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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
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Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 3
Agenda
1. 통합 솔루션
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 4
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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Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 5
Condition Monitoring Overview
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 6
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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Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 7
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
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• 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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Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 9
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
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 10
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
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 12
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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Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 13
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
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 14
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
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Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 15
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
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Turbine Supervisory Instrumentation
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Rockwell Automation API-670 Complince
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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
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Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 19
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
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 20
Agenda
2. 경쟁력 분석
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Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 21
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
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 22
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
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 24
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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Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 25
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
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 26
Agenda
3. 주요실적
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Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 27
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
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 28
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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Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 29
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
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 30
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
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 32
USA Allegheny Energy Supply - TSI 2x684MW
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India PSEB Bhatinda – TSI
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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
Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 36
TMPAGeneral Electric D8 Turbine
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Cabinets & HMI
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보령화력 발전소 1,2 호기 TSI Layout
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광명 열병합 발전 VMS Layout
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Agbami FPSO Condition Monitoring System
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