCs


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Condition Monitoring

• Machinery Protection and Condition based Maintenance are essential for:

– Operational continuity– Regulatory compliance– Safety– Maintenance & Reliability

• Traditionally these are separate and isolated disciplines

• Protection and CbM are merged in Integrated Architecture

TRADITIONAL APPROACHDCS Protection CbM

INTEGRATED ARCHITECTURE


Agenda

2. 경쟁력 분석

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RA CMS Architecture for Competition

Ethernet Plant LAN

CMMSCMMSDatabaseDatabase

CMSCMSDatabaseDatabase

Server 1:DAS

ProcessProcessHistorianHistorian

Sensors (Vibration, Speed,Temperature, Other)

On-line Data Collection Device- XM

Manually PortableData Collection

Data Sharing Between Systems

Server 2:DAS

Server 4:Master Database.

CMS Workstation

BN 3500 SystemVMPSFor P2S/P3

“Supplied by Packages”

CMSFor All rotating equipments

Server 3:DAS

CMSFor P1/P2

“Supplied by CMS Providor”

To RAS


BN3500 Buffered Output Interface

Displacement Signal1 to 3500/42M Slot 2 Ch1

Displacement Signal2 to 3500/42M Slot 2 Ch2

BUFFER1 Out of Buffered Output Signal Module

Tach. Signal to 3500/25KPH Out of Buffered Output Signal Module

Wiring to XM Module via BN Buffered Output

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Hardware Competition vs. Allen-Bradley XM

Expensive Proprietary components

Individual modules for Rack Interface, Communications, Vibration Measurements,

Speed Measurements, and Relays – more $$$

In-Expensive DIN-Rail components

ONE MODULE


Bently Nevada’s 3500 Monitor

Bently’s most capable monitoring system3500/05 (19” Rack)3500/15 (Power Supply Unit)3500/20 (Rack Interface Module)3500/32 (Relay Card)3500/XX (eg /40M & /42 Monitoring Module)3500/25 (Key Phasor Module)3500/92 (Communications Module)

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XM Strategy vs. BN 3500(Basic 4-channel Count)

• The weakness of the 3500 is the large “startup” cost. Accentuate that by focusing on low channel count solutions or distributed applications. And insure that the client asks for speed, phase or order data

Offer small systems or large distributed systemsOffer small systems or large distributed systems

3500 System - $7,000*• Rack• Redundant Power Supply• Rack Interface Module • Rack Configuration Software• Proximitor Seismic Monitor• Tachometer Module

19”XM System - $4,300*• Redundant Power Supply• 2 Vibration Modules with

Speed & Phase• 2 Terminal bases

7”

*Based on 4 channel configuration


Agenda

3. 주요실적

Allen-Bradley PLCs


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Proven Capability

• Rockwell Automation has provided TSI, MPS, and VMS systems to power companies all over the world. These are supported by our local Rockwell Automation Sales & Support Offices, Power Centers of Excellence in the US and India as well as a network of highly qualified OEMs and System Integrators.

• Three of our most recent projects are highlighted below. The following pages are only a representative sample of the power companies wehave supplied on-line systems to over the last 30 years:

• Shanghai Electric 2 x 600 MW TSI & VMS BOP India• Harbin Electric 6 x 300 MW TSI Azerbaijan• Allegheny Energy 2 x 650 MW TSI USA


Rockwell Automation TSI, MPS, VMS Sample Project List

TSI Steam Turbine GeneratorSCS – Oglethorpe

TSI Steam Turbine Generator & VMS BOPMid American – Riverside

TSI Steam Turbine GeneratorAES – Beaver Valley

TSI Steam Turbine GeneratorIndianapolis Power - Martinsville

TSI Steam Turbine GeneratorIndianapolis Power – Harding

VMS BOPExelon – Eddystone

TSI Steam TurbineConsumers - Weadock

TSI Steam TurbinesArizona Public Services

VMS BOPDuke Energy

TSI Steam Turbine Generator & VMS BOPFlorida Power & Light

VMS BOPSCS – Alabama Power

VMS BOPSCS – Gulf States Power

VMS BOPSCS – Mississippi Power

TSI Steam Turbine Generator & VMS BOP

VMS BOP

TSI Steam Turbine & VMS BOP

TSI Steam Turbine Generator x 2

TSI Steam Turbine Generator

TSI Steam Turbine Generator

Basin Electric

SCS – Georgia Power

TMPA – Gibbons Creek

NRG – Norwalk

AES - Greenidge

AES – Somerset

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Rockwell Automation TSI, MPS, VMS Sample Project List

VMS of CHP,NTPC BARH

VMS of CHP,NTPC Singhrauli

MPS/VMS: Sweat Water PumpsNTPC IVRCL )

MPS/VMS: CWP'sNTPC Simahadri

MPS/VMS: Cooling Tower PackageNTPC India Mumbai

VMS: ID Fans, PA Fans, FD Fans, BFP's, Mill MotorsNTPC Sipat

VMS: ID Fans, PA Fans, FD Fans, BFP's, Mill MotorsNTPC Kahalgaon

VMS: ID Fans, PA Fans, FD Fans, BFP's, Mill MotorsNTPC Farakka

VMS: CWP,CEP,DSP, ID, FD FAN 6x210 MW Turbine.NTPC Vindhyachal

TSI of 2 X 100 MW LMZ TurbineUPSEB Hurduaganj

TSI: 35 MW Steam Turbine

VMS: TG Set 2 X 30 MW

TSI: 3 X 60 MW

VMS for Pumps

TSI of 2 X 110 MW LMZ Turbine

TSI of 1x110 MW Steam turbine

TSI 2x110 MW BHEL Steam turbine

TSI 110 MW BHEL Steam turbine

TG VMS OF 3 X 210 MW

ESSAR POWER

NTPC -SAIL BHILLAI

NTPC -SAIL BOKARO

NTPC Ramagundam

UPSEB Obra

PSEB BHATINDA

KTPS Kota

BHEL-EDN, Bangalore

NTPC Vindhyachal


Major customer list

• 국내(Power, Oil&Gas)- 한국전력공사(영월, 군산, 영동, 보령

화력발전)

- 한국수력원자력(영광)

- 한화건설 (광명 열병합 발전)

- 반월 열병합발전소

- 한전기공㈜ (고리, 당진, 삼천포, 태안, 하동 전문기술 지원실 등)

- 대우조선해양 (FPSO)

- ㈜SK (FCC Plant)

- S-OIL

- 풍산금속

- 한국 오토글라스

- 현대 중공업㈜

- 삼성중공업㈜

- 태영 화학㈜ 등

• 해외 (OIL&GAS, OFFSHORE, CHEMICAL)- Chevron Agbami FPSO - Chevron Tahiti SPAR- Air Liquide (Gas Compressor)- ExxonMobil (Pumps)- TOTAL Refinery (Furnace) - Petrotech (GE Frame 5 Turbine, Compressor) –

Dakota Gasification Company - Rolls Royce (Gas Turbine Compressor Train) - North Atlantic Refinery (Compressor)- Peter Brotherhood (Recip Compressor) - BASF (Air Blowers, Booster & Feed Water Pumps)- Potash Corp of Saskatchewan - PCS Nitrogen (Air Compressor, Steam Turbine

Generator)- Columbia Gulf Pipeline (GE Turbine)- CACT Operators Group (Oil Pipeline Pump)- ADMA – OPCO Das Island (Pump Station)- Shell (Engine-Gearbox-Pump) 외 다수

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Major customer list

• 해외 (Power Plant)- Pitchess Cogeneration - Saugus, CA- Cinergy CG&L – North Bend, OH- National Thermal Power – India- New Brunswick Power – Colson Cove,

NB- Mid America Energy – LA- Southern Hydro – Victoria, Australia- Carlton United Brewary - Victoria,

Australia- Hydro Tasmania – Tasmania, Australia- Newfoundland & Labrador Hydro - City Utilities – Springfield, MO- Nevada Cogeneration – Las Vegas, NV- Rosaboud Funtes Power – Qatar

• 해외 (Power Plant)- Penobscot Energy Reclamation

Company – Orrington, ME- Decorative Panels, Inc. – Alpena, MI- Sask Power – Canada- Dominion Energy – Hammond, IN- Texas Municipal – Carol, TX- Southern Company – Pascagoula, MS- Consumer Energy – Essexville, MI- Basin Electric – Stanton, ND- Texas Municipal Power – Bryan, TX- Wood Group / HELCO – Hawaii- Louisiana Generating – Baton Rouge, LA- Consumers Energy – Essexville, MI- Stanwell Power – Stanwell Australia 외

다수


USA Allegheny Energy Supply - TSI 2x684MW

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India PSEB Bhatinda – TSI


India BHEL-EDN – TSI

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Harbin Turbine – Dovlet Rayon

End User: Dövlet Rayon Stansiyasi Power Plant, AzerbaijanUnit: 7x330MW Super critical generation units

EPC: China National Electric Equipment Corporation DI: Harbin Power System Engineering & Research Institute OEM: Harbin Turbine Automation Control Company


TMPAGeneral Electric D8 Turbine

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Cabinets & HMI


보령화력 발전소 1,2 호기 TSI Layout

Allen-Bradley PLCs


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광명 열병합 발전 VMS Layout


Agbami FPSO Condition Monitoring System

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Copyright © 2008 Rockwell Automation, Inc. All rights reserved.

Insert Photo Here Thank you!

Allen-Bradley PLCs


Documents

Rockwell Automation System Introductionucc.colorado.edu/allen-bradley/3_JBLee-ICM_EPC.pdfanalysis and intelligent advisory software Sensors/Software • Enpac connects to Emonitor