Process and Power Control

Transcription

1 Process and Power Control Insert Photo Here Sergio Gama Rockwell Automation Rockwell Automation Process Solutions User Group (PSUG) November 14-15, 2011 Chicago, IL McCormick Place West Copyright 2011 Rockwell Automation, Inc. All rights reserved.

2 Agenda Sample 1. The Value Proposition 2. Ethernet /IP as the enabler Copyright 2011 Rockwell Automation, Inc. All rights reserved. 2

3 Intelligent Motor Control Rockwell Automation defines Intelligent Motor Control as a reference architecture for the integration of motor control devices to your plant-wide control system Intelligent Motor Control leverages your investment in automation to provide continuous optimization in: Energy Availability Engineering Safety Reduce energy consumption Track performance Energy management Reduce downtime Reinstate systems faster Avoid system disruption Reduce development time Reduce commissioning time Common user experience Protect personnel Protect assets Copyright 2011 Rockwell Automation, Inc. All rights reserved. 3

4 Intelligent Motor Control Control & Visualization Control Visualization Information Network Technology EtherNet/IP Motor Control Devices Simultaneous real-time control, configuration and data acquisition... Integrated Architecture is our differentiator Copyright Rockwell Automation, Inc. All rights reserved.

5 Intelligent Motor Control Intelligent devices with energy saving features combined with the overall communication capabilities of the Integrated Architecture enable an energy management strategy to bring you both an immediate and measurable impact on your operational efficiency Energy Savings Energy Management Energy Availability Engineering Safety Copyright 2011 Rockwell Automation, Inc. All rights reserved. 5

6 Energy Efficiency = Savings Motors typically consume over 60% of the energy in an industrial facility. Reduce Energy Consumption & Demand Peaks Significant energy by driving variable torque loads at the speed required by the application. Reduce the inrush current and extend the life of electric motors associated with critical rotating assets. Copyright 2011 Rockwell Automation, Inc. All rights reserved. 6

7 Energy Reducing the speed of a variable torque application by only 20% can save up to 50% in energy consumption Reduction of energy consumption through adoption of variable speed control. Key driver for the replacement of control valves Copyright 2011 Rockwell Automation, Inc. All rights reserved. 7

8 Energy Reduce inrush currents ( peak demand charges) and excessive starting torque A 50% reduction in voltage results in a 75% reduction in motor torque 180% 100% Full Voltage Torque 0 Reduced Voltage Torque Percentage of Full Speed 100% Copyright 2011 Rockwell Automation, Inc. All rights reserved. 8

9 Energy Variable frequency drives Reduce wear on motors from excessive starting torque Reduce energy consumption by running motors at the needed speed Reduced voltage starters Significantly reduce inrush currents that result in peak demand charges Reduce wear on motors from excessive starting torque Efficiency translates to savings motors typically consume over 60% of a plants energy Copyright 2011 Rockwell Automation, Inc. All rights reserved. 9

10 Energy Management Easily retrieve information from Intelligent Motor Control devices about the energy consumed by each motor in the system without impact on the control function Energy Management Easily retrieve information on energy consumption of devices Monitor your key assets electric consumption, torque signature and relevant process variables to assess and track asset performance Make informed decisions along the lifecycle of your assets Copyright 2011 Rockwell Automation, Inc. All rights reserved. 10

11 Energy Management Power consumption is reported across the network Information can be easily retrieved without impact on the control function Copyright 2011 Rockwell Automation, Inc. All rights reserved. 11

12 Asset Performance Monitor information from Process Control instrumentation. By correlating energy comsumption and operational data it is possible to track the performance of mechanical equipment in the plant. Copyright 2011 Rockwell Automation, Inc. All rights reserved. 12

13 Intelligent Motor Control With Intelligent Motor Control devices you can drive strategies to improve overall plant availability Reduce Unplanned Downtime Avoid System Disruption Reinstate systems faster Energy Availability Engineering Safety Copyright 2011 Rockwell Automation, Inc. All rights reserved. 13

14 Availability In resource based industries, production downtime directly impacts the top line Downtime = Lost revenue Copyright 2011 Rockwell Automation, Inc. All rights reserved. 14

15 Availability Diagnostic data from intelligent motor control devices can trigger either manual or automatic intervention before occurrence of unplanned shutdown. Predictive diagnostics Electric motor current indicating loading conditions. Vibration signature indicating mechanical unbalance. Torque signature indicating Process anomalies. Copyright 2011 Rockwell Automation, Inc. All rights reserved. 15

16 Motor Diagnostics Full Voltage Starters Scalable offer to match Asset size and relevance E Motor & Feeder E1 + Thermal Overload Phase Loss - Enhanced sensing Ground Fault Jam detection Thermistor monitoring Thermal overload Phase loss - Adjustable delay Ground fault Jam detection Stall detection Hours of operation Underload detection Current imbalance Thermal overload Phase loss - Imbalance sensing Phase reversal Ground fault Jam detection Stall detection Hours of operation Underload detection Current imbalance Short circuit protection RTD monitoring Thermal overload Phase loss - Imbalance sensing Phase reversal Ground fault Jam detection Stall detection Hours of operation Underload detection Current imbalance Short circuit protection RTD monitoring Power Factor Arc Protection Copyright 2011 Rockwell Automation, Inc. All rights reserved. 16

17 Availability Reduce time to troubleshoot and repair with immediate access to diagnostic information on any device in the system from any location Reduce time to troubleshoot and repair Full access to information in each motor control device from any location in the system. No dependency of information previously mapped to control system. Copyright 2011 Rockwell Automation, Inc. All rights reserved. 17

18 Availability Reinstate systems faster Certified Safety devices helps personnel to safely perform maintenance work without bringing equipment to full stop. Avoid complete shutdown and restarting sequence Copyright 2011 Rockwell Automation, Inc. All rights reserved. 18

19 Engineering With Intelligent Motor Control, you can reduce the time required to configure and commission your system all while using a common platform and Engineering toolset. Reduce Development Time Reduce Commissioning Time Common User Experience Energy Availability Engineering Safety Copyright 2011 Rockwell Automation, Inc. All rights reserved. 19

20 Engineering Shorter time to develop application code and configure devices across the system, while reducing risks associated with human error Reduce development time Develop application code independent of electrical layout Data in motor control devices automatically mapped in controller memory. Reuse data structures, application code and graphical objects Copyright 2011 Rockwell Automation, Inc. All rights reserved. 20

21 Engineering Develop application code independent of electrical layout and list of variables Reuse data structures, application code, and graphical objects Copyright 2011 Rockwell Automation, Inc. All rights reserved. 21

22 Engineering Get your systems up and running faster by commissioning and configurating your devices using a common software tool. Reduce commissioning time Engineering tools and libraries to speed deployment and maintenance Eliminate I/O mismatch errors Motor Control Centers wired, configured and tested from factory Reduction of Project risk Copyright 2011 Rockwell Automation, Inc. All rights reserved. 22

23 Engineering Reduce commissioning time Motor Control Centers wired, configured and tested from factory Reduce installation and set-up time Use one software tool to configure your entire Logix system Device parameters mapped in controller memory Eliminate I/O mismatch errors Copyright 2011 Rockwell Automation, Inc. All rights reserved. 23

24 Engineering Consistent operation across the product families to help reduce training and labor costs Common User Experience Integrated profiles and instruction set for motor control devices No logic or tables to move data in the system Single software tool to program controllers and configure motor control devices Field device integration, with Ethernet as the backbone Copyright 2011 Rockwell Automation, Inc. All rights reserved. 24

25 Engineering Common user experience Single software tool to program controllers and configure motor control devices Significant reduction of learning curve More efficient maintenance Integrated profiles and instruction set for drives Copyright 2011 Rockwell Automation, Inc. All rights reserved. 25

26 Intelligent Motor Control The Intelligent Motor Control portfolio is designed to deliver improved safety resulting in greater productivity, costsaving advantages and, most importantly, protection for personnel and assets Protect Personnel Protect Assets Energy Availability Engineering Safety Copyright 2011 Rockwell Automation, Inc. All rights reserved. 26

27 Safety IMinimize operator exposure and help protect from electrical and mechanical hazards Reduce Exposure Remote access to devices from any point within the system Design and construction features to minimize operation risk. Copyright 2011 Rockwell Automation, Inc. All rights reserved. 27

28 Safety Remote Monitoring Minimize operator exposure by monitoring remotely Diagnostic IntelliCENTER Comment Overload detection (monitor warning/trip) Door Closed Status shown on Elevation View Change overload relay setting (FLA and Trip Class) Door Closed Via Parameters in Monitor View Measure/monitor phase currents Door Closed Trend or Meter in Monitor View Measure baseline motor current Door Closed Trend and Save Data Ground fault detection (monitor warning/trip) Door Closed Elevation or Monitor View Monitor motor thermistor Door Closed Trend or Meter in Monitor View Time to trip, Time to reset Door Closed Trend or Meter in Monitor View Reset overload relay Door Closed Monitor View Event history Door Closed Event Log View Verify control power Door Closed Monitor View Verify starter operation Door Closed Monitor or Elevation View Unit documentation Door Closed Documentation View Component identification Door Closed Monitor View / Spares / Manuals Copyright 2011 Rockwell Automation, Inc. All rights reserved. 28

29 Safety design and Construction Maintenance managers need to reduce personnel exposure to the energized electrical equipment Center placement of bus Horizontal bus is not accessible for maintenance personnel to accidentally contact Horizontal bus is separate from where you need to run conduit Automatic Shutters Provide you immediate isolation when unit is removed from column Form 4b Isolation and Separation Keep live load terminals isolated, while performing periodic maintenance on other units Form 4b (optional) Copyright 2011 Rockwell Automation, Inc. All rights reserved. 29

30 Safety Design and Construction SecureConnect - Reduce Electrical Shock and Exposure to Harmful Voltages Connect and Disconnect unit stabs without opening the enclosure door or being in the arc flash boundary (no exposure to live electrical parts) Enhanced compliance with NFPA70E Section for your Electrical Safety Program Shutters Open Shutters Closed Copyright 2011 Rockwell Automation, Inc. All rights reserved. 30

31 Safety Design and Construction The Plant Safety Officer needs to reduce the potential exposure of all plant personnel to arc flash hazards Fundamental design of CENTERLINE 2500 MCCs minimizes the likelihood of an arc flash occurring CENTERLINE 2500 MCCs with ArcShield 1 Copyright 2011 Rockwell Automation, Inc. All rights reserved. Continually-braced bus Automatic shutters Arc-free zones Standard PE in all columns, making first connection when unit is inserted and disconnects last Helps protect your personnel if an arc flash were to occur within an MCC Provides personnel and assembly protection1 Per IEC/TR 61641:2008 for arcing durations up to 300 ms; available for systems at 415V (max), with 65kA (max) available current 31

32 Intelligent Motor Control Intelligent Motor Control helps you implement a single solution plant-wide that supports continuous improvement Availability Energy Time Availability to Market Engineering Safety Energy Safety Copyright 2011 Rockwell Automation, Inc. All rights reserved. 32

33 Agenda 1. The Value Proposition 2. Ethernet /IP as the enabler Copyright 2011 Rockwell Automation, Inc. All rights reserved. 33

34 Communication technology Access to information throughout the enterprise Ethernet /IP One Network One Network Technology No Tables and / or Logic to move data No Data routing limitations One name / address for data Logical Segmentation per designer s choice Topology options Copyright 2011 Rockwell Automation, Inc. All rights reserved. 34

35 EtherNet/IP Standard Protocol Model Standard Application Layer FTP SMTP HTTP VOIP DNS SNMP CIP TCP IP UDP Standard Ethernet Implementation of OSI Model IEEE CSMA / CD Copyright 2007 Rockwell Automation, Inc. All rights reserved. Physical Layer

36 EtherNet/IP Technology Convergence Commercial Technologies More Than a Fieldbus Webpage FTP Video/Voice Over IP Instruments Business & Traditional Plant Floor Applications HMI Drives Wireless Business System Robots Real-Time Plant Floor Control Applications Controllers Remote Access I/O Mix Business, Industrial, and Commercial Technologies to Solve Applications Plant-wide Copyright 2007 Rockwell Automation, Inc. All rights reserved. Devices Other Commercial Technologies Programming Terminals

37 Access from I/O Location Master/Slave Interface to Supervisory Network I/O network Master I/O Slaves Separate networks Supervision & Programming I/O Control I/O devices (slaves) can only communicate with Controller (master). Copyright 2011 Rockwell Automation, Inc. All rights reserved. 37

38 Access from I/O Location Master/Slave Interface to Supervisory Network I/O Network Master Access to system wide information requires extension of Supervision network to remote I/O location. I/O Slaves Copyright 2011 Rockwell Automation, Inc. All rights reserved. 38

39 Access from I/O Location Ethernet /IP I/O, Control and Visualization devices on the same network Immediate access from any point to the entire system Only one network needs to be installed Copyright 2011 Rockwell Automation, Inc. All rights reserved. 39

40 Remote Monitoring Master/Slave Interface to Supervisory Network I/O Slaves I/O network Master Full access to controller memory Access to device information previously mapped to Master (controllers). No remote access directly to slave devices Copyright 2011 Rockwell Automation, Inc. All rights reserved. 40

41 Remote Monitoring Ethernet /IP Full access to any device in the system Communication with devices concurrent with Control application Copyright 2011 Rockwell Automation, Inc. All rights reserved. 41

42 System Configuration Master/Slave Devices configured at each individual master-slave link Device parameters organized in data tables Tables and / or logic to move data Programer needs to identify each parameter in data table Copyright 2011 Rockwell Automation, Inc. All rights reserved. 42

43 System Configuration Ethernet /IP Devices configured from single location in the system Device parameters automatically mapped into controller memory No tables and / or logic to move data Parameters immediately identifiable to Programmer Automatic Device Configuration Copyright 2011 Rockwell Automation, Inc. All rights reserved. 43

44 Take away Ethernet/IP + Logix + IMC Devices Continuous improvement strategies throughout the plant lifecycle. Life Cycle Costs of mechanical assets are a key parameter in the evaluation of a new project Single network and software model provide more value than traditional systems Ethernet/IP, simultaneous control, configuration and information management Copyright 2010 Rockwell Automation, Inc. All rights reserved. 44

45 Questions? Copyright 2011 Rockwell Automation, Inc. All rights reserved. 45