Rockwell Automation Safety Solutions. Guard Logix Application Example. Steelfactory. Stephen Podevyn Safety Solution Architect

Steelfactory Existing application. schematic view A Control room were the installation is operated is at one end In the field, in open space are the raw materials like the cokes, iron ore etc.stored A big excavator / crane is riding left and right, on rails to put the raw materials on a transport system to the factory Control Room Vaste wal Iron ore cokes rails Excavator / crane transportsystem 300 meters Copyright 2008 Rockwell Automation, Inc. All rights reserved. 7

Steelfactory In the control room, «vaste wal» are several CLX configurations In the rolling crane is a control space which is connected to the control room through a wireless ethernet IP link. Here we find a CLX controller and many safety relais. The control of this mammoth crane is done from the control room and in 80% of the use, there is nobody on the crane. Control Room Vaste wal Iron ore cokes rails Excavator / crane transportsystem 300 meters Copyright 2008 Rockwell Automation, Inc. All rights reserved. 8

Project Steelfactory / cabinet example Control Room Vaste wal A small part of one of the cabinets in the control room And one in the excavator / crane Copyright 2008 Rockwell Automation, Inc. All rights reserved. 9

Project Steelfactory / architecture with safety Control Room Vaste wal EtherNet/IP Excavator / crane CIP CIP ControlNet safetyrelais safetyrelais DeviceNet Copyright 2008 Rockwell Automation, Inc. All rights reserved. 11

Current Safety implementation Problem : In the mobile crane are up to 20 classic safety relais. Sometimes the cranes stops because : somebody activated a safetyfunction a vibration occured a safetyrelais went off In each case they never know what happened because of no diagnostics and many functions are wired in series Result : Crane down MTTR high, because they have no diagnostics and a lot of walking to the crane approx 300 meters production loss risc, buffer for 2 hours Bad morale due to stress Copyright 2008 Rockwell Automation, Inc. All rights reserved. 12

Maintenance and Productivity MTTR is unplanned downtime How much does MTTR cost? Cost of downtime is measured in many ways: Opportunity cost of lost production Overtime costs associated with recovery Maintenance cost variance Facility overhead Penalty payments Customer satisfaction MTTR Cost = MTTR * Cost of Downtime Example: In a given year, a piece of equipment experiences 40 hours of unplanned downtime at an opportunity cost of 50 / Minute for the first 2 hours MTTR Cost = 40 hrs. * 60 min/hr. * 50/min = 120,000 We don t want to calculate the cost after 2 hours Copyright 2008 Rockwell Automation, Inc. All rights reserved. 13

Project Steelfactory / architecture Control Room Vaste wal EtherNet/IP Excavator / crane CIP CIP ControlNet safetyrelais safetyrelais DeviceNet Copyright 2008 Rockwell Automation, Inc. All rights reserved. 14

Project steelfactory / Safety solution Control Room Vaste wal EtherNet/IP CIP Safety Excavator / crane EtherNet CIP CIP ControlNet DeviceNet Guard I/O IP20 Block A45 DeviceNet Copyright 2008 Rockwell Automation, Inc. All rights reserved. 15

Project steelfactory / Safety solution Advantage : Fast / Easy implementation (no extra network) on existing network and wireless ethernet with CIP safety Only one extra processor (LSP) for safety the safety application on the whole installation. Thanks to networks they already applied they can reach the whole installation. Very fast time to develop with complete diagnostics and visualisation of the safety function Validation is a lot easier thanks to the Complete overview / diagnostics of all safety funtions + hardware; MTTR is extremly low, almost no downtime Thanks to use of digital equipment, no vibrations Less hardware, (removal of 20 plus safety relais on the crane only) A very happy customer with a good morale Copyright 2008 Rockwell Automation, Inc. All rights reserved. 16