Turbine Supervisory Instrumentation Selection Guide - Rockwell

TURBINE SUPERVISORY INSTRUMENTATION SELECTION GUIDE

MEASUREMENT MODULES RELAY MODULES POWER SUPPLY COMMUNICATIONS SOFTWARE GRAPHIC TERMINALS 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.

Rockwell Automation - a global leader in industrial automation with more than 100 years of experience serving the changing needs of our customers in industries such as power generation, oil and gas, and others - understands the importance of turbo machinery as a primary mover for critical applications and offers solutions specifically designed to meet the unique requirements of steam, gas, and hydro turbines.

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.

XM Condition Monitoring and Protection modules

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 software

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

Rockwell Automation is committed to your success. Therefore, you're provided services that include every step - from initial planning and assessment through to the final commissioning and documentation. Rockwell Automation has the ability to perform complete turnkey turbine supervisory instrumentation installation and retrofits or just the support you need to complete your project. All services are designed to meet your specific needs.

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

Below is an illustration of a typical Rockwell Automation integrated TSI system.

Ethernet

DeviceNetVersa View

EmonitorEnterprise

PanelView

CMMS RSMACCEnterprise Online

Reliability OnLine

DCS

Proprietary Serial,OPC, Modbus, etc.

Controller

TSI System Selection Guide 3

Retrofit Integration

The Rockwell Automation architecture can also be adapted to an existing turbine system. Below is an illustration of a typical Rockwell Automation TSI retrofit system.

4 Introduction

Turbine System Comparison

✞ Recommendation is in bold text.

Monitoring System Components Steam Turbine✞ Gas Turbine✞ Hydro Turbine✞

Measurements • Radial Vibration - Shaft Relative

• Absolute Shaft

• Thrust/Expansion/Position• Eccentricity• Speed/Accel/Overspeed

• Temperature

• Phase

• Radial Vibration• Thrust

• Speed

• Temperature

• Phase

• Radial Vibration• Thrust

• Speed

• Temperature

• Phase

Measurement Modules• XM-120• XM-120E• XM-121

• XM-121A

• XM-160/161/162

• XM-220

• XM-320• XM-361/362

• XM-120

• XM-123• XM-160/161/162

• XM-220

• XM-320

• XM-361/362

• XM-121• XM-160/161/162

• XM-220

• XM-320

• XM-361/362

Sensors • 9000 Series

• 2100 Series• 9000 Series

• 2100 Series• 9000 Series

• 2100 Series

Power Supply 1606-XLP 1606-XLP 1606-XLP

HMI • VersaView• PanelView Standard

• Strip Chart

• LED Indicator

• RSView

• VersaView• PanelView Standard

• Strip Chart

• LED Indicator

• RSView

• VersaView• PanelView Standard

• Strip Chart

• LED Indicator

• RSView

Control • PLC/DCS DeviceNet Interface

• ControlLogix

• OPC Gateway• Gateways and Bridges

• Relay Logic (XM-440)• 4-20mA I/O

• Overspeed Relay (XM-442)

• PLC/DCS DeviceNet Interface• ControlLogix

• OPC Gateway

• Gateways and Bridges

• Relay Logic (XM-440)

• 4-20mA I/O

• PLC/DCS DeviceNet Interface• ControlLogix

• OPC Gateway

• Gateways and Bridges

• Relay Logic (XM-440)

• 4-20mA I/O

Reliability • Emonitor• RSMACC EOL• ROL

• Emonitor

• RSMACC EOL

• ROL

• Emonitor

• RSMACC EOL

• ROL


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 monitor on your turbine system.

Steam turbine system Gas turbine system Hydro turbine system

page 7page 19page 25

2 Select modules based on measurement

Match the measurements and the XM modules. Steam turbine systemGas turbine systemHydro turbine system

page 11page 21page 27

3 Select integration strategy

Choose the HMI and control hardware for your system.

HMI productsControl systems

page 31page 33

4 Select software

Choose the software product you need to configure and manage your system.

XM Serial Configuration UtilityRSLinx softwareRSNetworx for DeviceNet softwareEmonitor Enterprise softwareRSMACC EOL software

page 37page 38page 38page 39page 40

5 Select project services

Determine the expertise needed to install a new system, or retrofit an existing one.

Engineering design servicesTurnkey projectsReliability Online Service programsAvailable product servicesTrainingRepair, Exchange & Renewal parts

page 41page 41page 42page 42page 43page 43

6 Select optional accessories

Choose sensors, power supply, enclosure, cables, junction boxes, etc. if necessary.

SensorsPower SuppliesCablesJunction BoxEnclosuresSensor Adhesives / Mounting ToolsPortable Data CollectorsSurveillance Monitoring

page 45page 46page 46page 46page 46page 47page 47page 48

6 Introduction

Steam Turbine System

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 Measurement - Shaft Relative

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.

EXCITERGENERATORLOW PRESSURETURBINE

HIGH PRESSURETURBINE

VALVE POSITION

SPEED/OVERSPEED

ROTOR ACCELERATION

DIFF. EXPANSION1 SET TO MONITOR

1 SET SPARE

"A""B"

"A""B"

ROTOR/THRUSTPOSITION"A" & "B"

CASEEXPANSIONRIGHT

CASEEXPANSIONLEFT BRG #1 BRG #2 BRG #3 BRG #4 BRG #5 BRG #6 BRG #7

PHASE

ECCENTRICITY

RADIAL MEASUREMENTS

TEMP TEMP TEMP TEMP TEMP TEMP TEMP

(OR OTHER DRIVEN COMPONENT)

Typical Radial System Overview

7

8 Steam Turbine System

Absolute Shaft Measurement

Absolute Shaft Vibration is a measure of the shaft’s motion relative to free space. The measurement is typically applied when the rotating assembly is five or more times heavier than the case of the machine. Absolute shaft motion is proportional to the vector addition of the casing absolute motion and the shaft relative motion.

Phase Measurement

Phase is defined as the angle between a reference mark (usually a keyway on 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.

Speed/Acceleration Measurement

Speed is a measurement of shaft rotation in revolutions per minute. During start-up, speed is a critical measurement as it allows the operator to: increase speed quickly through shaft critical frequencies; hold the speed stable during “heat soak” plateaus; and, for electric generators, to accurately match the synchronous frequency before connecting the generator to the power grid.

Acceleration measures how fast speed is increasing or decreasing. It is monitored by the operator during turbine roll up, so that a steady increase in machine speed is achieved. Once the turbine is in normal operation, acceleration is not monitored.

Eccentricity Measurement

Eccentricity is a measurement of the amount of sag or bow in a rotor. It may also provide indication of a bent shaft. This measurement is used by the operator to indicate when the machine can safely be brought up to speed without causing rubs or damage to the seals.

W

D GAPAPPROX..060

PREFERRED

(PROTRUSION)

D=1/4W=3/8 OR LARGER

D

W

GAP

(DEPRESSION)

ALTERNATE

AXIAL DRILLED HOLE3/8"DIA.x 1/4" DEEP SHIM STOCK

EPOXIED STEEL


Differential Expansion (DE) Measurement

Differential expansion is the difference between the thermal growth of the rotor compared to the thermal growth of the case. Differential expansion monitoring is most critical during a turbine "cold" start-up. A common steam turbine has a thick, heavy case, and a lighter, hollow rotor. Due to the mass of 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 machined onto the turbine.

Rotor/Thrust Position Measurement

The primary purpose of the thrust position measurement is to monitor thrust bearing wear and to ensure against axial rubs. Dual (redundant) thrust motion detection should be used when the machine is required to shutdown. This method requires two transducers mounted on each bearing. When both independent set points cross the shutdown limit the machine will be turned off. Single thrust motion detection should be used when the machine does not have to be shutdown and there is another means of verifying thrust bearing failure. Thrust position measurements are taken within 12 inches of the thrust bearing, monitoring the thrust collars movement between the active and inactive thrust shoes and their subsequent wear. Measurements taken outside of the thrust bearing area (greater than 12 inches) are generally effected by the rotors thermal expansion and an increase in the required dynamic measurement range. This measurement is typically referred to as rotor (axial) position.

Valve Position Measurement

Valve position is a measurement of how much a valve is open or closed, usually a throttle valve. It provides the operator with an idea of the current load on a machine in the form of a percentage; 0% correlates to a valve closed and 100% correlates to a valve open.

ROTOR LONG

2"MIN.2"MIN.

550mils NOMINAL GAP

Collar

Dual Thrust

Single Thrust

ab

c

d

SHAFT

d = BEVEL ANGLEa = DETECTED RANGEc = INDICATED RANGE

Ramp


Overspeed - Triple Redundant Protection Measurement

Overspeed is one of the most dangerous conditions that can occur in a turbine, and is defined when a machine accelerates beyond its maximum permissible rotational speed. It is monitored by an Electronic Overspeed Detection System (EODS).

Shell (Case) Expansion Measurement

Steam temperature varies greatly between startup, operation, and shutdown. Shell expansion is a measurement of how much the turbine's case expands from its fixed point outward as it is heated. Continuous indication of shell thermal growth allows the operator to manage the amount of shell distortion as the load is increased or decreased.

Temperature Measurement

Temperature measurements are taken to determine how hot a bearing is operating. These measurements may provide a secondary validation of operation or maintenance problems. An increase in a temperature reading may be due to excessive bearing loading, insufficient clearances, or misalignment.

9-1/23

10-3/16

3-1/44-1/2

15/163/8

2-5/83-1/2

3/4

Figure 9-1


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.

Your selection of measurements determines which XM module you need for your steam turbine system.

If you want to measure select description

Radial Vibration - Shaft Relative

Phase

XM-120 Standard Dynamic Measurement Module

The XM-120 Standard Dynamic Measurement Module is an intelligent, 2-channel, general-purpose monitor. The module supports monitoring of shaft, casing or pedestal vibration in rotating equipment by accepting input from any eddy current probe, standard accelerometer, or any voltage output measurement device such as a velocity or pressure transducer. In addition to dynamic inputs, the module accepts one tachometer input to provide speed, phase and order analysis functions making it capable of calculating over 14 critical parameters per channel simultaneously.

For more information on the XM-120 module, see publication ENMON-TD120.

Absolute Shaft XM-121 Low Frequency Dynamic Module

The XM-121 Low Frequency Dynamic Module with alternative XM-121A firmware loaded is an intelligent 2-channel monitor capable of supporting a single absolute shaft measurement. The XM-121A firmware is included on the distribution CD with every standard XM-121.

Many of the specifications are similar to the XM-121 Low Frequency Module. The HPF’s available in the XM-121 allow for measurements to be as low as .2 Hz (12 CPM).

For more information on the XM-121 module with XM-121A firmware, see publication GMSI10-TD047.

Speed

Acceleration

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 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).


Eccentricity XM-120 Standard Dynamic Measurement Module

The XM-120 Standard Dynamic Measurement Module with alternative XM-120E firmware, enables eccentricity monitoring, critical for steam turbine operation. The XM-120E firmware is included on the distribution CD with every standard XM-120.

For more information on the XM-120 module with XM-120E firmware, see publication ENMON-TD002.


Differential Expansion

Rotor/Thrust Position

Valve Position

Shell (Case) Expansion

XM-320 Position Module The XM-320 Position Module is a 2-channel multi-purpose monitor. The module can be configured to measure any of: Axial Position, Valve Position, Case Expansion or Differential Expansion. The XM-320 supports multiple single and dual-probe methods of measuring differential expansion. The appropriate method is machine specific and requires review of the installation.


Temperature XM-361 Universal Temperature Module

or

XM-362 Isolated Temperature Module

The XM-361 Universal Temperature Module is a 6-channel general purpose temperature monitor. Each channel can be configured to measure either an RTD or an isolated thermocouple.

The XM-362 Isolated Temperature Module is a 6-channel temperature monitor designed specifically for use with thermocouples.

For more information on the temperature modules, see publication ENMON-TD361.

Triple Redundant Overspeed

XM-220 Dual Speed Module

XM-442 Voted EODS Relay Module

The XM-442 Voted EODS Relay Module provides high performance voted relays as a component of an Electronic Overspeed Detection System. When coupled with three XM-220 Dual Speed Modules, an XM-442 provides a single 2-out-of-3 overspeed trip relay plus separate relays for alarm (1 of 3 voting), system fault and transducer fault. A single XM-442 paired with three XM-220 modules meets the requirements with regards to the measurement, detection and relay actuation component of API-670 section 5.4.8 Electronic Overspeed Detection.

For more information on the XM-220 module, see publication ENMON-TD220. For more information on the XM-442 module, see publication GMSI10-TD048. For more information on the Electronic Overspeed Detection System, see publication GMSI10-UM015.



Typical Configurations The following configurations are examples of a typical system. Reference OEM specifications and existing sensor dimensions before selecting replacement sensors.

Radial Vibration - Shaft Relative Configuration

✞ For probe holder options, see publication ENACC-PP210.

Absolute Shaft Configuration

TIP Additional requirements may include power supply, enclosure, cables, junction box, sensor adhesives/mounting tools, etc. See Optional Accessories on page 45.

Radial Vibration Configuration Parts

Cat. No. Description Qty

1440-VST02-01RA XM-120 Standard Dynamic Measurement Module 1

1440-TB-A Terminal Base for XM-120 / XM-121 / XM-122 1

Option 1✞

EK-2105-70-00-1-10 8mm dia NCPU probe, 1m cable 2

EK-2170-0-80 8mm extension cable, 8m 2

EK-2108-9-001 8mm probe driver, 9m system 2

Option 2 (for replacement of existing shaft riders only)

EK-17253 Shaft Rider 18.5 to 20 in 1

EK-09712 Model 544M Velocity Transducer 1

Absolute Shaft Configuration Parts


1440-VLF02-01RA XM-121 Low Frequency Dynamic Measurement Module with XM-121A firmware

1


EK-43808I Model 9100VO Velocity Output Accelerometer 1

EK-46801I 32' Accelerometer Cable (splash proof) 1




EK-29000-DPH-01 Dual Probe Holder 1


Speed/Phase Configuration

Only one option is necessary for a speed/phase measurement.

Speed/Acceleration Configuration

Only one option is necessary for a speed/acceleration measurement.

Phase Configuration Parts


Included with XM-120/121/122/123 Modules

Option 1




Option 2

EK-44395 Hall Effect speed sensor, magnetic, zero velocity 1

EK-47774 Cable, Hall Effect speed sensor, 16ft, blunt cut 1

Speed/Acceleration Configuration Parts


1440-SPD02-01RB XM-220 Dual Speed Module 1

1440-TB-B Terminal Base B for XM-320 / XM-220 1

Option 1




Option 2




Eccentricity Configuration

Differential Expansion (DE) Configuration

Eccentricity Configuration Parts


1440-VST02-01RA XM-120 Standard Dynamic Measurement Module with XM-120E firmware

1





Differential Expansion Configuration Parts


1440-TPS02-01RB XM-320 Position Module 1


EK-48486 Calibrated System, 500 MilIncludes:

• (1) 25mm dia tip right angle mounting plate & 1 meter armored cable

• (1) 8.0 meter armored extension cable

• (1) Drive calibrated for 25mm probe 9 meter electrical length

1


Rotor/Thrust Position Configuration

Valve Position Configuration

Rotor/Thrust Position Configuration Parts




Option 1: Rotor/Thrust

EK-2105-70-00-1-10 8mm dia NCPU probe, 1m cable 1 or 2

EK-2170-0-80 8mm extension cable, 8m 1 or 2

EK-2108-9-001 8mm probe driver, 9m system 1 or 2

Option 2: Position




Valve Position Configuration Parts




Select one of the following part numbers

EK-15383 LVDT - 0-2 in range 1

EK-15629 Cam (Valve) position detector rotary potentiometer 1400 Ohm

1

EK-16282 Cam (Valve) position detector rotary potentiometer 2000 Ohm

1


Triple Redundant Overspeed Configuration

Shell (Case) Expansion Configuration

Temperature Configuration

Triple Redundant Overspeed Configuration Parts




1440-REX03-04RG XM-442 Voted EODS Relay Module 1

1440-TB-G Terminal Base G for XM-442 1




Shell (Case) Expansion Configuration Parts




EK-15383 Linear Variable Displacement Transducers (LVDT) 1

Temperature Configuration Parts


Option 1:Thermocouple or 2 or 3 Wire RTD

1440-TUN06-00RE XM-361 Universal Temperature Module 1

1440-TB-E Terminal Base E for XM-36x 1

Option 2: Isolated Thermocouple

1440-TTC06-00RE XM-362 Isolated TC Temperature Module 1



Gas Turbine System

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.

Radial Vibration Measurement

Radial Vibration gives the first indication of a fault, such as unbalance, misalignment, cracked shaft, oil whirl, or other dynamic instabilities.

Shaft Relative - Fluid Film (Sleeve/Babbit) Bearing

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.

ShaftShaft TurbineCompressorGENERATOR

(OR OTHER DRIVEN COMPONENT)

BRG #1 BRG #2

TEMP

RADIAL MEASUREMENTS

TEMP

THRUSTPOSITION"A" & "B"

PHASE

SPEED

SPEED

Typical Gas System Overview

IMPORTANT The turbine OEM should be referenced before choosing type and placement of measurements.

Two Plane Arrangement

19

20 Gas Turbine System

Case Absolute - Anti-friction (Ball or Rolling Element) Bearings

Vibration measurements can be made by a transducer mounted on the machine’s casing. Mounting locations are generally determined by the OEM.

Phase Measurement


Speed Measurement

Speed is a measurement of shaft rotation in revolutions per minute. Speed is a critical measurement during start-up and operation.

Thrust Position Measurement

The primary purpose of the thrust position measurement is to monitor thrust bearing wear and to ensure against axial rubs. Dual (redundant) thrust motion detection should be used when the machine is required to shutdown. This method requires two transducers mounted on each bearing. When both independent set points cross the shutdown limit the machine will be turned off. Single thrust motion detection should be used when the machine does not have to be shutdown and there is another means of verifying thrust bearing failure.



Case MountedArrangement

W

D GAPAPPROX..060

PREFERRED

(PROTRUSION)


D

W

GAP

(DEPRESSION)

ALTERNATE


EPOXIED STEEL

Dual Thrust

Single Thrust



Your selection of measurements determines which XM module you need for your gas turbine system.


Radial Vibration

Phase

XM-123 Aeroderivative Module

Note: For FFT, TWF and additional calculated parameters, the XM-120 module (1440-VST02-01RA) should be used in conjunction with the XM-123 module.

The XM-123 Aeroderivative Module is an intelligent 2-channel special-purpose monitor that is uniquely suited for monitoring Aeroderivative Gas Turbines. The XM-123 can be configured, per channel, to perform either tracking filter or band pass style measurements while it also continuously measures each channel’s broad band overall level. These capabilities, along with its extraordinary configurability, enable the XM-123 to meet the demanding monitoring requirements of almost any engine in service today.

For more information on the XM-123 module, see publication ENMON-TD123. For more information on the XM-120 module, see publication ENMON-TD120.

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 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).


Thrust Position XM-320 Position Module The XM-320 Position Module is a 2-channel multi-purpose monitor. The module can be configured to measure any of: Axial Position, Valve Position, Case Expansion and Differential Expansion.



or







Radial Vibration Configuration

✞ 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.



Cat. No. DescriptionProbe Operating 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 +177°C)

2

EK-2170-0-80 8mm extension cable, 8m Connector: max. 257°F (+125°C)

2

EK-2108-9-001 8mm probe driver, 9m system -36 to +176°F (-38 to +80°C)

2

Option 2: Case Absolute

EK-43807I✞ 9100HT High Temperature Accelerometer -65 to +500°F (-54 to +260°C)

1

EK-46801I 32’ Accelerometer Cable (splash proof) 1

TIP For FFT, TWF and additional calculated parameters, the XM-120 module (1440-VST02-01RA) should be used in conjunction with the XM-123 module.


Phase/Speed Configuration

Only one option is necessary for a phase/speed measurement.

Thrust Position Configuration

Phase Configuration Parts


Phase/Speed

Included with XM-123/120/121/122 Modules

Speed



Option 1




Option 2



Thrust Position Configuration Parts


1440-TPS02-01RB XM-320 Dual Position Module 1









Option 1: Thermocouple or 2 or 3 Wire RTD






Hydro Turbine System

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.

Radial Vibration Measurement

Radial Vibration gives the first indication of a fault, such as unbalance, misalignment, cracked shaft, oil whirl, or other dynamic instabilities.

Shaft Relative - Fluid Film (Sleeve/Babbit) Bearing

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.

Shaft

Turbine

SPEED/PHASE

TEMP

TEMPTHRUSTPOSITION"A" & "B"

Generator

CAVITATION

RADIAL

MEASUREMENTS

Typical Hydro Turbine System Overview

25

26 Hydro Turbine System

Case Absolute - Anti-friction (Ball or Rolling Element) Bearings

Vibration measurements can be made by a transducer mounted on the machine’s casing. Mounting locations are generally determined by the OEM.

Cavitation is defined as the formation of vapor pockets in a liquid. In hydro turbines, cavitation can cause a large amount of noise, damage to the machine, and a loss of efficiency. It is measured by a case mounted accelerometer on either the draft tube or turbine head cover.

Phase/Speed Measurement


Speed is a measurement of shaft rotation in revolutions per minute. Speed is a critical measurement during start-up and operation.

Thrust Position Measurement

The primary purpose of the thrust position measurement is to monitor thrust bearing wear and to ensure against axial rubs. Dual (redundant) thrust motion detection should be used when the machine is required to shutdown. This method requires two transducers mounted on each bearing. When both independent set points cross the shutdown limit the machine will be turned off. Single thrust motion detection should be used when the machine does not have to be shutdown and there is another means of verifying thrust bearing failure.



Cavitation

W

D GAPAPPROX..060

PREFERRED

(PROTRUSION)


D

W

GAP

(DEPRESSION)

ALTERNATE


EPOXIED STEEL

Dual Thrust

Single Thrust



Your selection of measurements determines which XM module you need for your hydro turbine system.


Radial Vibration

Phase

XM-121 Low Frequency Dynamic Module

The XM-121 Low Frequency Vibration Module is identical to the XM-120 Standard Vibration Module except for the available high pass filter (HPF) selections. The HPF’s available in the XM-121 allow for measurements to be as low as .2 Hz (12 CPM) making it ideal for monitoring low speed machinery such as hydroturbines and many fans, gearboxes, paper rolls, extruder presses and other low speed equipment.


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 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).


Thrust Position XM-320 Position Module The XM-320 Position Module is a 2-channel multi-purpose monitor. The module can be configured to measure any of: Axial Position, Valve Position, Case Expansion and Differential Expansion.



or







Radial Vibration Configuration




1440-VLF02-01RA XM-121 Low Frequency Dynamic Measurement Module 1

1440-TB-A Terminal Base A for XM-120 / XM-121 / XM-122 1

Option 1: Shaft Relative




Option 2: Case Absolute and Cavitation

EK-43784I 9100 General Purpose Accelerometer 1

EK-46801I 32’ Accelerometer Cable (splash proof) 1


Phase/Speed Configuration

Only one option is necessary for a phase/speed measurement.

Thrust Position Configuration

Phase/Speed Configuration Parts


Phase/Speed

Included with XM-121/120 Modules

Speed



Option 1




Option 2



Thrust Position Configuration Parts











Option 1: Thermocouple or 2 or 3 Wire RTD






Integration Products

This section describes the integration strategy. Select the human machine interface (HMI), control system, and reliability products that best fit your needs.

XM systems use the DeviceNet™ open standard for all communications. DeviceNet is an open, low-level network that provides connections between simple industrial devices (such as sensors and actuators) and higher-level devices (such as HMIs, PLCs, and computers). The DeviceNet network uses the proven Common Industrial Protocol (CIP) to provide the control, configure, and data collection capabilities for industrial devices.

HMI Products Rockwell Automation offers the following HMI products for your system.

VersaView Industrial Computers and Monitors

VersaView® products are a family of industrial computer and monitor solutions, comprised of integrated display computers, workstations, non-display computers, and flat panel monitors. VersaView products offer effortless management of changing technology, a rugged but cost-effective design, and easier product configuration. All VersaView products provide the latest industrial solution available, optimized for visualization, control, information processing, and maintenance application.

VersaView CE Industrial Computers

VersaView CE products offer open Windows CE terminals in Windows® desktop environments - bringing together features of operator interfaces and industrial computers. It is a high performance computer with a compact flash drive and integrated RSView® Machine Edition runtime (no activation required). There’s no hard disk, no fan, and no moving parts, which means maximum reliability on the plant floor. Easy to set up and maintain, VersaView CE means an open system that’s rugged and economical, offering high functionality in an easy to use package.

31

32 Integration Products

RSView Enterprise Series Software

RSView Enterprise Series software from Rockwell Software is a line of HMI software products designed with a common look, feel, and navigation to help speed HMI application development and training time. With RSView Enterprise Series 3.0, you can reference existing Logix data tags. Any changes made to these referenced tags are automatically inherited by RSView software. RSView Enterprise Series software includes:

• RSView Studio lets you create applications in a single design environment. It configures RSView Supervisory Edition, RSView Machine Edition, VersaView CE, and PanelView Plus applications. It supports editing and reusing projects for improved portability between embedded machine and supervisory HMI systems.

• RSView Machine Edition (ME) is a machine-level HMI product that supports both open and dedicated operator interface solutions. It provides a consistent operator interface across multiple platforms (including Microsoft Windows CE, Windows 2000/XP, and PanelView Plus solutions), and is ideal for monitoring and controlling individual machines or small processes.

• RSView Supervisory Edition (SE) is an HMI software for supervisory-level monitoring and control applications. It has a distributed and scalable architecture that supports distributed-server/multi-user applications. This highly scalable architecture can be applied to a stand-alone, one-server/one-user application or to multiple users interfacing with multiple servers.

PanelView Standard Operator Terminals

PanelView™ Standard operator terminals are engineered for maximum performance in space saving flat panel designs. These electronic operator interfaces feature pixel graphics capabilities and high-performance functionality in color, grayscale, and monochrome displays. The PanelView Standard family offers a complete line of rugged electronic operator interface solutions in a variety of sizes and configurations to meet specific application requirements, all with a rich collection of hardware and software features designed to simplify programming and improve operator productivity. The high performance functionality of the PanelView Standard line includes advanced alarm handling, screen security, analog gauges, ATA PC memory card, universal language support, and online printing for more intuitive operator control.


Control Systems Rockwell Automation offers the following control system solutions for your system.

PLC/DCS DeviceNet Interface

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

The ControlLogix system provides sequential, process, motion, and drive control together with communications and state-of-the-art I/O in a small, cost-competitive package. The system is modular, so you can design, build, and modify it efficiently - with significant savings in training and engineering. A simple ControlLogix system consists of a standalone controller and I/O modules in a single chassis.

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.

For more information on the ControlLogix products, see publication 1759-SG001.

OPC Gateway

OPC (OLE for Process Control) is a set of industry-standard specifications that allow plant floor devices such as DCSs and PLCs to communicate and exchange data with software applications such as HMIs and Process Historians. The OPC standards allow different automation and control applications, field systems and devices, and business and office applications supplied by different vendors to work with one another.

RSLinx Classic software is an OPC-compliant server exposing the required interfaces for an OPC client application to access data consistent with other OPC-compliant servers.


Gateways and Bridges

XM-500 Ethernet Gateway

The XM-500 Ethernet Gateway provides a powerful bridge between an XM DeviceNet network and Ethernet. The Gateway provides complete DeviceNet Master functionality and support for a fully populated DeviceNet network with up to 63 devices. On the Ethernet side, the XM-500 offers a standard TCP/IP interface and support for the Ethernet protocol. Recommended for systems designed primarily to communicate with RSMACC EOL and Emonitor.

For more information, see publication ENMON-TD500.

1788 EN2DN Ethernet/IP to DeviceNet Linking Device

The 1788 EN2DN Ethernet/IP to DeviceNet Linking Device has the capability to bridge explicit messages from an Ethernet/IP network to a DeviceNet network, or scan the DeviceNet network via Ethernet/IP. Can be used with any Logix controller or third party controller with Ethernet/IP support. Recommended for systems requiring integration with automation environments, e.g. PLCs, and visualizations.

1788 CN2DN ControlNet to DeviceNet Linking Device

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.

XM-440 Master Relay Module

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.

IMPORTANT Rockwell Automation's Encompass Partners provide additional gateways for almost any network; see http://www.rockwellautomation.com/encompass/ for further details.


XM-442 Voted EODS Relay Module

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

The XM modules offer a 4-20mA isolated analog output per channel proportional to the selected measurement. Each output is independently programmed to represent any measured parameter, from either channel with a maximum load of 300 ohms. The 4-20mA outputs can interface directly with existing strip chart recorders and LED indicators to monitor and control the health of your turbine system.


Software Products

Your network configuration determines what software packages you need to configure and manage your system.

XM Serial Configuration Utility Software

The XM Serial Configuration Utility software is an easy to use Windows application for installing and configuring the XM Series modules. The tool can 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.

The Utility software is provided on the XM Documentation and Configuration Utility CD that is packaged with the XM modules.

IMPORTANT To use the XM Serial Configuration Utility, connect the PC to a module’s serial port using the following serial cable.

Cat. No. Description

1440-SCDB9-FXM2 XM Serial Communications Cable

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38 Software Products

RSLinx Software RSLinx™ software is a complete communication server providing plant-floor device connectivity for a wide variety of Rockwell Software applications such as RSLogix™ 5/500/5000, RSView32, RSView Enterprise Series, and RSMACC™ Enterprise Online Condition Monitor (RSMACC EOL). In addition, several open interfaces are provided for third-party HMI, data collection and analysis packages, and custom client-application software. RSLinx software can support multiple software applications simultaneously, communicating to a variety of devices on many different networks.

RSLinx 2.x software is now joined by RSLinx Enterprise software, a new product within the RSLinx family that provide unparalleled connectivity to Logix processors. RSLinx Enterprise software currently can support working as a data server for widely distributed RSView Supervisory Edition products, RSSql™, RSBizWare Historian™, and RSBizWare PlantMetrics™ applications, RSView Machine Edition including PanelView Plus and VersaView hardware platforms, and RSView Supervisory Edition Station.

You can communicate from anywhere to anywhere using RSLinx software. RSLinx v2.43 or later is required for compatibility with the entire line of XM modules.

RSNetWorx for DeviceNet Software

RSNetWorx™ software configures and manages the communication between the devices on your control network. RSNetWorx for DeviceNet provides an instant, selectable view of any DeviceNet network. With this software, you can


configure DeviceNet I/O devices and create a scan list. The DeviceNet scanner stores the configuration information and scan list.

Emonitor Enterprise Software

The Emonitor® suite is a complete machinery information software system for Condition Based Maintenance programs. By incorporating multiple data 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:

• Open Database Connectivity (ODBC) - ODBC provides access to data from any application regardless of which database management system (DBMS) is handling the data. It is independent of programming language, database system, and operating system.

• MIMOSA - MIMOSA is an open standard in which equipment asset software components are able to communicate and exchange data automatically without propriety or supplier-specific interface protocols.

• Extensible Markup Language (XML) - XML is a simple, flexible text format designed to facilitate the sharing of data across different systems. Programs are able to modify and validate documents in languages based on XML without prior knowledge of their form.

RSMACC Enterprise Online Software

RSMACC Enterprise Online Condition Monitor is an information presentation and analysis tool that provides you the ability to quickly and intuitively evaluate plant, machinery, and system status at a glance. Using the Enterprise Online Configuration Utility from within RSMACC Enterprise Online Condition Monitor, you can remotely configure data collection parameters, alarms, and relays on the XM modules.

Third Party Software Products

Rockwell Automation offers connectivity solutions allowing our products to integrate with a variety of third party data sources directly via OPC, DeviceNet 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.

Rockwell Automation Project Services provides the expertise needed to scope and install a new TSI system, or the retrofit of an existing one.

Engineering Design Services

Rockwell Automation has the engineering resources and specific TSI knowledge to effectively design a new system or plan a retrofit. The design services include:

• Functional Design Specification• Installation Drawings• Custom Product Design• Application Review• Network Evaluation• Customized Operational and Troubleshooting Guides

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

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42 Project Services

Reliability Online (ROL) Service Programs

Rockwell Automation ROL Services turns TSI data into actionable Condition-based Maintenance information.

• 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)

Select the Product ServicesServices Menu

Cat. No. Description

1443-S-OLTK Turnkey Installations and Services for on-line systems

1443-S-DOC Documentation Service - Reports, Drawings and System Specifications

1443-S-MON On-line Systems Commissioning, Inspection, Application and Training

1443-S-CAL Standard Annual Calibration or Troubleshooting Service for on-line systems

1443-ROL-CAS Reliability Online (ROL) analysis service


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.

Repair, Exchange & Renewal Parts

Rockwell Automation provides comprehensive repair services including remanufacturing services for a wide variety Rockwell Automation products, 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.

Training Menu

Course No. Description

CCP422 DeviceNet Maintenance and Troubleshooting

CCP163 DeviceNet/RSNetWorx Design and Configuration

EK-ICM101 Introduction to Vibration Technology

EK-ICM121 Dynamic Balancing

EK-ICM141 Emonitor Odyssey/Enshare Basic

EK-ICM162 Using Your Enpac with Emonitor

EK-ICM165 XM System Fundamentals

EK-ICM201 Vibration Analysis I

EK-ICM221 Emonitor Odyssey/Enshare Advanced

EK-ICM261 Vibration Analysis II

EK-ICM281 Time Waveform Analysis

EK-ICM301 Vibration Analysis III

RS-RSMACC RSMACC Installation and Configuration

44 Project Services

Optional Accessories

Sensors Rockwell Automation offers a comprehensive range of Sensors for use with both condition monitoring and protection systems.

Accelerometers bare the workload in vibration monitoring and data collection processing. Designed for use in a broad range of applications, various types of accelerometers including high frequency, low frequency, high temperature, and specialty sensors offer a variety of frequency ranges and reference sensitivities to provide the best selection for each measurement concern.

9000 Series Accelerometers

9000 series Accelerometers are designed for use in a broad range of applications including high frequency, low frequency and high temperature and offer a variety of frequency ranges and reference sensitivities to provide the best selection for each measurement application.

For more information on 9000 series accelerometers, see publication GMSI10-SG001, which is available on the Rockwell Automation web site (http://www.rockwellautomation.com/services/conditionmonitoring/sensors.html).

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.

We also provide a variety of probe holder options. For more information on 2100 series non-contact pickups and probe holder options, see publication ENACC-PP210, which is available of the Rockwell Automation web site (http://www.rockwellautomation.com/services/conditionmonitoring/sensors.html).

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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.

It may be necessary to provide a redundant power source to the XM system for critical applications. All XM modules provide redundant power supply input terminals so if the primary 24V power supply fails, the secondary power supply will automatically be used in its place.

For assistance in calculating the power requirements for your XM system, contact your local Rockwell Automation Customer Service.

Cables Rockwell Automation offers a variety of cables for interfacing industrial vibration sensors to termination and switch boxes, portable data collectors, readout devices, and recording and analysis instruments. For individual product offerings, see publication GSMG10-PL001.

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.

Enclosures Rockwell Automation offers a broad line of UL approved NEMA enclosures to house and protect your XM system. NEMA enclosures are rated by the National Electrical Manufacturers Association (NEMA) and designed for hazardous or non-hazardous locations and indoor or outdoor use.

Cat. No. Full Rated Load

1606-XLP-30E 1.3A

1606-XLP-50E 2.1A

1606-XLP-100E 4.2A


Rockwell Automation offers the following enclosure types.

✞ NEMA Type 4X and 12 rated enclosures are available with solid door or polycarbonate window.

For individual product offerings, see publication GMSG10-PL001.

Sensor Adhesives / Mounting Tools

Rockwell Automation offers sensor adhesives and mounting tools to prepare the machinery surfaces for installation of the sensors. For individual product 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.

For more information on the Enpac 2500, see publication GMSI10-PP03.

Enclosure Type Intended Use and Description

NEMA 4 Indoor or outdoor use primarily to provide a degree of protection against windblown dust and rain, splashing water, and hose directed water; undamaged by the formation of ice on the enclosure.

NEMA 4X✞ Indoor or outdoor use primarily to provide a degree of protection against corrosion, windblown dust and rain, splashing water, and hose-directed water; undamaged by the formation of ice on the enclosure.

NEMA 12✞ Indoor use primarily to provide a degree of protection against dust, falling dirt, and dripping noncorrosive liquids.

48 Optional Accessories

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.

For more information on the Enwatch, see publication GMSI10-PP014.


GMSI10-SG002A-EN-P - June 2006 Copyright ©2006 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Listen. Think. Solve, Allen-Bradley, Emonitor, PanelView, RSBizware Historian, RSBizware PlantMetrics, RSLinx, RSLogix, RSMACC, RSSQL, VersaView and XM are trademarks ofRockwell Automation, Inc.

DeviceNet is a trademark of the Open DeviceNet Vendor Association (ODVA).

Windows is a registered trademarks of the Microsoft Corporation.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

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Turbine Supervisory Instrumentation Selection Guide - Rockwell

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