t63 - powerflex® medium voltage drives for heavy industry … file... powerflex® medium voltage...
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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T63 - PowerFlex® Medium Voltage Drives for Heavy Industry Applications
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
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.
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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Focus on the Heavy Industry End-User
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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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Drive Project Lifecycle
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Evaluate
Purchase
Factory Acceptance
Test
TransportInstall
Integrate &
Commission
Operate
Maintain
Repair
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Agenda
Summary
How Rockwell Automation® Can Help
Heavy Industry Performance Requirements
How MV Drives Enable Success
Introduction
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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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
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MV Drive Project Goal Categories
Users have some or all of these four principal goals:
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Agenda
Summary
How Rockwell Automation® Can Help
Heavy Industry Performance Requirements
How MV Drives Enable Success
Introduction
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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Agenda
Summary
How Rockwell Automation® Can Help
Heavy Industry Performance Requirements
How MV Drives Enable Success
Introduction
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
14
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Motor Control Technologies Scalable Low Voltage & Medium Voltage Solutions
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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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Intelligent Motor Control
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ENABLER EtherNet/IP
REDUCED Costs
FASTER Installation
REAL-TIME Data
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Value Delivered
17
Faster Time to Market
Improved Asset Utilization
$Lower Total Cost
of OwnershipEnterprise Risk
Management
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Reduce development time
Reduce commissioning time
Enable common user experience
ENABLED BY
Faster Time to Market
Efficient engineering Premier Integration
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Premier Integration
Motor Control Device parameters... automatically mapped in
Minimizeaddressmismatches
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Premier Integration
All Motor Control Studio 5000® configures...
Simplifycommissioning
One-time configuration of controller & devices
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Premier Integration
Associate variables in logic... to
Develop modular code
Reuse from project to project
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Lower Total Cost of Ownership
Energy savings
Energy management
ENABLED BY
$• Variable speed control
• Energy intelligence
22
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Reduce Operating Costs
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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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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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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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PowerFlex® 7000
ContinuousPerformance Monitoring
ImmediateAlerts
TroubleshootingAssistance
ProblemResolution
Remote MonitoringVirtual Support Engineer™
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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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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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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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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
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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
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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™
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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
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
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
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