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SELECTION GUIDE
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PROGRAMABLE CONTROLLERS
Introduction
In the past, the primary concern for companies that depend on turbo
machinery was simply protecting the asset from catastrophic failure. In today's
competitive environment, companies must not only protect their turbo
machinery but they must also protect the people that operate it while
maximizing production availability by detecting changes early and taking
corrective action.
For a solution that includes both protection and monitoring of your critical
turbo machinery, Rockwell Automation's proven hardware, software and
services include everything you need to be successful.
Our XM condition monitoring and protection system gives you the ability to
detect changes and faults as early as possible so that uptime and maintenance
planning are optimized. In addition to this capability, the modular design and
open industry network protocol of XM give you flexibility that results in the
most cost effective design, installation and information sharing available.
Emonitor and RSMACC Enterprise Online expert data analysis and CMMS
integration software makes storage and analysis of data easy, while making it
possible to integrate this information into CMMS systems so that the data
becomes actionable. Emonitor software also integrates data from portable
data collectors and online surveillance systems, giving you a complete picture
of plant asset health.
Services
1
2 Introduction
TSI System Integration Our integrated solution lowers your total cost by utilizing your existing plant
information and control platform as well as open industry standard protocols.
Integrated Architecture
Proprietary Serial,
OPC, Modbus, etc.
Ethernet
PanelView
Controller
Versa View
DeviceNet
TSI System Selection Guide 3
Retrofit Integration
System Selection Checklist Use the following Checklist as a guide to specify your turbine system.
✓ Step See
1 Select the measurements
Choose the measurements that you want to Steam turbine system page 7
monitor on your turbine system. Gas turbine system page 19
Hydro turbine system page 25
2 Select modules based on measurement
Match the measurements and the XM modules. Steam turbine system page 11
Gas turbine system page 21
Hydro turbine system page 27
3 Select integration strategy
Choose the HMI and control hardware for your HMI products page 31
system. Control systems page 33
4 Select software
Choose the software product you need to XM Serial Configuration Utility page 37
configure and manage your system. RSLinx software page 38
RSNetworx for DeviceNet software page 38
Emonitor Enterprise software page 39
RSMACC EOL software page 40
5 Select project services
Determine the expertise needed to install a new Engineering design services page 41
system, or retrofit an existing one. Turnkey projects page 41
Reliability Online Service programs page 42
Available product services page 42
Training page 43
Repair, Exchange & Renewal parts page 43
6 Select optional accessories
CASE
EXPANSION RADIAL MEASUREMENTS
LEFT BRG #1 BRG #2 BRG #3 BRG #4 BRG #5 BRG #6 BRG #7
ECCENTRICITY
PHASE
"B" "A"
"B" "A"
ROTOR/THRUST
POSITION
"A" & "B"
SPEED/OVERSPEED
VALVE
POSITION ROTOR ACCELERATION
DIFF. EXPANSION
1 SET TO MONITOR
1 SET SPARE
CASE
EXPANSION
RIGHT
Measurements This section describes the recommended vibration monitoring for a steam
turbine. Use this information to help you select the measurements that you
want to monitor.
Radial vibration measures the radial motion of the rotating shaft relative to the
case. This measurement gives the first indication of a fault, such as unbalance,
misalignment, cracked shaft, oil whirl or other dynamic instabilities. Vibration
measurements can be made in a single plane or a two plane (X-Y) arrangement
where the sensors are 90 degrees apart and perpendicular to the shaft. Eddy
current probes are usually installed in a hole drilled through the bearing cap
and are held in place by either a bracket or a probe holder.
7
8 Steam Turbine System
Phase Measurement
D GAP
APPROX. D GAP
.060
PREFERRED
W D=1/4
W=3/8 OR LARGER
ALTERNATE
W
Phase is defined as the angle between a reference mark (usually a keyway on
(PROTRUSION) (DEPRESSION)
the shaft) and the heavy spot on the rotor. Phase measurement is required for
accurate balancing of any rotor. It also provides an indication of shaft cracks,
misalignment, mass loss (such as throwing a blade), and other faults.
AXIAL DRILLED HOLE EPOXIED STEEL
3/8"DIA.x 1/4" DEEP SHIM STOCK
Speed/Acceleration Measurement
Eccentricity Measurement
d b
a
Differential expansion is the difference between the thermal growth of the
c
d = BEVEL ANGLE
rotor compared to the thermal growth of the case. Differential expansion
monitoring is most critical during a turbine "cold" start-up. A common steam
a = DETECTED RANGE
c = INDICATED RANGE
Ramp turbine has a thick, heavy case, and a lighter, hollow rotor. Due to the mass of
ROTOR LONG
the case it will grow slower than the rotor, so the operator must make sure the
case has expanded enough to keep it from making contact with the rotor. To
monitor, transducers can be placed on a collar or ramp that have been
2"MIN.
550mils NOMINAL GAP machined onto the turbine.
2"MIN.
Collar
3 9-1/2
Figure 9-1
Temperature Measurement
XM Modules The XM series is a group of intelligent, specialty I/O modules designed for
machinery protection and condition monitoring. The XM modules monitor
critical machinery parameters such as vibration, temperature, position, and
speed. The XM modules may be applied as a standalone system, or they can be
integrated with existing automation and control systems, including PLCs and
displays, to provide maintenance and operations with intelligent information
to aid in protecting machinery from catastrophic failures and planning
production and maintenance activities.
For more information on the XM-121 module with XM-121A firmware, see
publication GMSI10-TD047.
Speed XM-220 Dual Speed Module The XM-220 Speed Module is an intelligent 2-channel measurement
module that accepts input from two tachometers of any standard type
Acceleration including eddy current probes, magnetic pickups, optical tachometers and
TTL output devices. The module measures speed, rotor acceleration and
peak speed and is capable of detecting zero speed, locked rotor and
reverse rotation. The module may also serve as a component of an
Electronic Overspeed Detection System (EODS).
For more information on the XM-120 module with XM-120E firmware, see
publication ENMON-TD002.
12 Steam Turbine System
Typical Configurations The following configurations are examples of a typical system. Reference
OEM specifications and existing sensor dimensions before selecting
replacement sensors.
Speed/Phase Configuration
Speed/Acceleration Configuration
Eccentricity Configuration
Temperature Configuration
RADIAL MEASUREMENTS
BRG #1 BRG #2
TEMP TEMP
SPEED
PHASE
SPEED
GENERATOR
Compressor Shaft Turbine Shaft (OR OTHER DRIVEN
COMPONENT)
THRUST
POSITION
"A" & "B"
Measurements This section describes the recommended vibration monitoring for a gas
turbine. Use this information to help you select the measurements that you
want to monitor.
19
20 Gas Turbine System
Phase Measurement
D GAP
APPROX. D GAP
.060
the shaft) and the heavy spot on the rotor. Phase measurement is required for
(PROTRUSION) (DEPRESSION)
Speed Measurement
Temperature Measurement
XM Modules The XM series is a group of intelligent, specialty I/O modules designed for
machinery protection and condition monitoring. The XM modules monitor
critical machinery parameters such as vibration, temperature, position, and
speed. The XM modules may be applied as a standalone system, or they can be
integrated with existing automation and control systems, including PLCs and
displays, to provide maintenance and operations with intelligent information
to aid in protecting machinery from catastrophic failures and planning
production and maintenance activities.
Typical Configurations The following configurations are examples of a typical system. Reference
OEM specifications and existing sensor dimensions before selecting
replacement sensors.
Probe Operating
Cat. No. Description Temperature Range Qty
1440-VAD02-01RA XM-123 Aeroderivative Module 1
1440-TB-A Terminal Base for XM-123 / XM-120 1
Option 1: Shaft Relative
EK-2105-70-00-1-10✞ 8mm dia NCPU probe, 1m cable -40 to +350°F (-40 to 2
+177°C)
EK-2170-0-80 8mm extension cable, 8m Connector: max. 257°F 2
(+125°C)
EK-2108-9-001 8mm probe driver, 9m system -36 to +176°F (-38 to 2
+80°C)
Option 2: Case Absolute
EK-43807I✞ 9100HT High Temperature Accelerometer -65 to +500°F (-54 to 1
+260°C)
EK-46801I 32’ Accelerometer Cable (splash proof) 1
✞ Sensors must meet operating temperature requirements. Specialty, high temperature probes and case mounted
sensors are available. Special care should be taken when specifying sensor for aeroderivative gas turbine
applications.
Phase/Speed Configuration
Temperature Configuration
Generator
R
A
D
I
A
THRUST
TEMP L
POSITION
"A" & "B" M
E
A
S
U
Shaft R
SPEED/PHASE E
M
TEMP E
N
T
S
Turbine
CAVITATION
Measurements This section describes the recommended vibration monitoring for a hydro
turbine. Use this information to help you select the measurements that you
want to monitor.
This measures the radial motion of the rotating shaft relative to the case.
Vibration measurements can be made in a single plane or a two plane (X-Y)
arrangement where the sensors are 90 degrees apart and perpendicular to the
shaft. Eddy current probes are usually installed in a hole drilled through the
bearing cap and are held in place by either a bracket or a probe holder.
25
26 Hydro Turbine System
Phase/Speed Measurement
D GAP
APPROX. D GAP
.060
PREFERRED
W D=1/4
W=3/8
OR LARGER
ALTERNATE
W
Phase is defined as the angle between a reference mark (usually a keyway on
(PROTRUSION) (DEPRESSION)
the shaft) and the heavy spot on the rotor. Phase measurement is required for
accurate balancing of any rotor. It also provides an indication of shaft cracks,
misalignment, mass loss (such as throwing a blade), and other faults.
AXIAL DRILLED HOLE EPOXIED STEEL
3/8"DIA.x 1/4" DEEP SHIM STOCK
Single Thrust
Temperature Measurement
XM Modules The XM series is a group of intelligent, specialty I/O modules designed for
machinery protection and condition monitoring. The XM modules monitor
critical machinery parameters such as vibration, temperature, position, and
speed. The XM modules may be applied as a standalone system, or they can be
integrated with existing automation and control systems, including PLCs and
displays, to provide maintenance and operations with intelligent information
to aid in protecting machinery from catastrophic failures and planning
production and maintenance activities.
Typical Configurations The following configurations are examples of a typical system. Reference
OEM specifications and existing sensor dimensions before selecting
replacement sensors.
Phase/Speed Configuration
Temperature Configuration
This section describes the integration strategy. Select the human machine
interface (HMI), control system, and reliability products that best fit your
needs.
HMI Products Rockwell Automation offers the following HMI products for your system.
31
32 Integration Products
Control Systems Rockwell Automation offers the following control system solutions for your
system.
The XM module may be linked directly to a PLC or other control system via
industry standard DeviceNet scanner cards. Host controllers can then scan
XM modules for data, alarm and relay status information in real-time.
Prioritizing messaging insures that changes to any alarm or relay status is
immediately communicated to network controllers.
ControlLogix
You can also use the ControlLogix system as a gateway. Include the
communication modules you need for connectivity to other networks. For this
use, a controller is not required. The ControlLogix Gateway integrates into
existing PLC-based systems so that users with existing networks can send or
receive messages to or from other networks.
OPC Gateway
One side of the Linking Device is a DeviceNet scanner with the capacity for
handling 500 bytes of data in and out from DeviceNet compliant devices. The
other side is a ControlNet scheduled adapter with redundant media
communications and a Network Access Port.
The XM-440 Master Relay Module combines four relay outputs with XM bus
master capabilities to provide remote, shared and voted relay operation for
distributed XM measurement modules. The XM-440 module offers high
power relays suitable for use in most protection applications.
TSI System Selection Guide 35
The XM-442 module is designed to mate with three XM-220 Dual Speed
Modules to provide an API compliant triple redundant Electronic Overspeed
Detection System (EODS). The XM-442 provides four high power relays that
serve as the EODS alarm and shutdown relays.
4-20mA Outputs
XM Serial Configuration The XM Serial Configuration Utility software is an easy to use Windows
application for installing and configuring the XM Series modules. The tool can
Utility Software read, write, and modify configurations stored on disk, upload configuration
from a module; download configurations and firmware updates to a module;
and view data from a module.
37
38 Software Products
RSNetWorx for DeviceNet RSNetWorx™ software configures and manages the communication between
the devices on your control network. RSNetWorx for DeviceNet provides an
Software instant, selectable view of any DeviceNet network. With this software, you can
TSI System Selection Guide 39
configure DeviceNet I/O devices and create a scan list. The DeviceNet
scanner stores the configuration information and scan list.
Emonitor Enterprise The Emonitor® suite is a complete machinery information software system
for Condition Based Maintenance programs. By incorporating multiple data
Software sources, such as online systems, portable data collectors and OPC servers,
Emonitor can easily present a complete picture of the state of your machinery.
A collection of analysis tools, statistical based alarms and rule-based logic
allows you to quickly and easily identify problem areas among large amounts of
data.
40 Software Products
Emonitor historical data can be accessed via any application utilizing the
following data access standards:
Third Party Software Rockwell Automation offers connectivity solutions allowing our products to
integrate with a variety of third party data sources directly via OPC, DeviceNet
Products Standard and Scanner Bridges.
Project Services
A TSI system retrofit begins with a walk down of the machine and the creation
of a project scope document. From this, a bill of material and quotation
document will be generated.
Engineering Design Rockwell Automation has the engineering resources and specific TSI
knowledge to effectively design a new system or plan a retrofit. The design
Services services include:
Turn Key Rockwell Automation’s performance history and depth of knowledge help to
deliver successful turnkey projects.
• Project Management
• Plan, design, build and install the solution
• Integrate TSI solution with other plant systems
• Factory Acceptance Testing with Documentation Package suitable for
most ISO 9000 Requirements
• Mechanical and Electrical services
• On-Site Acceptance Testing with Documentation Package
• System Commissioning
• Software Configuration
• As-Built Drawing Package
• Factory or On-Site Training of plant personnel on operation and
maintenance of the system
• Final Report Documentation Package
41
42 Project Services
Reliability Online (ROL) Rockwell Automation ROL Services turns TSI data into actionable
Condition-based Maintenance information.
Service Programs
• The TSI system can be designed to be accessed over a phone line or
through a secure internet connection
• Regular or on demand analysis expertise is provided remotely
• Asset health information is accessed through the internet with an easy
to use web portal (see illustration below)
Training Utilizing the Rockwell Automation training offerings can significantly improve
the productivity and efficiency of the plant floor staff by giving them the
knowledge, skills and learning aids to maintain both legacy automation systems
and today’s advanced automation technologies.
Training Menu
Repair, Exchange & Rockwell Automation provides comprehensive repair services including
remanufacturing services for a wide variety Rockwell Automation products,
Renewal Parts repair services for non-Rockwell Automation products, exchange services for
over 12,000 Allen-Bradley catalog products, and renewal parts for many legacy
Allen-Bradley products.
44 Project Services
Optional Accessories
Sensors Rockwell Automation offers a comprehensive range of Sensors for use with
both condition monitoring and protection systems.
2100 Series
The 2100 Series of non-contact pick-ups are designed to meet the stringent
requirements of the American Petroleum Institute (API) Standard 670. The
sensors are non-contacting eddy-current type transducers that measure the
dynamic and/or static displacement of the target relative to the mounting
fixture. The system consists of a non-contact pickup probe,
oscillator/demodulator (probe driver) and interconnecting cable. These
systems are typically used to measure shaft radial and axial vibration, shaft
eccentricity, shaft axial position, case expansion, differential expansion and
other instances where non-contacting, relative measurements must be made.
45
46 Optional Accessories
Power Supplies The XM series is designed to operate with 24V DC power supplies. The
following Allen-Bradley 1606-XLP power supplies are recommended for use
with all XM applications. The 1606-XLP series is a general purpose,
DIN-rail-mount power supply.
Capacity of the power supply must meet or exceed the total maximum load
required by the XM system. If the total system power requirement exceeds the
1606-XLP-100E power supply, use multiple powers supplies and connections.
Note that the total current draw through the side connector cannot exceed 3A.
Maximum loads for each module can be found in the data sheet and User
Manual for the specific module.
Junction Box Rockwell Automation offers a 20 terminal junction box to house electrical
components and facilitate wiring. For individual product offerings, see
publication GMSG10-PL001.
✞ NEMA Type 4X and 12 rated enclosures are available with solid door or polycarbonate window.
Sensor Adhesives / Rockwell Automation offers sensor adhesives and mounting tools to prepare
the machinery surfaces for installation of the sensors. For individual product
Mounting Tools offerings, see publication GMSG10-PL001.
Portable Data Collectors A portable data collector is capable of performing condition monitoring data
collection, analysis, and root cause correction. The Enpac portable data
collectors are Windows CE based, high performance, data collectors and signal
analyzers. Their comprehensive measurement capability, analysis functions and
ease of use make them the perfect tool for a portable predictive maintenance
strategy.
The Enpac 2500 is an easy to use, cost effective, scalable solution that meets
the needs of the novice as well as advanced user. Key attributes include size,
easy to read color display, and speed of data collection. The Enpac 2500 is a
rugged and reliable instrument with a built in laser tachometer and advanced
analysis capabilities such as optional 2-channel functions, 2-plane balancing,
and more.
Surveillance Monitoring The Enwatch is a cost-effective solution for monitoring the condition of the
important machines in a plant. It bridges the gap between portable data
collectors with manual periodic update capabilities and more expensive
continuous monitoring systems.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
GMSI10-SG002A-EN-P - June 2006 Copyright ©2006 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.