Dynamix Integrated Vibration Protection System on EtherNet/IP

Dynamix Integrated Vibration Protection System on EtherNet/IP Mike Matabuena Business Manager, A&S, Southeast Asia Rev 5058-CO900E

Session Summary Topic Dynamix Integrated Vibration Protection System on EtherNet/IP Description Learn about the Dynamix 1444 Series, integrated vibration I/O and the equipment protection system. Dynamix leverages the power of the Logix controller and Ethernet to deliver unprecedented power, performance and flexibility in a distributed I/O architecture. See how this innovative design can provide a lower cost and simpler solution for equipment monitoring applications.

Agenda What is Condition Monitoring? Introducing the Dynamix1444 Series Applications Functional Summary Dynamix and the Integrated Architecture Questions? 3

Condition Monitoring helps Industries achieve Smart, Safe, Sustainable Manufacturing By providing real time machinery health information and guide operation management towards further optimizing production capacity By protecting critical machinery assets from unplanned stoppages 4

As the CONSEQUENCE of a critical asset failure is unimaginable. Aug. 2009 Russian Power Plant (Hydro-Electric Dam) Explosion Reports said that the investigation of the site has shown that the metal was worn out and caused the turbine to explode. Loss of life and/or bodily injury 69 dead and 8 missing Damage to the environment oil slick going down the river Loss of production / Broken equipment 10% of Siberia s energy needs were affected Long repair time 3 to 8 days just to pump the flooded engine room dry Cost of overtime, emergency spare parts, $310 million, maybe more 5

Condition Monitoring (as defined) Condition Monitoring is the collection and trending of parameters which change when machine condition begins to degrade. The goal is to identify changes in the condition of a machine that will indicate some potential failure. Physical characteristics are identified that collectively indicate the current condition of the machine. Each of these characteristics is measured, analyzed, and recorded so that trends can be recognized. Example: Vibration level increasing with time. 6

Vibration Vibrations are the first warning sign that a machine is prone to failure *Estimation based on field experiences

RA s Dynamix Family of Condition Monitoring Products Online Walk-Around Software Sensors Services & Solutions Stand Alone or easily Integrated Cost effective solutions for general purpose and Balance of Plant monitoring and protection Complete solution for Turbine Supervisory Instrumentation (TSI) System Emonitor Connectivity Light weight and easy to use Fast navigation and data acquisition Rugged to withstand harshest environments Expandable to dual channel, balancing, time waveform recording, and more. Emonitor, industry s leading Condition Monitoring software Multiple data collection platforms Comprehensive plotting Advanced alarming Intelligent diagnostics & advisories Real-time analysis of condition data from online sources Accelerometers Non-contact probes Full range of options Frequency response Environmental, Hazardous Area rating Mounting/exit Options Reliability Services Results Assurance Reliability Audits Program Management Reliability Online Training Phone Support Engineered and Custom Products Project and System Commissioning 8

XM-series of Intelligent Dynamic Measurement Modules LED Indicators Module Status Network Status Ch1, Ch2, Tach Status Set Point Multiplier Relay Status Single Relay Dual 4-20mA Outputs Serial Interface Redundant Power Input DeviceNet Communications Tach Input Dual Input (Dynamic) Buffered Output 9

Agenda What is Condition Monitoring? Introducing the Dynamix 1444 Series Applications Functional Summary Dynamix and the Integrated Architecture Questions? 10

Introducing the Dynamix 1444 Series Why Build a Next Generation Existing architecture was designed for another time The XM architecture 1 provides many modules 2, each designed to serve a specific application / requirement. This makes product selection and system design complex, and expensive. Often less than optimal solutions are deployed as trade-offs between products due to capabilities and limitations are frequently necessary. XM is a Machinery Protection system that is also capable of serving some condition monitoring data. XM was the first product of its kind to do this. The acceptance of the concept 3 and the demands from customers for more data, faster has exceeded the capability of the product and the capacity of the architecture s communications backplane, DeviceNet While XM can be integrated into a control environment, because it is DeviceNet based, the integration can be difficult and throughput performance is limited. 1 And most competitive products 2 The XM-124, with the coming Version 7 firmware, will help address this problem 3 API-670 5 th Edition will specifically allow for protection systems that also provide condition monitoring data 11

Introducing the Dynamix 1444 Series Next Generation Requirements An architecture that offers a single core module that: Can be applied to any Machinery Protection application Can serve any Condition Monitoring Application Applies a native EtherNet/IP backplane Is a component of Rockwell Automation s Integrated Architecture Design Goals: Simplify system design Reduce costs for spares, training, support Reduce costs for engineering, manufacturing and inventory Focus investment on the functionality of the product rather than the quantity of part numbers 12

Introducing the Dynamix 1444 Series Machine Protection Machine Condition Monitoring Intelligent, Distributed, Rugged, Safe High Performance Dual Processors, Ethernet, Integrated, Rated to +70 C and Marine standards for Shock & Vibration, Hazardous Area Approved 13

Introducing the Dynamix 1444 Series (just) 6 Catalog Numbers A Single Main Module + a single main module terminal base Three Optional Expansion Modules + one common terminal base for all expansion modules. 14

Introducing the Dynamix 1444 Series in a new, innovative package A Single Main Module + a single main module terminal base Ethernet connections located for easy, uncluttered access Connectors are angled for improved access and visibility Removable terminal connectors Both screw and spring version connectors available Recessed frame designed for easy gripping Integrated BNC connectors Soldered together card stack construction Innovative DIN mount design with tension and leveling control Three Optional Expansion Modules + one common terminal base for all expansion modules. 15

Dynamix 1444 Series 1 Main Module Dynamic Measurement Module (requires the 1444-TB-A terminal base) 4 Dynamic Inputs 2 Speed Inputs (TTL) 4 Buffered Outputs (BNC & Terminal Pins) 2 Digital Inputs Function is user programmable 2 Digital Outputs Function is user programmable 2 Ethernet ports Single or Device Level Ring (DLR) 1 SPDT Relay Many, perhaps most, applications will require only one or more Dynamic Measurement (Main) Modules 16

Dynamix 1444 Series 1 Tachometer Expansion Module Dynamic Measurement Module (requires the 1444-TB-A terminal base) 4 Dynamic Inputs 2 Speed Inputs (TTL) 4 Buffered Outputs (BNC & Terminal Pins) 2 Digital Inputs Function is user programmable 2 Digital Outputs Function is user programmable 2 Ethernet ports Single or Device Level Ring (DLR) 1 SPDT Relay Tachometer Signal Conditioner Expansion Module (requires the 1444-TB-B terminal base) 2 Speed Inputs any common speed sensors 2 Speed Outputs (TTL) to Local Bus & Terminal Pins 2 Buffered Outputs (BNC) 6 Dynamic Measurement Modules served per Tachometer Expansion Module 1 per Dynamic Measurement Module When (non TTL) speed signals must be monitored, a single Tachometer Signal Conditioner Expansion Module (TSCX) must be added. The TSCX is hosted by one Main Module but can serve its TTL output signals 6 Main Modules. 17

Dynamix 1444 Series 1 Relay Expansion Module When more than one relay is needed, up to three Relay Expansion Modules may be added. Relay function is specific to the host Main Module. Dynamic Measurement Module (requires the 1444-TB-A terminal base) 4 Dynamic Inputs 2 Speed Inputs (TTL) 4 Buffered Outputs (BNC & Terminal Pins) 2 Digital Inputs Function is user programmable 2 Digital Outputs Function is user programmable 2 Ethernet ports Single or Device Level Ring (DLR) 1 SPDT Relay Relay Expansion Module (requires the 1444-TB-B terminal base) 4 Singe Pole Double Throw (SPDT) Relays 5A, 250VAC/30VDC Tachometer Signal Conditioner Expansion Module (requires the 1444-TB-B terminal base) 2 Speed Inputs any common speed sensors 2 Speed Outputs (TTL) to Local Bus & Terminal Pins 2 Buffered Outputs (BNC) 6 Dynamic Measurement Modules served per Tachometer Expansion Module 1 per Dynamic Measurement Module 3 per Dynamic Measurement Module 18

Dynamix 1444 Series 1 Analog Output Expansion Module Dynamic Measurement Module (requires the 1444-TB-A terminal base) Tachometer Signal Conditioner Expansion Module (requires the 1444-TB-B terminal base) 4-20mA Output Expansion Module (requires the 1444-TB-B terminal base) 4 Channels Proportional to any measured value 1 per Dynamic Measurement Module 4 Dynamic Inputs 2 Speed Inputs (TTL) 4 Buffered Outputs (BNC & Terminal Pins) 2 Digital Inputs Function is user programmable 2 Digital Outputs Function is user programmable 2 Ethernet ports Single or Device Level Ring (DLR) 1 SPDT Relay Relay Expansion Module (requires the 1444-TB-B terminal base) 4 Singe Pole Double Throw (SPDT) Relays 5A, 250VAC/30VDC 3 per Dynamic Measurement Module 2 Speed Inputs any common speed sensors 2 Speed Outputs (TTL) to Local Bus & Terminal Pins 2 Buffered Outputs (BNC) 6 Dynamic Measurement Modules served per Tachometer Expansion Module When proportional analog outputs are required, one 4-20mA Output Expansion Module may be added. 1 per Dynamic Measurement Module 19

Dynamix 1444 Series 2 Terminal Bases 1444-TB-A Dynamic Measurement Module (requires the 1444-TB-A terminal base) Use with the 1444-DYN04-01RA 4 Dynamic Dynamic Inputs Measurement Module Includes last octets Ethernet 2 Speed address Inputs selection (TTL) Precision module / base alignment 4 Buffered guides Outputs (BNC & Terminal Pins) DIN mount tension / leveling 2 Digital screwsinputs Local Bus ribbon connectorsfunction is user programmable 2 Digital Outputs 1444-TB-B Function is user programmable Use with: 2 Ethernet ports 1444-TSCX02-02RB Tachometer Single Signal or Conditioner Device Level Ring (DLR) Expansion Module 1 SPDT Relay 1444-RELX00-04RB Relay Expansion Module 4-20mA 1444-AOFX00-04RB Output Expansion 4-20mA Module Output Expansion Module (requires Includes the 1444-TB-B address terminal selection base) for Relay Modules (addressing for other expansion modules is automatic) Relay Expansion Module 4 Channels Precision module / base alignment guides Proportional DIN mount to any tension / leveling screws measured value 4 Singe Pole Double Local Bus ribbon connectors Throw (SPDT) Relays 1 per Dynamic Measurement Module 5A, 250VAC/30VDC (requires the 1444-TB-B terminal base) Tachometer Signal Conditioner Expansion Module (requires the 1444-TB-B terminal base) 2 Speed Inputs any common speed sensors 2 Speed Outputs (TTL) to Local Bus & Terminal Pins 2 Buffered Outputs (BNC) 6 Dynamic Measurement Modules served per Tachometer Expansion Module 1 per Dynamic Measurement Module 3 per Dynamic Measurement Module 20

Dynamix 1444 Series (just) 6 Catalog Numbers! Dynamic Measurement Module Tachometer Signal Conditioner Expansion Module 4 Dynamic Inputs 2 TTL Speed Inputs 2 Speed Inputs 2 TTL Speed Outputs 4-20mA Output Expansion Module 4 Channels Relay Expansion Module 4 SPDT Relays 1 Main Module Base 1 Expansion Module Base Terminal Bases 21

Dynamix 1444 Series Ethernet Ethernet Connector (2): RJ45, shielded 1 Speed: 10MB / 100MB Modes: Half/full duplex Operation: Auto-switching Auto negotiation Auto mitigation Protocol ODVA Conformance Tested EtherNet/IP Industrial Protocol Connectivity Single Ethernet (IEEE 802.3) Device Level Ring (ODVA) IP Address Set by hardware switch on the terminal base, Set in configuration 2 Concurrent Access Controller (owner) Up to 3 additional sessions Time Synchronization IEEE-1588 Standard Ver. 2 CIP Sync (ODVA) 1 Allen-Bradley 1585 Ethernet Media recommend 2 IP address retained in nonvolatile memory 22

Dynamix 1444 Series A Compact, Distributed I/O Architecture 155 mm / 6.1 in XM 93.8 mm / 3.69 in 2 Channels + 1 Tach Input 94.0 mm 3.7 in 103.5 mm 4.1 in 54.7 mm 2.15 in 116 mm / 4..5 in 90.2 mm 3.55 in 100.7 mm / 3..96 in 4 Channels + 2 TTL Speed Inputs

Dynamix 1444 Series Power, Environment, Certifications & Approvals Power Redundant Supplies Supply Voltage Environment Operating temperature Conformal coating Integral redundant power supply inputs with supply fault detection and status available on I/O +24VDC (18V to 32V wide range input) designed to accommodate battery backed systems -25 C to +70 C All circuit cards are conformal coated Electrical Safety CE, CSA & UL Hazardous Area IECex-Zone 2 & ATEX Zone 2, cul Class 1 Div 2 Groups A,B,C,D Region & Country Marks CE, C-Tick, Russia*, Brazil*, Korean* Marine Certifications* DNV, BV, ABS, Lloyds, RINA, GL, KRS Functional Safety** TUV certified to SIL 2*** * May not be available at initial release ** Will not be available at initial release *** When used with local, expansion module, relays 24

1444 Series & the Integrated Architecture Fully Supported by Logix Integrated into the Logix architecture Configuration managed from any Logix controller Support included in Studio 5000 V20+ Standard assemblies for Configuration Input Output 25

Agenda What is Condition Monitoring? Introducing the Dynamix 1444 Series Applications Functional Summary Dynamix and the Integrated Architecture Questions? 26

Dynamix 1444 Series Designed to Serve Industry The only single architecture that is capable of serving the Machinery Protection and Condition Monitoring requirements of any application in any industry! 27

Machinery Protection General Protection Applications Provide alarm indication / annunciation via local relays and/or RA Visualization solutions Use a Logix integrated solution to detect faults and trend their propagation Serve data to condition monitoring software API-670 (5th Edition) Compliant Applications Can satisfy all the requirements of the standard While the controller is required for (initial) configuration, it is not required for a 1444 Series system to perform its function 1444 Series modules include nonvolatile memory. At power up the system will load its saved configuration, if or until its controller serves it another one Safety (SIL-2) Applications Requires use of local relays (expansion module) All safety related attributes in the configuration assembly are hidden 28

Machinery Condition Monitoring Stand Alone* Applications Simple OA Level Indication / Alarming Advanced Measurements for Any Class Machine Tracking & Band Pass Filters Absolute Shaft Vibration FFT Bands Spike Energy More Fault Detection / Alarming Alarm on known indicators of mechanical faults such as Imbalance, Misalignment, Rotor Rub, Loose Parts, etc. Alarm on known indicators of process conditions such as cavitation, fouled blades, pressure or flow related instabilities, etc. Alarm on event detection associated with random occurrences from mass change (lost blade), impact events, process upsets * Does not require further logic implemented in the controller. But does still requires Logix to manage the configuration. 29

Machinery Condition Monitoring Logix Integrated Solutions Apply simple rule based logic for Fault Diagnostic Trend fault indicators in Process Historian Implement advanced Monitoring Solutions for any class of machine or for any complexity of application Implement least cost per channel multiplexed* solutions Monitor machine tools and other cyclic applications with Profiles to detect deviant behavior relative to position or time Apply alarm limits based on process considerations (fluid type, material, speed, etc.) * Multiplexed systems are available as an SSB Solutions offering 30

Machinery Condition Monitoring Part of an Integrated Predictive Maintenance System Connect the 1444 Series to Rockwell Automation s Emonitor Software Emonitor is scalable software that provides the industry s most comprehensive suite of tools for establishing and executing a condition-based predictive maintenance program. Connect* any number of 1444 Series systems to Emonitor servers Consolidate all of your machinery condition information into a single plant or enterprise wide database * Data is harvested by the controller where it is read either on schedule or trigger by Emonitor 31

Agenda What is Condition Monitoring? Introducing the Dynamix 1444 Series Applications Functional Summary Dynamix and the Integrated Architecture Questions? 32

Dynamix 1444 Series Capabilities Machine Protection Machine Condition Monitoring Vibration Acceleration Velocity Displacement Absolute Shaft Vibration Spike Energy (gse) Speed Pressure Thrust Case Expansion Differential Expansion Rod Drop Relays 4-20mA Outputs Event Capture Event Log Trend / Alarm Startup / Coastdown Real Time, Continuous, Surveillance Real Time Processing of Critical Parameters, Continuous Processing of Diagnostic Data, Demand Processing of Infrequent Measures 33

1444 Series Functional Specifications Measurements Summary Dynamic (AC) Measurements Discrete Measurements o o Per Channel Pair SMAX Magnitude Shaft Absolute Vibration Per Channel Overall (2) Order Magnitude & Phase (4) FFT Band (8) Not 1x (1) Bias / Gap (1) gse Overall (1) Complex Measurements o o TWF and FFT (to 1600 lines) Asynchronous or Synchronous Speed Measurements Speed Retains maximum speed measured Rate of change of speed Demand Measurements Synchronous, Asynchronous TWF and FFT (to 12,800 lines) Simultaneous Cross Module Measurements Static (DC) Measurements Single DC Channels o o o o Axial Position Thrust Valve Position Eccentricity Rod Drop Proportional Voltage Paired DC Channels o Differential Expansion

1444 Series Functional Specifications Alarms & Relays Summary Alarms & Relays Measurement Alarms Apply limits to measured parameter 24 measurement alarms may be defined Voted Alarms Apply voting logic to Measurement Alarms 13 voted alarms may be defined Relays Main modules include a single onboard physical relay. With expansion modules this can be expanded to 5, 9 or 13 relays Associate with any voted alarm, or Leave unassigned to actuate only on fault.

Agenda What is Condition Monitoring? Introducing the Dynamix 1444 Series Applications Functional Summary Dynamix and the Integrated Architecture Questions? 36

Dynamix 1444 Series Controller I/O: The Usual 3 Assemblies Configuration Assembly Large Configuration Assembly Requires Logix V20+ Controller Input Input Assembly parameters selected in Module Definition. Basic application, channel input types, I/O, and compliance requirement defined in Module Definition allows Guided Configuration of low level parameters I/O is provided and managed the same way as for any IA product. It s just bigger! Assembly is fully exposed and programmatically accessible unless a SIL-2 application, in which case all Safety related assembly attributes are hidden Control Bits Controller Output Trip Inhibit Set Point Multiply (2) Gate Controls (2) Alarm Reset Alarm Buffer Trigger Alarm Buffer Reset Transient Buffer Resets (4) Data Speeds (2) Alarm Limits (16) 37

Rockwell Automation s Network Strategy Seamless, Secure Communications Everywhere Rockwell Automation follows a strategy of using open network technology for seamless, topfloor to plant level integration. These open networks speak a common language and share a universal set of communication services. As a result, information can be communicated seamlessly, safely and securely throughout the plant, from shop floor to top floor, even if the top floor is a world away. 38

Rockwell Automation s Network Strategy With Dynamix Integrated into the Architecture Dynamix Protection CBM, CBM Applications, Asset Management Applications Dynamix Condition Monitoring From the beginning the Dynamix 1444 Series was designed and developed to execute this core Rockwell Automation strategy. Native dual port Ethernet, the EtherNet/IP protocol, Device Level Ring, an integrated Logix solution, and all of the products and capabilities of Rockwell Automation s Integrated Architecture These are what makes the Dynamix 1444 Series the industries most open yet secure, integrated and capable solution for machinery monitoring and protection available today. 39

1444 Series System Architectures Dedicated Condition Monitoring System A single controller might manage an entire condition monitoring architecture for an entire plant... 40

1444 Series System Architectures Condition Monitoring within an Integrated Architecture Or a plants monitoring solutions might be split based on criticality into sub networks, each managed by its own controller. 41

The Dynamix 1444 Series and the Integrated Architecture An architecture with a single core module that: Can be applied to any Machinery Protection application Can serve any Condition Monitoring Application Applies a native EtherNet/IP backplane Is a component of Rockwell Automation s Integrated Architecture 42

Questions? Available: Spring 2014 Rev 5058-CO900E