T63 - PowerFlex Medium Voltage Drives for Heavy Industry Applications PUBLIC PUBLIC - 5058-CO900G
2 Agenda Introduction How MV Drives Enable Success Heavy Industry Performance Requirements How Rockwell Automation Can Help Summary
3 Session Synopsis 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.
Medium Voltage Drive Applications PUBLIC 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
5 Focus on the Heavy Industry End-User 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
6 Drive Project Lifecycle Evaluate Operate Maintain Repair Purchase Integrate & Commission Factory Acceptance Test Install Transport
7 Agenda Introduction How MV Drives Enable Success Heavy Industry Performance Requirements How Rockwell Automation Can Help Summary
8 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
9 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.
MV Drive Project Goal Categories Users have some or all of these four principal goals:
11 Agenda Introduction How MV Drives Enable Success Heavy Industry Performance Requirements How Rockwell Automation Can Help Summary
What Do Heavy Industry Users Value? Faster Time To Market 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 Lowest Total Cost of Ownership 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 PUBLIC Improved Asset Utilization Reduce unplanned downtime Reduce Mean Time To Repair (MTTR) Leverage Remote Monitoring and Predictive Analytics Enterprise Risk Management 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
13 Agenda Introduction How MV Drives Enable Success Heavy Industry Performance Requirements How Rockwell Automation Can Help Summary
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15 Motor Control Technologies Scalable Low Voltage & Medium Voltage Solutions Across-the-Line Starters Soft Starters Variable Frequency Drives Motor Control Centers Full Voltage Fixed Speed Reduced Voltage Fixed Speed Variable Speed Centralized Motor Control
16 Intelligent Motor Control ENABLER EtherNet/IP REDUCED Costs FASTER Installation REAL-TIME Data
17 Value Delivered $ Faster Time to Market Lower Total Cost of Ownership Improved Asset Utilization Enterprise Risk Management
18 Faster Time to Market Reduce development time Reduce commissioning time Enable common user experience Efficient engineering ENABLED BY Premier Integration
19 Premier Integration Minimize address mismatches Motor Control Device parameters... automatically mapped in
20 Premier Integration One-time configuration of controller & devices Simplify commissioning Studio 5000 configures... All Motor Control
21 Premier Integration Develop modular code Reuse from project to project Associate variables in logic... to
Lower Total Cost of Ownership Energy savings Energy management ENABLED BY Variable speed control Energy intelligence $ PUBLIC 22
23 Reduce Operating Costs On the Plant Floor 50% of the energy consumed is by electric motors PowerFlex variable speed control devices can help Reduce speed20% Save 50% energy
Reduce Operating Costs Lower Total Cost of Ownership Variable Speed Control Energy intelligence Energy savings Energy management 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 control http://www.rockwellenergycalc.com/
Improved Asset Utilization Reduce unplanned downtime Reduce time to repair ENABLED BY Embedded diagnostics Remote monitoring Virtual Support Engineer TM 25
Remote Monitoring Virtual Support Engineer PUBLIC 26 Continuous Performance Monitoring Immediate Alerts Troubleshooting Assistance Problem Resolution PowerFlex 7000
VSE Remote Monitoring Helping 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
28 VSE Data Security 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
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: Feedback Diagnostics Hardware Motor Model Metering Thermal Manager Control Loops Speed Current Torque Flux PWM Virtual Support Engineer simple, secure and cost effective
Enterprise Risk Management Personnel Safety Equipment Protection ENABLED BY Remote monitoring Remote control Safe Torque Off 31
32 PowerFlex 7000 with Safe Torque Off 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)
33 Advantages of PowerFlex 7000 with Safe Torque Off 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
34 PowerFlex 7000 with TorqProve 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
35 Agenda Introduction How MV Drives Enable Success Heavy Industry Performance Requirements How Rockwell Automation Can Help Summary
36 Value Delivered $ Faster Time to Market Lower Total Cost of Ownership Improved Asset Utilization Enterprise Risk Management
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