Rockwell Automation Condition Monitoring -...
Transcript of Rockwell Automation Condition Monitoring -...
Copyright © 2008 Rockwell Automation, Inc. All rights reserved.
Rockwell Automation Condition Monitoring
A Predictive element of a StrategicApproach to Maintenance
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SEEMS BAD.LET’S SHUT IT DOWN
I THINKIT’S
MISALIGNED
I DON’T THINK IT’STOO BAD!
LEAVE IT ALONE
Intro to Vibration
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Vibration Analysis
The vibrationanalysis says it’sout of balance.
At 7 mm/secit’s only slightly
rough.
That’s good!We can
continueoperations but
planmaintenance.
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What is Condition Monitoring?
– Physical characteristics are identified thatcollectively indicate the current condition of themachine.
– Each of these characteristics is measured,analyzed, and recorded so that trends can berecognized.
Example: Vibration level increasing with time.
– The goal is to identify changes in thecondition of a machine that will indicate somepotential failure.
• Condition Monitoring is the collection and trending of parameters whichchange when machine condition begins to degrade.
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Condition Monitoring
Rockwell Automation Services & Support
ConditionMonitoring
ProtectionSystems
SurveillanceSystems
PortableSystems
Sensors &Accessories
ConditionMonitoringServices
Predict• Service Assessments
– Identify the human and equipment issues that hinderproduction
– Develop a maintenance strategy to maximise youroverall equipment effectiveness
• Condition Monitoring– On-site Collection, Analysis and Reporting
• Remote Monitoring Services– Identify and correct problems that decrease efficiency
and could lead to equipment failure
• Repair / remanufacturing– All third party electromechanical equipment
DynamicXM-120 Standard – 2 channel
Overall MeasurementsXM-160/1/2 Overall Vibration Modules –6 channel
SpeedXM-220 Dual Speed – 2 channel
Process & TSIXM-360 Process – 6 channel
DynamicXM-120 Standard – 2 channel
Overall MeasurementsXM-160/1/2 Overall Vibration Modules –6 channel
SpeedXM-220 Dual Speed – 2 channel
Process & TSIXM-360 Process – 6 channel
16 channels
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Innovation in ICM: Wireless & Hosting
• Wireless: Integrated solution using XM / Enwatch with industrial GPRS modem– Commercial Off The Shelf products (COTS) in IP56 enclosure– Apply anywhere where there is GSM without IT complexity– Leading protection / surveillance hardware
– How it works:
• Hosted: Emonitor software on a central secure server– Hosted software with ‘local’ functionality– Access via Citrix– Central point for data import from multiple sources
– Data easily analysed elsewhere`
DNET ENET GPRS
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Remote Condition Monitoring
• Data collection andanalysis online viainternet
• Cost effective• Robust• Flexible• Adaptable• Upgradeable• COTS – Commercial
Off The Shelf solutions
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Technical Overview
•Types of regime•Data Transfer•Data Harvesting•Secure Connections•Data Analysis
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Direct Monitoring - Motor / Pump
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Direct Monitoring - Motor / Gear / Pump
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Direct Monitoring System Configurations
To HMIPr
oces
sor
Powe
rSup
ply
EWEB
orEN
et/IP
Devi
ceNe
t
Powe
rSu
pply
XM
To HMI
Proc
esso
r
Powe
rSup
ply
Ethe
rNet
/IP
EWEB
Powe
rSu
pply
1788
-EN
2DN
Single Location Distributed Systems
ENet/IP To Add’l Cabinets
Control Section
Remote SectionXM
Sensors
XM XMSensors
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Direct Monitoring Single Location System
• 1768 CompactLogix System– 2 MB memory - 84 machines– Web pages & faceplates as HMI, authenticated e-mails– L43, EWEB, DNet, I/O, XM, power supply
• XM120 or XM160– 2 channel XM120 for spectrum band alarms– 6 channel XM160 for overall alarms only– XM, power supply
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Direct Monitoring Distributed Systems
• 1768 CompactLogix System– 2 MB user memory - 84 machines max– 64 EtherNet/IP connections - 32 remote cabinets max– Web pages & faceplates as HMI, authenticated e-mails– L43, ENet/IP, EWEB, power supply
• XM120 or XM160– 2 channel XM120 for spectrum band alarms– 6 channel XM160 for overall alarms only– EN2DN, XM, power supply
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Support & Maintenance Services
• Start-up & Commissioning - estimated functions,not fixed price unless project– XM start-up - estimated at 8 modules per day– Logic and HMI customization - needs to be scoped– Emonitor database set-up
• Remote Analysis– Fixed price based on machine or point count– Program start-up– Web reporting
• Local service delivery leader involved inspecification and implementation of all supportservices
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Analysis
• 10 UK Based engineers• Average 20 years of industry experience per
engineer• Eight large ICM analysis contracts in: Paper & Pulp,
Marine, Oil & Gas, Mining• Vibration / Oil analysis / Thermography / Ultrasonic• Domain experts in ICM hardware and asset
management• Integration expert from ICM into automation systems
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Field electromechanical work
Through our local offices and partners, we can deliver:• Alignment / Balancing• Lubrications• Thermography analysis• Take portable vibration / lubrication data• Replace motors / bearings• Deliver and install motor control equipment• Hold local spares (consignment stock)• Guarantee engineering response times
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Red to Green – ICM in practice
Every X minutes Work Order
Emonitor Software Alarm Review
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Industrial Condition MonitoringPricing example XM160
EtherNet/IP
RSView32-ICM Faceplate
Devicenet
EtherNet IPGateway
XM160
XM160 6ch incl engineering:12000Euro
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Overview of ICM Services supplied to British Gypsum Ltd
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ICM Services
400 machines covered by vibration monitoring on monthly routine
400+ machines covered by thermal imaging on monthly routine
100+ slow moving units additionally covered by Ultrasonic
10 units with oil analysis baseline data- oil analysis routine to
be developed over next 12 months.
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Success stories
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Application notes:
http://www.rockwellautomation.com/services/conditionmonitoring/
‘Condition Monitoring literature’