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Page 1: T63 - PowerFlex® Medium Voltage Drives for Heavy Industry … file... PowerFlex® Medium Voltage Drives for Heavy Industry Applications. ... Learn how PowerFlex® 7000 medium voltage

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC

PUBLIC - 5058-CO900G

T63 - PowerFlex® Medium Voltage Drives for Heavy Industry Applications

Page 2: T63 - PowerFlex® Medium Voltage Drives for Heavy Industry … file... PowerFlex® Medium Voltage Drives for Heavy Industry Applications. ... Learn how PowerFlex® 7000 medium voltage

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 2

Agenda

Summary

How Rockwell Automation® Can Help

Heavy Industry Performance Requirements

How MV Drives Enable Success

Introduction

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Session Synopsis

3

Learn how PowerFlex® 7000 medium voltage drives contribute to the success of heavy industries that require continuous and efficient operations. New capabilities extend application reach for safety and hoist applications. To help reduce downtime, realize cost savings and increase plant safety, see how Virtual Support Engineer™ monitors equipment and collects valuable performance analytics.

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Medium Voltage Drive Applications

Oil & Gas• Oil Pipeline pumps• Natural Gas Pipeline compressors• Electrical submersible pumps• Induced draft fans

Cement• Kiln induced draft fans• Forced draft fans• Cooler baghouse fans• Raw mill induced draft fans• Kiln gas fans• Kiln drives• Cooler exhaust fans• Baghouse fans

Marine• Main propulsion• Positioning thrusters

Water / Wastewater• Raw sewage pumps• Bio-roughing tower pumps• Treatment pumps• Freshwater pumps

Mining & Metals• Slurry pumps• Ventilation fans• Descaling pumps• Conveyors• Baghouse fans• Cyclone feed pumps• Tailings pumps

Power Generation• Feed water pumps• Induced draft fans• Forced draft fans• Baghouse fans

Commercial• HVAC/OEM Chillers/Compressors • Airport Cogeneration• Hospital Cogeneration• University Cogeneration

Forest Products• Fan pumps• Induced draft fans• Boiler feed water pumps• Pulpers• Refiners• Kiln drives• Line shafts

Miscellaneous• Test stands• Wind tunnels• Agitators• Rubber mixers

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Focus on the Heavy Industry End-User

5

There are multiple key elements that contribute to a successful project

Success may mean different things to different parts of the equation

This presentation is focused on the needs of the Heavy Industry End-User

and System Integrator

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Drive Project Lifecycle

6

Evaluate

Purchase

Factory Acceptance

Test

TransportInstall

Integrate &

Commission

Operate

Maintain

Repair

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 7

Agenda

Summary

How Rockwell Automation® Can Help

Heavy Industry Performance Requirements

How MV Drives Enable Success

Introduction

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Justification

As the global economy continues to expand, constraints to growth may

arise as energy demands approach power generating capabilities.

Smart and efficient energy use is critical to sustainable economic

expansion and a better environment.

Medium voltage motors are typically some of the largest consumers of

power in many heavy industries

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Justification

Applying variable frequency drives for these applications can dramatically

reduce power consumption and energy costs, along with significantly

better process control and information sharing across your enterprise.

The environment also benefits as reductions in power use directly

correspond to lower CO2 and other emissions from power plants.

Rockwell Automation®, as one of the world’s leading suppliers of medium

voltage variable frequency drives, can help you successfully implement

these solutions for applications in your plant.

9

Page 10: T63 - PowerFlex® Medium Voltage Drives for Heavy Industry … file... PowerFlex® Medium Voltage Drives for Heavy Industry Applications. ... Learn how PowerFlex® 7000 medium voltage

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

MV Drive Project Goal Categories

Users have some or all of these four principal goals:

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 11

Agenda

Summary

How Rockwell Automation® Can Help

Heavy Industry Performance Requirements

How MV Drives Enable Success

Introduction

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

What Do Heavy Industry Users Value?

• Help protect People• Help protect Assets and

Information• Maximize Enterprise Effectiveness• Regulatory Compliance• Infrastructure Compatibility• Fit for Purpose• Leverage expertise and value-add

services from engaged Solution Partners

Enterprise Risk Management

• Reduce time and cost to integrate motor control asset into the supervisory control system

• Reduce asset commissioning time and cost

• Similar user experience across a wide variety of assets

Faster Time To Market

• Minimize one-time equipment, transportation, installation, commissioning, and integration time and costs

• Minimize Operational costs, and Maintenance and Repair time and costs during the entire product lifecycle

Lowest Total Cost of Ownership

• Reduce unplanned downtime• Reduce Mean Time To Repair

(MTTR)• Leverage Remote Monitoring and

Predictive Analytics

Improved Asset Utilization

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 13

Agenda

Summary

How Rockwell Automation® Can Help

Heavy Industry Performance Requirements

How MV Drives Enable Success

Introduction

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Motor Control Technologies Scalable Low Voltage & Medium Voltage Solutions

15

Across-the-Line Starters

Full Voltage

Fixed Speed

Soft Starters

Reduced Voltage

Fixed Speed

Motor Control Centers

Centralized Motor Control

Variable Frequency Drives

Variable Speed

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Intelligent Motor Control

16

ENABLER EtherNet/IP

REDUCED Costs

FASTER Installation

REAL-TIME Data

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Value Delivered

17

Faster Time to Market

Improved Asset Utilization

$Lower Total Cost

of OwnershipEnterprise Risk

Management

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 18

Reduce development time

Reduce commissioning time

Enable common user experience

ENABLED BY

Faster Time to Market

Efficient engineering Premier Integration

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Premier Integration

Motor Control Device parameters... automatically mapped in

Minimizeaddressmismatches

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Premier Integration

All Motor Control Studio 5000® configures...

Simplifycommissioning

One-time configuration of controller & devices

20

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Premier Integration

Associate variables in logic... to

Develop modular code

Reuse from project to project

21

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Lower Total Cost of Ownership

Energy savings

Energy management

ENABLED BY

$• Variable speed control

• Energy intelligence

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Reduce Operating Costs

23

PowerFlex® variablespeed control devices can help…

Reduce20%speed

50%energy

Save

On the Plant Floor 50%of the energy consumedis by electric motors

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Reduce Operating Costs

• Variable Speed Control

• Energy intelligence

• Energy savings

• Energy management

Lower Total Cost of Ownership

Reducing the speed of a

variable torque application by

only 20% can save up to 50%

in energy consumption

Pumps and Fans are the most

common examples of variable

torque loads.

Reduction of energy

consumption through adoption

of variable speed controlhttp://www.rockwellenergycalc.com/

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

25

Improved Asset Utilization

Reduce unplanned downtime

Reduce time to repair

ENABLED BY• Embedded diagnostics• Remote monitoring• Virtual Support Engineer

TM

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 26

PowerFlex® 7000

ContinuousPerformance Monitoring

ImmediateAlerts

TroubleshootingAssistance

ProblemResolution

Remote MonitoringVirtual Support Engineer™

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

VSE Remote MonitoringHelping Mitigate Operational Risk at site

Operator Safety is a critical requirement in Heavy Industries

Intelligent Motor Control systems can help reduce the exposure to

electrical hazard

Diagnostic can be acquired over the network, w/o the need to get close to the

electrical equipment

Diagnostic information can be correlated with process operating conditions allowing

for more intelligent, safer decisions

Adjustments in device configuration, including clearing faults, can also be

performed over the network

Troubleshooting tools are also run over the network, providing full detail about the

devices from a remote location.

Remote monitoring capabilities in the Intelligent Motor Control system help

increase Asset Utilization and Mitigate Enterprise Risk at the same time

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 28

Communication

• Originates with gateway

• Does not come from an outside entity

Firewall

• Common configuration for secure website access

• Port 430 outbound open

Gateway Connections

• Two network connections for drive and control network

• No direct connection to internet

• Must be authenticated to send information to the cloud

VSE Data Security

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 29

Maximize Your Uptime with Virtual Support Engineer™

Virtual Support Engineer™

Reduce downtime

Maximize productivity

Increase safety

Optimize maintenance

24/7 MV drive system monitoring and troubleshooting for 78 parameters:

Virtual Support Engineer™ – simple, secure and cost effective

Feedback

Diagnostics

Hardware

Motor Model

Metering

Thermal Manager

Control Loops

Speed

Current

Torque

Flux

PWM

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31

Enterprise Risk Management

Personnel Safety

Equipment Protection

ENABLED BY• Remote monitoring• Remote control• Safe Torque Off

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PowerFlex® 7000 with Safe Torque Off

32

What does it do? Removes rotational power from

the motor

Prevents motor from unexpected

restart

Drive remains powered and

reliably monitors safe state

Operational benefits? Reduces unnecessary downtime

Reduces system complexity

Reduces maintenance costs

Meets highest functional safety

ratings (SIL3/PLe)

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Advantages of PowerFlex® 7000 with Safe Torque Off

33

Meets the top functional safety requirements

for drives (SIL 3/PLe)

Certified by a global leader in functional

safety certification and training, TÜV

Able to meet any functional safety

specifications without the addition of extra

components

Suitable for both the high performance and

standard application markets

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PowerFlex® 7000 with TorqProve™

34

What does it do? Delivers 100% torque at zero

speed

Provides lifting torque/brake

proving

Offers configurable functions Load limit check, weight calculation, slack

cable detection, shaft break detection

Operational benefits ? High dynamic speed and torque

control required for complex

applications like hoisting, conveyors

Minimized mechanical wear of

equipment

Lower energy consumption

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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 35

Agenda

Summary

How Rockwell Automation® Can Help

Heavy Industry Performance Requirements

How MV Drives Enable Success

Introduction

Page 35: T63 - PowerFlex® Medium Voltage Drives for Heavy Industry … file... PowerFlex® Medium Voltage Drives for Heavy Industry Applications. ... Learn how PowerFlex® 7000 medium voltage

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Value Delivered

36

Faster Time to Market

Improved Asset Utilization

$Lower Total Cost

of OwnershipEnterprise Risk

Management

Page 36: T63 - PowerFlex® Medium Voltage Drives for Heavy Industry … file... PowerFlex® Medium Voltage Drives for Heavy Industry Applications. ... Learn how PowerFlex® 7000 medium voltage

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

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