atap feb. 2005 - ucc.colorado.eduucc.colorado.edu/allen-bradley/atap-sea_2007-03.pdf · intelligent...

AutomationAutomationTODAY ASIA PACIFIC

SOUTHEAST ASIA

InsideRockwell AutomationWins Contract fromSara Lee Foods

Melbourne WaterPumps UpEnvironmental Efforts

DeviceLogix™ BringsDecision-Making to the Local Level

AC Drives Improve Energy Efficiency of Coal-Fired Plants

Combining Motion and Sequential Control in One Device

March 2007

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Intelligent ChoicesD eveloping motor control and

protection technology has been a core discipline for Rockwell

Automation for more than 100 years. We understand how to bring motors up to speed in a controlled manner, limit wear on motors and other mechanical components , and protect automation equipment. We accomplish this through our Intelligent Motor Control strategy.

Intelligent Motor Control integrates motor control and protection in a networked environment, enabling modern control devices with built-in intelligence to exchange information. Strategically, this brings to motors the same benefits as the plant as a whole, including built-in fault diagnosis, warnings before shutdowns and rapid troubleshooting.

Rockwell Automation’s data-driven approach to motor control allows manufacturers to capture and apply crucial information, leading to more informed decision-making throughout the operation and more efficient motor communication and monitoring. The strategic use of Intelligent Motor Control products — including ArmorStart® motor starters, PowerFlex® drives, electronic overload relays, intelligent motor control centres and network communications — results in manufacturers being better able to predict and prevent downtime, respond more quickly to changes in their manufacturing processes, increase efficiencies and save energy.

The power of Intelligent Motor Control lies in its ability to take advantage of network communications. Networking standards such as DeviceNet™, ControlNet™ and EtherNet/IP™ allow for seamless information flow between the factory floor and the enterprise. Networks provide added value by leveraging the functionalities built into Intelligent Motor Control products.

For example, DeviceNet supports Intelligent Motor Control components featuring DeviceLogix™. This technology enables intelligent devices to process functions and logic at the local level rather than communicating information back to a PLC. Local processing leads to fast input sense to output actuation, a reduction in overall network traffic, smaller programs in the controller, and local networking redundancy in process continuation and controlled shutdowns.

Rockwell Automation has the most complete Intelligent Motor Control product portfolio on the market. In this issue of Automation Today Asia Pacific, we invite you to learn how the strategic implementation of these intelligent devices can increase factory efficiencies, save energy and improve your bottom line.

Scott Summerville

Automation Today is published by

ROCKWELL AUTOMATION ASIA PACIFIC LTD

Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong Tel: +852 2887 4788 • Fax: +852 2508 1846

EDITOR: Gail Anderson – [email protected]

ROCKWELL AUTOMATION SOUTHEAST ASIA PTE LTD55 Newton Road, #11-02 Revenue House Singapore 307987

Tel: +65 6356 9077 • Fax: +65 6356 9011

Copyright© 2006 Rockwell Automation, Inc. All rights reserved. The contents of this publication may not be reproduced in whole or part without the consent of the copyright owner. 1336 PLUS, Allen-Bradley, ArmorBlock MaXum, ArmorPoint,

ArmorStart, Compact I/O, CompactBlock I/O, CompactLogix, ControlLogix, DeviceLogix,Encompass, Entek, FactoryTalk, Kinetix, LaserSight, On-Machine, PanelView, PLC-5, PowerFlex, Powermonitor, Rockwell Software,

RSAdvantage, RSAssetSecurity, RSEnergyMetrix, RSLogix, RSNetWorx, RSView Supervisory Edition, SLC, SMC Flex, SoftLogix, XM 160 and XM 441 are trademarks or registered trademarks of Rockwell Automation, Inc.

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

Features6 Feature Story — Intelligent Motor Control: Making Factories More Efficient Data-driven motor control, combined with motor protection and network integration, provides optimal motor performance.

3 News & Events Rockwell Automation developments from around the world.

4 Country News News and events from your country.

10 Application Story Melbourne Water’s Western Treatment Plant introduces new sewage treatment processes that improve final effluent quality, thanks to Rockwell Automation’s Integrated Architecture.

13 Technology Watch DeviceLogix™ components control output and manage status information in a distributed control environment.

16 Value Proposition Chinese power plants rely on AC drives to reduce energy consumption.

17 Product Focus Recent additions to the Rockwell Automation product portfolio.

Scott Summerville, PresidentRockwell Automation Control Systems, Asia Pacific Region

CONTENTSEDITORIAL

2 March 2007 AUTOMATION TODAY ASIA PACIFIC

AUTOMATION TODAY ASIA PACIFIC March 2007 3

How to Manage Energy Costs in the Food Industry

A new Rockwell Automation white paper, entitled How a Well-Planned Strategy

Can Help the Food Industry More Effectively Manage Its Energy-Related

Costs, outlines steps food manufacturers can take to reduce energy costs andimprove power quality.

The white paper highlights several examples of how food manufacturershave utilised energy management systems to control energy consumption andreduce costs. It discusses how power optimisation tools, such as variable frequency drives, can be applied to motor systems to reduce the amount of energy used in manufacturing processes. For a copy of the white paper, visitwww.rockwellautomation.com/industries/food.

R ockwell Automation won a contract valued at approximately US$650,000 tosupply Sara Lee Foods with automation products and services for its roastedcoffee plant in Brazil. This project includes MPS services and products

based on Integrated Architecture with Logix, RSView® Supervisory Edition™, ArmorPoint® I/O, ArmorStart® motorstarters, SMC™ Flex soft starters and PowerFlex® AC drives.

Leogap, a Brazilian OEM, won an order for the roasters and will deliver RockwellAutomation’s ControlLogix® with RSView SE – instead of their standard solutionSLC – and their own SCADA. Total value of the order is valued at approximatelyUS$130,000.

R ockwell Automation chairman and CEO Keith Nosbusch recently traveledmore than 4,300 miles in six days on a visit to India. During the trip, Nosbusch had the honour of representing the first automation company to

present to the Confederation of Indian Industries (CII), a non-government, not-for-profit, industry-managed organization helping to lead India’s developmentprocess. Nosbusch’s keynote address focused on enabling world-class manufacturing for global competitiveness.

While in India, Nosbuschalso met with global customers that have local facilities includingKimberly Clark, the SteelAuthority of India Limited and OEMsUttam Galva Steel andLakshmi Machine WorksLtd. In addition, hekicked off the company’s

first Integrated Condition-Based Monitoring University and Customer Support andMaintenance master’s degree training program; toured PSG College of Technologyand inaugurated their Integrated Architecture Lab; and spoke with technology editors of The Business Standard and Hindu Business Line.

Nosbusch Journeys to India,Meets with Customers

Sara Lee Selects Rockwell Automation Solutions

NEWS & EVENTS

Two Companies NamedEncompass PartnersPanduit and ECT International are nowGlobal Encompass™ and Encompass AsiaPacific partners, respectively. Panduit,located in Singapore, provides network andcabling solutions including fibre optic andcopper connectors, fibre and copper patchcords, communication outlets, racewaysystems, rack systems, cable tie systemsand network identification systems. ECT,with offices in China and Australia,provides promise-e software for electricalcontrol system design and documentation.For more information, visit:www.ab.com/db/encompass/bps_ext.dir_list_dynam.

Rockwell AutomationRecognized for CustomerServiceRockwell Automation recently received theFrost & Sullivan Customer ServiceLeadership Award for its demonstratedexcellence and outstanding contributionsto the worldwide medium voltage drivesmarket. The award recognizes thecommitment the company has showntoward understanding customerrequirements and providing high-qualityproducts and services around the world.Rockwell Automation’s PowerFlex® familyof drives offers customers a range ofperformance capabilities while itssimplified design reduces commissioning,training, maintenance time and cost ofownership.

Acquisition Paves the Wayfor Sales of MES SolutionsAs part of a just-announced ManufacturingExecution Systems (MES) sales initiative,Rockwell Automation will market its newRSAdvantage™ product, part of theFactoryTalk® suite, to customers in thefood, beverage, medical devices,electronics and automotive industries. Thecompany acquired the software inNovember 2005 when it bought DatasweepInc., a pioneer in the development of highlyscalable software that supports multipleproduction disciplines for delivery of MESsolutions across multiple industries.

BRIEFS

Allen-Bradley PLCs



COUNTRY NEWS

disciplines including sequential, motion, process control, drive control, safety and information. Unlike traditional architectures, Integrated Architecture reduces total cost of ownership by using a single control platform for the entire range of factory automation applications, large or small. This enables users to re-use engineering designs and practices to reduce development time and cost, respond more quickly to market demands, reduce maintenance costs and downtime and easily gain access to plant and production data from business systems for better decision making.

CompactLogixThe Allen-Bradley CompactLogix

family leverages the same Logix Control engine, motion, networking technology and communications services as the ControlLogix and SoftLogix controllers, making it part of a complete, scaleable control architecture.

For example, the new CompactLogix 1768-L43 controller controlling up to four axes of motion, is ideal for applications requiring speed, motion synchronization and information-

sharing capabilities – all in a small, cost effective package.

CompactLogix also shares the use of Rockwell Software RSLogix 5000 programming software with other Logix controllers, allowing users to save time by reusing codes or moving

it easily from one Logix application to another with no additional program development or training.

CompactLogix users can select from among several I/O options including Compact I/O and POINT I/O, providing a high degree of flexibility and maintaining low inventory and commissioning costs, while easing initial assembly and speeding module replacement.

POINT I/OSelecting the precise number of

I/O points required for an application enables users to save valuable panel space and reduce expense. Allen-Bradley POINT I/O offers a broad range of highly granular I/O modules designed for installations requiring a high mix of I/O types in a minimal envelope. With

built in diagnostics, and full networking capability, POINT I/O helps bring important plant floor data into the hands of those who need it.

PanelView Plus terminalsThe Allen-Bradley PanelView Plus

400 and PanelView Plus 600 terminals offer all of the standard preconfigured e lements ava i lab le wi th l a rger PanelView Plus models, but in a smaller size. The terminals provide users with advanced functionality including animation, trending, data logging, and object math and logic expressions – all valuable for improving operator

OEMs Gain Competitive Edge with Scaleable, Integrated Architecture from Rockwell Automation

E n h a n c e m e n t s t o R o c k w e l l Automation’s portfol io help integrate machines quickly, simply

and cost-effectively.OEMs and End Users interested in

reducing costs, improving time to market and increasing productivity will benefit from the increased mid-size control system capabilities of the Rockwell Automation Integrated Architecture. This architecture already provides seamless integration of control and information environments, provid-ing users with the means to make faster, better decisions with more clarity. Users with less-complex applications can now take advantage of this architecture with a suite of integrated products from Rockwell Automation, including the Allen-Bradley CompactLogix Programmable Automation Controller family, PanelView Plus 400 and 600 terminals, POINT I/O modules, and the PowerFlex 40 drive – all connected on a single communication network such as EtherNet/IP.

“The CompactLogix family of controllers opens the door for many manufacturers who until now did not have the means to implement a full-scale architecture,” said John Nesi, Vice President Commercial Marketing, Automation Control and Information Group, Rockwell Automation. “ With the latest enhancements to the Logix Control platform, manufacturers of all sizes can enjoy real-time communication throughout the enterprise, optimizing maximum efficiency and increasing productivity, Machine Builders can also reduce development and commissioning time while providing additional value to their customers.”

The Rockwell Automation Integrated Architecture is an industrial automation infrastructure providing scaleable solutions for the full range of automation

number of other Rockwell Automation technologies targeted at OEMs were described during the workshop. With an increasing need for machines to be connected rather than standalone, Selvakumar Subbiah, Business Manager, Automation Control and Information Group, provided a comprehensive account of the advantages of EtherNet/IP industrial network technology.

And with machine safety becoming an important upfront consideration rather than an afterthought, Puneet Mehrotra, Regional Marketing Manager, provided delegates with an overview of funda-mental safety principles and techniques. Technology trends in the safety arena include advanced safety relay systems including networking for diagnostics, increased usage of safety light curtains and area scanners over gated access, emergence of safety networks and safety PLCs, and tighter integration of standard control and safety control.Control Engineering Asia (www.ceasiamag.com),

Jan/Feb 2007


SOUTHEAST ASIA

the application of EtherNet/IP users save money and ease integration via the use of standard off-the-shelf components and protocols. The industry backing, unmatched performance and range of EtherNet/IP solutions available today deliver the best option for business that want to take advantage of the promise of Ethernet across the enterprise.

In addition, EtherNet/IP closes the gap between control and information throughout the enterprise, enabling users to make better, faster decisions and improve productivity.

efficiency, optimizing processes, and diagnosing problems virtually anywhere on the plant floor. Sharing a tag-based environment with Logix controllers, PanelView Plus users can dramatically reduce development time and errors.

PowerFlex40A s p a r t o f t h e A l l e n - B r a d l e y

PowerFlex family, the PowerFlex 40 AC drive provides performance-enhancing motor control in an easy-to-use, compact package. To simplify programming, the PowerFlex 40 can leverage drive

mass market appeal," explained Han Tok, Sales Engineer, OEM, Rockwell Automation.

One of the ways that OEMs can save time and money, said Han, is through standardization. Benefits of a standard software approach include code re-usability, fewer errors, easier scalability, and simplified maintenance. In one case, Rockwell's Power Programming solution was used by a packaging OEM for a filling machine, reducing development time by almost 50 percent, from 38 to 20 days.

Along with Power Programming, a

Meeting The Machine Challenge

paramenters from other PowerFlex drives, allowing for fast and easy start up. With flexible packaging options and an uncompleted programming structure, the PowerFlex 40 can be easily installed and configured for a variety of applications.

EtherNet/IPThe combination of CompactLogix,

P o i n t I / O , P a n e l Vi e w P l u s a n d PowerFlex on one network, EtherNet/IP, provides users the access to real-time information anytime, anywhere. With

Rockwell's OEM workshop tackled pertinent tissues faced by today's machine builders.

W hat matters most to your business? That was the title of the OEM workshop organised

by Rockwell Automation targeted at machine builders. For delegates at the December 2006 event in Singapore, they were promised the opportunity to find out how to deliver machines in an environment characterized by increas-ing demands for flexibility – to keep up with frequent line changes, scalability – to handle the continuous introduction of new products, and other usual suspects like speed, cost and accuracy.

"For an OEM, intoducing new machines and releasing new features is key to a profitable operation. If a machine introduction is delayed, the market window for that machine can close. To maximise machine sales volume, quick time to market is crucial.

The critical path is to get machines released for full production, through prototype and pre-production testing without delays. When this occurs, machine sales will have the greatest Allen-Bradley PLCs



A ccording to a recent researchstudy, three attributes play akey role in selecting motor

control devices — performance, protection and ease of use (in installing, programming and troubleshooting motors).

Throughout the world, manufacturersstrive to improve motor performance,reduce power consumption and protecttheir motor investments. For years, conventional or passive motor controldevices have effectively carried out simple functions such as short circuitprotection, isolation, switching and loadprotection.

A new generation of motor controlcomponents and systems, however,

Making Factories MoreEfficient

Intelligent Motor Control:

Data-driven motor control, combined with motor

protection and network integration, provides optimal

motor performance.

based on the Logix Control Platformand FactoryTalk® manufacturing software suite — enabling manufacturersto better predict and prevent downtime,maximise control and motor efficiency,and meet user requirements for ease ofstart-up and operation.

Count on Control Rockwell Automation motor control

products, from drives to soft starters toelectronic overload relays, deliver enhanced protection in applicationsranging from fractional horsepowerthrough medium voltage applications upto 34,000 horsepower. Bringing motorsup to speed in a controlled manner, limiting wear on the motor and othermechanical components, and protectingthe automation equipment are key motor control functions.

Efficient motor operations start withselecting the right type of motor control.According to Gary Woltersdorf, Rockwell Automation application

takes performance, protection and easeof use to the next level. By integratingmotor control and protection in a networked environment, modern control devices with built-in intelligencelet motor starters and relays exchangeinformation — bringing to motors thesame benefits as the plant as a whole, including built-in fault diagnosis, warnings before shutdown and rapidtroubleshooting.

The Rockwell Automation strategythat takes conventional motor controldevices to the next level is called “Intelligent Motor Control.” This strategy links data-driven motor controlsolutions with a single-control infrastructure — Integrated Architecture,


engineer, an across-the-line starter canbe used on fixed-speed applications toturn the motor on or off. A soft starteroffers more flexibility for fixed-speedapplications by raising the motor froman initial torque value to full voltage. Avariable frequency drive provides speedcontrol from zero to a rated speed and,in some applications, above base motorspeed operation.

Motor overload devices for across-the-line starters protect motorsfrom operating beyond their design limits. They continuously monitor motor currents on all three phases of AC motors. In addition to an overloadtrip capability, multiple abnormal conditions — including phase loss,ground fault, stall, current imbalanceand others — can be detected to protectequipment. What’s more, since the intelligent overload devices are networked, action can be taken in realtime.

In soft starting, Rockwell Automation’ssmart motor controllers (SMCs) minimise mechanical wear resultingfrom full-voltage starting of AC induction motors, enabling longer system life and limiting line disturbances from inrush currents.Downtime is decreased due to advancedprotection of motor winding equipmentand materials.

SMCs provide intelligence to optimise processes. Fault/warning datais available so that operators can takeaction to prevent equipment damage. Inaddition, load profiles can be developedto model normal conditions. Then, thatinformation can be used to assist maintenance scheduling.

Variable speed drives address a rangeof control needs. Starting withvolts/hertz control for the simplest applications, these drives also handlechallenging torque and positioning operations.

Rockwell Automation’s PowerFlex®

family of low to medium voltage drivesprovides this flexibility. What’s more,the drives are able to connect to an integrated factory automation system,sharing the benefits of Integrated Architecture and making it possible toaccurately monitor the savings andstudy the efficiency of individual activities.

most flexible motor control, and the network connection gives you the datayou need to increase the performance ofyour whole process.”

Protecting Investments Manufacturers depend on motors

to operate efficiently and at capacity to meet production needs. By implementing an Intelligent Motor Control solution, manufacturers canspeed troubleshooting, reduce maintenance costs and more effectivelyprotect their automation investments.

Intelligent control devices such aselectronic overload protection relays increase motor life because they measure and collect information — voltage and current — in order to modelthe effect in motor heating caused byfault conditions. Predictive alarmingcan prolong motor life by identifying a

Woltersdorf explains, “In a casewhere multiple motors are used to sharethe load of a machine, such as a chainconveyor, a network connection oneach drive allows speed and torque signals to be passed quickly from onedrive to the next. Each drive processesthe information and immediately takescorrective action to ensure each motorprovides the speed or torque required tomove the chain in a coordinated way.

“Load conditions,” he continues, “canbe monitored and thresholds set tosense abnormal conditions that may bea result of pending mechanical trouble,such as an automatic oil dispenser notfunctioning. Corrective action can thenbe taken before any damage occurs.

“Without the network connection,” hesays, “you wouldn’t be able to access theinformation you need to protect yoursystem. An intelligent drive provides the

The Rockwell Automation Intelligent Motor Control strategy links data-driven motor controlsolutions and motor protection with a single-control infrastructure.

Alarm messagingto mobile phone

Remote control and monitoring using RSView HMI software

Industrial PC PanelView Plus HMIPower MonitorControlLogix

Allen-Bradley PLCs



breakers, and power monitoring andcontrol equipment to plug right into thenetwork.

“By networking your motor controls,you can observe and compare the interaction among various elements ofyour process rather than monitor a single device,” says Retlich. This capability allows users to view motorcontrols as a system instead of individual components.

DeviceNet is more than an industrialcommunications network. It providesadded value by leveraging the functionalities built into various Intelligent Motor Control products.

For example, DeviceNet supports intelligent components featuring DeviceLogix™, a function that controlsoutputs and manages status informationonboard intelligent devices. In a networked environment, these intelligent devices can process functions and logic at the local levelrather than communicating informationback to a PLC. This leads to fast inputsense to output actuation, a reduction inoverall network traffic, smaller programs in the controller, and localnetworking redundancy in process continuation and controlled shutdowns.(For more information on DeviceLogix,see the article on page 13.)

The power of DeviceNet can also beseen in Auto Device Replacement

fault condition before it occurs andalerting the equipment operator.

Intelligent products also capture andreport faults, motor status and real-timeprocess conditions. This enables manufacturers to log and trend data using computers or programmable automation controllers (PACs) so thatthey can establish a more comprehensive and predictive maintenance schedule to increase plantuptime.

Another benefit of Intelligent MotorControl is reduced maintenance costs.Because intelligent devices can tell operators what happened, where something happened and why it happened, manufacturers can decreasethe time associated with troubleshootingsystem faults.

Easy Does It Intelligent Motor Control solutions

are easy to implement and use, taking advantage of commonality ofprogramming tools and interfaces. Theyfeature embedded start-up routines,plain-language parameter names andlogical parameter arrangements to reduce programming and troubleshooting time, resulting in quicker implementation.

Start-up wizards and on-line controlblock diagrams also are embedded inRockwell Automation software. Suchfeatures ease start-up, troubleshootingand monitoring of motor control devices.

The Networked Advantage The power of Intelligent Motor

Control lies in its ability to take advantage of network communications.A factory that is networked enablesmanufacturers to gain access to the information they need to make the bestdecisions for their operations — and acton them quickly.

Kevin Retlich, Rockwell Automationproduct manager, explains that the NetLinx Architecture provides open connectivity throughout the manufacturing enterprise at various levels. For simple systems, DeviceNet™enables manufacturers to monitor anddiagnose equipment from a central location, allowing products such as I/Odevices, electronic overloads, circuit

(ADR) applications, in which replacedcomponents are automatically set up tooperate exactly as their predecessors.Network DeviceNet PLC scanners storea device’s configuration and downloadthe original parameters to the replaceddevice, greatly reducing downtime andminimising loss in operational performance.

As systems become more complex,ControlNet™ and EtherNet/IP™ can beseamlessly integrated with DeviceNet tocreate large-scale solutions. As needsgrow, the network architecture growswith them. Unlike traditional control architectures, Rockwell Automation’sIntegrated Architecture provides a single control infrastructure for the entire range of factory automation applications, large or small.

The Integrated Architecture enablesdata to be accessed wherever it resides,by each application that needs the information. To further optimise plantperformance and reliability, data can beshared at the enterprise level with a variety of software applications.

Integrated Architecture also plays akey role in the deployment of motorcontrol centres (MCCs), which areevolving from their legacy role as cabinets that house basic electro-mechanical devices to centres of automation that may include smart motor controls, variable frequency drives and PLCs. MCCs combine intelligent motor control components;high-speed, plant-wide networks; andsoftware for monitoring data and establishing predictive maintenancepractices.

Intelligent device parameters can beviewed and amended via the network,saving hours of time during productchangeovers. Advanced diagnostics allow impending failures to be predictedand prevented, minimising downtime,increasing product quality and improving safety.

Overall, data-driven motor controlprovides easy access to motor systeminformation and helps improve motorperformance, reduce power consumption and protect motor investments. Better knowledge andmore control of manufacturing processes improve operations, reducecosts and speed time to market. AT


Phoenix Cement™ Company, based in theUnited States in Clarkdale, Arizona, was

on a mission to modernise its operations.Originally built in 1959, the plant hadreached its maximum rated capacity of approximately 650,000 tonnes per year bythe early 1990s.

The company began negotiations in 1998to build a state-of-the-art kiln line with afive-stage preheater/precalciner, a verticalraw mill and a vertical cement finish millwith an annual capacity of over 1.1 milliontonnes — an increase of more than 65 percent.

“The challenge was to find an automationcontrol system that would meet the plant’sgoals of high reliability, system programflexibility, and provide as much equipmentoperating information as possible,” saysGregg St. Clair, director Cement Operationsfor Salt River Materials Group at the plant.The upgrade required automation controlsystems to run its induced draft (ID) fans,main processing equipment and materialhandling conveyors. It also required a smartdiagnostic and communication system thatwould help save time and money.

Phoenix Cement turned to Rockwell Automation for Intelligent Motor Controlsolutions based on Integrated Architecturedesign. The Phoenix Cement team was already comfortable with the Allen-Bradley®

PLC-5® systems running on the existingline and was impressed with the ControlLogix® capabilities. The team alsosaw the benefits of the intelligent motorcontrol centre (MCC) using DeviceNet™ toaccess critical motor data via other Allen-Bradley solutions — the E3 Plus electronic overload relay and the DeviceNetStarter Auxiliary (DSA).

The control system util ises six ControlLogix processors for each majorfunctional area: the raw mill, preheater, coalmill, cement mills and storage. ControlLogix programmable controllersprovide the required tight integration between the programming software, controller and I/O to reduce developmenttime and cost at commissioning and duringnormal operation.

Attached to the ControlLogix via DeviceNet are two Allen-Bradley

PowerFlex® 7000medium voltage drives,rated for 2000 hp and800 hp; 20 Allen-Bradleylow voltage drives; 152Allen-Bradley intelligentMCC sections with over500 E3 Plus electronicoverload relays; and sixEntek® 6600 vibrationmonitor systems on critical fans. IntegratedDeviceNet networkc o m m u n i c a t i o ncapabilit ies a l l owPhoenix Cement to access data in its intelligent sensors and actuators.

The PowerFlex 7000 medium voltagevariable speed drives support improved process control as well as reducecosts through energy savings, reducedmaintenance and increased life of mechanical equipment. Soft starting andspeed control of the fan at the optimum operating point provide maximum efficiency, resulting in substantial energysavings.

The Entek 6600 vibration monitor systemmonitors and protects machinery againsthigh vibration and the resulting damage. It also monitors associated process parameters such as temperature, pressureand flow.

The intelligent MCCs integrate many controlling devices into one package. Multifunction, solid-state, microprocessor-based electronic E3 overload relays protectinduction motors and provide ambientcompensated overload protection. The E3overload relays also include advanced features such as warning diagnostics, variable frequency, true RMS current sensing and I/O capabilities to allow for remote monitoring and diagnostics via software.

Civil work began in May of 2001 with thefirst cement produced from the new kiln lineon October 18, 2002. With the increase incement demand accelerating in 2004, thecompany’s modernisation has been criticalto its long-term future.

Start-up time savings has been estimated

at 20 percent due to DeviceNet capabilitiesand elimination of the electrical contractorchange orders that can add significant cost.Rockwell Automation engineers performedan efficient startup and provided training onthe operation of the Allen-Bradley controlsystems and drives.

According to Rob Prouty, electrical engineer at Phoenix Cement, “It was thesmoothest, easiest startup of a project thissize that I have ever been involved in.” Themajority of the motor starters connected toDeviceNet, so wiring between the marshalling panel and the MCC was greatly reduced or eliminated, resulting in additional upfront cost savings of approximately 20 percent.

Effective use of information from the intelligent MCCs has resulted in a more cohesive operation and a maintenance teamthat works together. Using DeviceNet totroubleshoot motor and equipment problems from the control room has alsohelped improve safety. The control roomsupervisor can determine problems withthe equipment and alert the field personnelon what to expect before they begin working on it.

“Working with Rockwell Automationon this project has been a win-win forPhoenix Cement,” says St. Clair. “Withcosts r ising dramatical ly in virtual lyevery area from energy to health care,the cost e f f i c ienc ies and increased capacity we’ve achieved through thismode rn i sa t i on have comp le t e l y redefined our future.”

Concrete Improvements in Process Control

Allen-Bradley PLCs



transformation of two existing lagoonsystems into “enhanced lagoons” and the cessation of traditional land filtration methods. Just a year after thesecond upgraded lagoon system—known as 25 West (25W) — wascommissioned, the targeted 1,000-tonnes-per-year reduction of dischargednitrogen has been achieved.

Development of the enhanced lagoons has been no small feat. Traditional lagoon treatment involvesthe gravitational flow of sewage througha series of shallow ponds, during whicha natural progression of ultraviolet(UV), microbiological and biologicaltreatment processes break down organic waste and other micro-organisms. This system is still in place;however, in order to beef up the nitrogen-removal capability, an activated sludge process has been

T he majority of the world’s population gives little thought tothe massive infrastructure

required to process raw sewage into aneffluent suitable for ocean discharge orwater recycling. For Australia’s largestsewage treatment facility, MelbourneWater’s Western Treatment Plant atWerribee, adoption of an “EnvironmentImprovement Plan” has meant greaterfocus than normal.

When a 1990’s environmental study revealed the prudence of reducing nitrogen loads into Victoria’s PortPhillip Bay, Melbourne Water startedprogressively upgrading the sewagetreatment processes at the 11,000-hectare Western Treatment Plant. Themain goal was to improve nitrogen removal from the treated effluent, mostof which is discharged into the bay. The resulting project has involved the

added to the front end of the 55 East(55E) and 25W lagoon systems. The activated sludge process involvespumping the sewage between a series ofoxygenated and deoxygenated zonesloaded with bacteria to speed up naturalprocesses.

After the successful 2001 upgrade of 55E, Melbourne Water identified anumber of areas in which the plantcould be further improved at 25W. Onewas the introduction of large blowers toprovide diffused oxygen into theprocess, instead of surface mechanicalaerators. Another advance was the incorporation of a different control philosophy. This utilised the latest distributed process and Intelligent Motor Control technology from Rockwell Automation’s Integrated Architecture suite.

Sewage and SludgeMelbourne Water’s Trevor Gulvosen,

a process engineer at Western Treatment Plant, explains that the firststage of sewage treatment is the anaerobic area, also known as Pond 1,where 60 percent of the pollutant loadis removed in the form of gases such asmethane, carbon dioxide and hydrogensulphide. “From here it gets pumped ata rate of around 180 ML per day to theactivated sludge plant, where the nitrogen content is reduced from about60 mg to 15 mg per litre,” he says.

Upon entering the main activatedsludge plant basin, the sewage is mixedwith brown return activated sludge(RAS) from the end of the process. Thisprovides the bacteria for the treatment,which begins in the deoxidising anoxiczone. From here, the sewage moves intothe adjoining aerobic zone, where oxygen is added via submerged diffusers to promote the conversion ofammonia to nitrates. In order to transform the nitrates into atmosphericnitrogen, sewage from the aerobic zoneis pumped at high volumes back into theanoxic zone, where this reaction takesplace.

“It can take a few loops for treatment

Melbourne Water Pumps UpEnvironmental Efforts

APPLICATION STORY

New sewage treatment processes improve final

effluent quality — with Rockwell Automation’s

Integrated Architecture playing a key role in control of

the facility.

The Rockwell Automation system controlsmultiple pumping stations, along with amyriad of flow meters and level sensors.


EtherNet/IP communications backboneconnects a series of six motor controlcentres (MCCs) located outdoorsaround the extensive plant. These take responsibility for controlling differentsections of the activated sludge plant:diffused aeration system including three750-kW blowers, mixers (to ensurethere is sufficient turbulence in thebasin to keep the bacteria suspended)and the various pump stations. Each MCC incorporates at least oneControlLogix and a redundant DeviceNet network to connect a local Allen-Bradley PanelView™ 550 human-machine interface (HMI), localAllen-Bradley Powermonitor™ andCompactBlock I/O™.

To provide local manual motor control, independent of the control system, the unique Allen-Bradley DeviceLogix was utilised. “A small DeviceLogix program is downloadedinto each CompactBlock I/O, which hasa miniprocessor inside,” Manners says.“Each CompactBlock I/O is paired witheither a variable speed drive (VSD) orthe electronic overload relay in a directon-line (DOL) motor starter — as well as hard-wired analogue process instrumentation.

“During normal operation,” Mannerscontinues, “ControlLogix sends commands to and receives informationfrom each drive and motor starter viathe DeviceLogix program. In this case,

to happen, which means the recycle rateis fairly high,” says Gulvosen. The thirdzone of the 25W activated sludge plantcomprises five gravity-fed clarifyingtanks. Here, the bacteria settles to thebottom to be recycled into the front ofthe process as the RAS, and the clear effluent at the top, overflows into Pond2 to make its way through the original lagoon system.

The Rockwell Automation controlsystem at 25W ensures the entireprocess operates effectively and automatically. “The most critical part ofthe process is the oxygenation zone,”says Gulvosen. “The bacteria will die ifthe dissolved oxygen levels are wrong,so the levels are measured via directoxygen probes. Based on this, the control system will allocate the duty cycle for the blowers. There are fivecontrol zones with different air distribution along the length of thebasin.”

The automation system also monitorsa myriad of flow meters and level sensors located throughout the plant.The flow measurements are integral tothe variable speed control of the variouspumping stations, which direct sewagefrom stage to stage, along with the various recycle flows. These flows areall balanced by the control system to ensure the optimum flow throughoutthe plant.

Split the CodeThe Melbourne division of systems

engineering group, SEMF (formerlyknown as Austek), worked closelywith Rockwell Automation and Melbourne Water to deliver the control solution for the 25W activatedsludge plant. This was based on a conceptual design by Sinclair KnightMerz, founded on Rockwell Automation’s powerful hybrid controller,Allen-Bradley® ControlLogix®, alongwith Allen-Bradley DeviceLogix™ toprovide Intelligent Motor Control.The design also included dual-redun-dant EtherNet/IP™ communicationson optical fibre and redundant DeviceNet™ fieldbus networks.

James Manners, SEMF mechatronicsengineer, explains that the dual-redundant, industrially hardened

the DeviceLogix program holds the drive interlock and safety functions that would traditionally have been implemented in the PLC and duplicatedin hard wiring for redundancy. If communications to the PLC are lost, forany reason, the DeviceLogix programcontinues to execute, maintaining fullmanual drive functionality.”

According to David Ellis, process control and instrumentation specialistwith Melbourne Water, this manual control functionality is an essential feature for a critical public infrastructureplant. “Manual control is important for redundancy,” he says. “If the PLC fails, wecan still put the drive into ‘run’ via theCompactBlock. It has also simplified thenumber of components in the motor

Six distributed outdoor motor control centres, linked by a dual-redundant EtherNet/IP fibreoptic communications backbone, control different sections of the activated sludge plant.

Allen-Bradley CompactBlock I/O withDeviceLogix provides Intelligent MotorControl — a critical redundancy featurepermitting full manual operation of thepumps.

Allen-Bradley PLCs



control building and the various MCCsis provided on two optical fibre cables,buried metres apart. Similarly, eachControlLogix includes two Ethernet cards to integrate it with thedual networks.

Ellis says that Melbourne Water hasadopted the dual-redundant Hirschmanhiper-ring arrangement across the whole Western Treatment Plant. Individual EtherNet/IP hiper-ring architectures have been deployed at55E and various other pump stationsand new plants around the site. These are now linked via a central ControlLogix gateway, also located inthe control building.

The ControlLogix gateway allowsseamless connectivity between differentsections of the facility, plus it provides a direct connection to the site-wide SCADA system located in the main siteoperations centre at one end of the vastWestern Treatment Plant site. This SCADA terminal is Western TreatmentPlant’s link to the outside world, and Melbourne Water’s numerous otherplants and pumping stations around thecity.

Child’s PlaySEMF first became involved in the

25W upgrade project in early 2003, aftersuccessfully completing the similar 55Eproject using Rockwell Automationtechnology. “We began developmentwork on the software and bench-testingfor 25W in about August 2003,” saysManners.

starter, as we’ve eliminated a heap of relays that used to provide the redundancy function.”

Not only is ControlLogix adept at handling the sequential control aspectsof the plant, its hybrid nature makes italso ideal for the essential process control parameters — such as dissolvedoxygen levels and numerous flow andlevel loops. “When it came to this project,” says Ellis, “we investigatedControlLogix and talked with otherswho were very happy with the equipment. It has proven itself a robustsystem, and we were happy to adopt thetechnology.”

Ethernet on FibreMaster control of the 25W plant is

provided by a central ControlLogix and PanelView™ 1400 HMI located in a small control building near to Pond 1. Also located here is technologyprovided by Rockwell Automation Encompass™ Partner, Hirschmann, to ensure integrity of the dual-redundantEtherNet/IP communications network,which is established in a hiper-ring configuration.

“The Hirschmann ring-managerswitch sends out a signal in one direction, and so long as it returns onthe other side, the switch creates an artificial break in the network,” saysSEMF’s Manners. “However, if a breakin Ethernet communications is detected,the ring manager removes the barrierand restores the connection.” The EtherNet/IP network between the

Manners explains that a modular approach was adopted for developmentof both the hardware and software.“This means, for example, that thestarter for every pump in a pump stationhas identical code, identical wiring andidentical configuration,” he says. “Duplication was child’s play, as it waspossible to replicate the starter to anynumber of other drives in the MCC,where there might be as many as 10pumps. It also meant that we only had todebug one module of code, instead of10. In the end, commissioning only tookfour months, and MCCs were fully commissioned inside two days.”

This modular approach, enabled byRockwell Automation’s RSLogix™ 5000 programming software, not only reduced programming and commissioning time but also provides ongoing benefits for maintenance and diagnostics. In addition, it has allowedSEMF to extend the control system philosophy to subsequent projects carried out at the site — namely, the recently completed biogas regenerationand water recycling plants.

Both are also important elements ofthe Environment Improvement Plan.The biogas plant converts the emittedgases from the anaerobic stage intoelectricity while the water recyclingplant further treats the high-quality effluent from 25W and 55E to make itsuitable for irrigation.

The new 25W activated sludge plantwas commissioned on 20 September,2004. Both 25W and 55E now have capacities of 180 ML per day (increasedfrom 100 ML per day). This means that thetraditional land filtration system, whichoriginally treated around 30 percent ofthe 500 ML of sewage received per day atWestern Treatment Plant, is no longer required. Moreover, Melbourne Water hasmet its targeted nitrogen load of 2,700tonnes per year into Port Phillip Bay,down from 3,700 tonnes per year prior tothe 55E upgrade. AT

APPLICATION STORY

o n t h e w e b

For more information on Intelligent MotorControl, visit:www.rockwellautomation.com/solutions/intelligentcontrols/

Trevor Gulvosen, Melbourne Water senior process engineer, inspects the PanelView screeninside one of the MCC shelters.

DeviceLogix DefinedSmart components execute logic

functions independently of a centralprocessor. In a distributed environment,smart devices process functions andlogic rather than communicating backto a PLC. DeviceLogix™, introducedfive years ago, is the Rockwell Automation technology that enablesthem to do so.

DeviceLogix is a function that controls outputs and manages status information onboard smart devices. ADeviceLogix-enabled component combines inputs and/or outputs and local logic functions to determine its behaviour.

Inputs and outputs can be physical ornetworked. Physical inputs and outputsare realised by physical connections tothe device. In a networked environment,the device accepts inputs from othernetworked devices and produces outputs onto the network.

T here is no doubt about it. Factoryfloor devices are becoming“smarter” with each new generation.

The emergence of smart componentsin control system architecture reflectsthe increasing ability to integrate low-cost computational power into actuators, I/O blocks, motor startersand other general-purpose control system components.

What this means for system-level end-users and original equipment manufacturers (OEMs) is that smartcontrol system components can perform simple control functions suchas Boolean logic execution, signal-conditioning, event detection andalarming. Being able to perform thesefunctions at the local level translatesinto cost savings through reduced design time, quicker installation, improved diagnostics, optimal systemperformance and improved processmaintainability.

The local logic of a DeviceLogix component is programmed using a variety of different function blocks outside of the embedded inputs, outputsand diagnostics information. Thesefunctions include Boolean operatorssuch as AND, OR, XOR, NAND, NORand XNOR. Bi-stable latches such as RSand SR are also available in addition toUp Counters, Down Counters, PulseTimers, On-Delay and Off-Delay Counters.

Users configure DeviceLogix featuresthrough RSNetWorx™ for DeviceNet™.A software tool called the DeviceLogixEditor ships as part of RSNetWorx,which operates in an offline or onlinenetworking mode.

Taking ControlAndy Jaap, Rockwell Automation

Smart Motor Controllers product manager, explains how DeviceLogixcomponents make a difference in distributed control environments. Firstand foremost, they provide local logiccontrol. Carrying out logic control at thedevice level rather than at a centralisedmaster controller leads to fast inputsense to output actuation. Since the logic needed to perform an operation resides within the smart device, the timefor an input to be sensed and for an output to be actuated decreases significantly.

“Smart devices avoid network turnaround and I/O scans,” Jaap explains. Depending on the products, a 1ms to 2 ms response time is possible compared with turnaround times in someprocess applications of up to 500 ms.

Local logic control also reduces overall network traffic. That is becauselocal control requires less messaging. In addition, there is increased performance when local logic control iscombined with DeviceNet’s Change ofState (COS) messaging. COS messagingallows notification to be sent to a mastercontroller any time a locally controlledoutput changes state or when timers orcounters reach their preset values.

Local logic control also translatesinto smaller programs in a controller.This saves memory and reduces scantimes.

TECHNOLOGY WATCH

Smart Devices Bring Decision-Making to the Local LevelDeviceLogix components control output and manage

status information in a distributed control

environment.

With a Rockwell AutomationArmorStart component programmedwith DeviceLogix, a pallet conveyorsystem can be controlled toachieve zero-pressureaccumulation, reduce powerconsumption or noise, or managefast-response applications like adiverter.

With a Rockwell AutomationArmorStart component programmedwith DeviceLogix, a pallet conveyorsystem can be controlled toachieve zero-pressureaccumulation, reduce powerconsumption or noise, or managefast-response applications like adiverter.


With a Rockwell AutomationArmorStart component programmedwith DeviceLogix, a pallet conveyorsystem can be controlled toachieve zero-pressureaccumulation, reduce powerconsumption or noise, or managefast-response applications like adiverter. Allen-Bradley PLCs



difference between a process operatingefficiently or not. Ed Joe, Rockwell Automation DeviceLogix program manager, explains, “In this type of application, sections of a conveyor system typically are managed in zones,or small areas. Companies use DeviceLogix programming logic embedded directly in a component tocontrol local zones as small as 10 ft.”

Joe notes that a product such as theRockwell Automation ArmorStart®

Distributed Control has the ability to notonly control the process within a localised zone of a production line butalso to react very quickly — in less than2 ms — to events occurring in otherzones on the line. “The ArmorStart product,” says Joe, “can manage largerhorsepower motor applications typically seen in a conveyor system, likea diverter, and takes advantage of thelogic working in its own processor foroperational control.”

Jaap cites another example of DeviceLogix in action. In a food processing plant, if products in dangerof spoiling were only partially through aprocess when a PLC went down,

DeviceLogix components also play akey role in ensuring local network redundancy. Their use increases systemreliability, improves diagnostics and reduces troubleshooting. In traditionalsystems, failure of the master controllermeans a loss of control at the variousdistributed I/O nodes. Upon detection ofthe master controller’s failure, the outputs of the distributed I/O nodes typically configure to transition into a“hold-last-state” condition or into someother user-defined safe condition.

Jaap notes that the value of local network redundancy is evident inprocess continuation and controlledshutdowns. Because the smart components operate independently of aPLC, users have the option to execute amore complex sequence of actions upondetection of a fault, enabling them tocontinue to run a process in the event ofa network interruption or to safely shutdown critical operations.

In the material handling industry, for example, the ability to achieve “zero-pressure accumulation” — in whichheavy loads do not bunch up and motorsdo not overload — can make the

DeviceLogix components can continueto operate based on preprogrammedlogic and execute the process to a finalstate, or shutdown procedure, thuseliminating or reducing scrap. There aremany other applications like these — inwarehouses, packaging processes, discrete manufacturing and batch processing — where DeviceLogix hasprovided an effective solution to a demanding production problem.

Distributed IntelligenceOver the past few years, Rockwell

Automation has introduced a number ofDeviceLogix-enabled components, according to Jaap. All have been designed to provide more power and diagnostics at the local level.

Smart I/O systems, for example, deliver fast sense-to-actuation time andcan indicate malfunctioning devices,short circuits and other problematicscenarios. CompactBlock I/O™ fits into shallow enclosures, operator workstation panels, pushbutton stations or wireways. The ArmorBlock®

MaXum™ and high current ArmorBlock I/O products feature

Data Comm over Fiber Optics

• Compatible with all A-B protocols• Configurable for all network

topologies• DIN-Rail mounting, modular

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for Class I, Div 2

Fiber Optic Converters for Bus

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RS-232/485 • DH-485 • REMOTE I/O • CONTROLNET • DH+ •

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TECHNOLOGY WATCH

Ethernet over Fiber Optics• Two-fiber Self-healing Ring – Media

Redundancy• Switched Media Converters• Fully Managed & Unmanaged

Switches• Expandable Ethernet Modules• Multi-mode or Single Mode

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wwww.weedinstrument.comTel.: +1 512 434 2850Fax: +1 512 434 2851


The ArmorStart Distributed MotorController family is an integrated, pre-engineering starter for three types ofapplications. The Bulletin 280/281 ArmorStart model is designed for full-voltage and reversing applications;Bulletin 283 ArmorStart delivers a softstart, in which the motor is raised from aninitial torque value to full voltage; and theBulletin 284 ArmorStart features volts-per-Hertz mode of operation, amethod that provides speed regulationand high levels of torque across the speedrange of the drive and improved speedregulation even as loading increases.

The100-DNY DeviceNet Starter Auxiliary is optimised for use in enclosed starters as well as multi-motorstarter control panels. It provides fastresponse to controller inputs and performs functions such as signal conditioning, event detection andalarming without the need for additionalcomponents, such as mechanical timersand relays.

The Evolution of IntelligenceToday’s DeviceLogix-enabled devices

provide simple logic control, but

sealed-housing blocks suitable for On-Machine™ or back-panel mounting.The 1799 Embedded I/O products areprinted-circuit boards for machine-embedded applications.

The 800E/F and 800T Push Button Stations are designed for applicationswhere response time is critical, such asmotor E-stop notification or a quick jogging operation. Horizontal and vertical models with enclosures in 2-, 3-and 4-hole configurations are available.

The E3 Plus Solid-State Overload Relay constantly monitors motor operation, following trends and allowing remedial action to be taken before potential failures occur. It provides ground fault and thermistorfunctionality and protects against thermal overload, phase loss, underload, stall, jam and current imbalance. For high capital cost installations and applications whereproduction downtime is to be avoided,the 825-P Modular Protection Systemmonitors the critical elements of three-phase low- and medium-voltagemotors including current, line voltageand temperature.

according to Joe, tomorrow they willprovide even greater functionality.

A new release of DeviceLogix is currently under development that willenhance the runtime firmware library,including the addition of new analoguefunction blocks. EtherNet/IP is also being evaluated for future versions. Inaddition, the software configurationtool now includes a ladder logic programme editor.

According to Joe, there will be evenmore Rockwell Automation productsusing smart component technology enabled by DeviceLogix over the next several years. “The beauty of DeviceLogix is its flexibility to develop avery unique control automation solution,” says Joe.

“DeviceLogix technology,” agreesJaap, “is completely adaptable. Its onlylimiting factor is the creativity of theprogrammer.” AT

o n t h e w e b

For more information on DeviceLogix-enabled components, visit: www.ab.com

Allen-Bradley PLCs



E lectric capacity in the People’s Republic of China is rising, andprivatisation has enabled new

investors and independent power producers to enter the market. In addition,new government environmental protection incentives have brought tolight the need for more efficient, cleanerenergy production — especially for coal-fired plants, which account for nearly 75 percent of the power generationin the country.

Two coal-fired plants — the government-operated Zhenhai PowerPlant in Zhejiang Province near Shang-hai and the Tianjin JunliangchengPower Plant in North China — are working to reduce costs, increase plantefficiency and enhance their positionswithin the burgeoning marketplace.Part of their strategy includes utilisingtechnology from Rockwell Automation.

The Zhenhai Power installation operates four 200 MW and two 125 MWgenerating units and generates between5 billion to 6 billion kWh annually. Theinstallation includes three drainagepumps, corresponding to three feed-water heat exchangers needed in eachgenerating unit. The drainage pumpsuse a mechanical choke valve at the water outlet to adjust the amount of water drained from the heat exchangers.

In the past, rapid changes in the required pump flow rate occurred withvarying power demands, resulting in thepumps running faster and expendingmore energy than necessary. At low flowlevels, the pumps also became easily exhausted and experienced cavitation due to the accumulation of airwithin the partially filled pump chamber.

Zhenhai Power enlisted ZhongnengGreat Wall Control Company, a

The traditional system at the Junliangcheng Power Plant relied on anelectromagnetic clutch system tochange the speed of the pulverised coalfeeder and thereby adjust the amount of coal powder fed to the burners. However, it could not adjust the feeder’smotor speed quickly to the changingload conditions. As a result, the boilerburned unstably and often used more coal — and generated more emissions — than current load conditions warranted.

Zhongneng Control recognised better control of the pulverised coalfeeder was key to the solution, so it recommended replacing the electromagnetic clutch mechanismwith a completely integrated digitalcontrol system. The OEM selected theAllen-Bradley Bulletin 1305 AC variablespeed drive. In all, 64 Allen-Bradley1305/5-hp drives were used, which encompassed the pulverised coal feeders on all four 200MV generators.

With the new Allen-Bradley 1305 ACdrives controlling the pulverised coalfeeder’s speed, the amount of coal powder fed to the boiler now correlatesprecisely with the load requirements.Comparing the electromagnetic clutchsystem, the feeder with the new drive inplace has a 40 percent energy savings, which will allow Junliangcheng Powerto achieve payback for the drive installation in only 20 months. AT

VALUE PROPOSITION

o n t h e w e b

For more information on Allen-Bradley ACdrives, visit:www.ab.com/drives/1336PlusII/ andwww.ab.com/drives/1305/

Beijing-based OEM focused on the energy industry, to develop a solution.While the traditional choke valve system controlled the water outlet and flow rate, which impacted thepump speed, Zhongneng Control recommended installing a drive to directly control the velocity of thepump motor — and thereby the waterflow rate — in line with load demands.

For this retrofit, Zhongneng Controlchose three Allen-Bradley®1336 PLUS™II adjustable frequency AC drives in 75kW, 55 kW and 37 kW ratings — one foreach of the three drainage pumpsutilised for each generator. The solutionwas applied to all four 200 MW generating units.

Zhenhai Power is pleased with the stable performance of its pumps — andits energy savings. While the 75 kWpumps typically consumed 145 amps before the drive solution was installed,they now generally draw just 98 amps.This energy savings of more than 30 percent has allowed Zhenhai Power torecover the investment for the new drives in just 16 months. And, four yearsafter installation, Zhenhai Power has yetto replace a drainage pump due to corrosion. As a result, Zhenhai Power estimates annual replacement savings ofnearly US$19,300, or US$77,324 in thefour years since the drives were installed.

The Tianjin Junliangcheng PowerPlant faced a specific government stipulation that required electric generators under 200 MW to conform tonew environmental emission standardswithin five years. With four generatorsfalling within the 200 MW limit, Junliangcheng Power also turned toZhongneng Great Wall Control Company for a solution.

Power Plants Rely onAC Drives to ReduceEnergy ConsumptionAllen-Bradley AC drives from Rockwell Automation enable Chinese

coal-fired plants to improve energy efficiency.

The Allen-Bradley® SLC™ 500-Seriescontrollers include enhancements thatimprove messaging performance over Common Industrial Protocol(CIP)-based networks and providehigher levels of security in controlsystem programming. Thesefeatures are available in Allen-Bradley SLC-5/03, -5/04 and -5/05 controllers with Series C, VersionFRN-10 firmware, and require RockwellSoftware® RSLogix™ 500, Version 7.10or higher, for programming andconfiguration.

New instruction updates allow generic CIPcommands to be initiated in devices, such asdrives, that communicate on EtherNet/IP™,ControlNet™ and DeviceNet™ networks. The instructions greatlysimplify the programming, configuring, monitoring andtroubleshooting of explicit messages on ControlNet andDeviceNet. In addition, users of SLC-5/05 controllers can nowleverage the new explicit message capability on an EtherNet/IPnetwork.

The new firmware release for the SLC-5/03, -5/04 and -5/05processors includes a secured processor capability through

Rockwell Software RSAssetSecurity™.Using the RSAssetSecurity service of

the Rockwell Software FactoryTalk®

suite of production andperformance management software,

the RSLogix 500 programming softwarecan configure a processor to be moresecure against unauthorised access. Once

secured, only users authorised byRSAssetSecurity will be able to upload

or download this processor.A new Read Program Checksum instruction

helps evaluate the checksum ID of a processor’sladder programme. It can be used within the user ladder

logic to determine whether online edits have changed theprogramme or can verify that the programme in the memorymodule matches the programme in the processor’s RandomAccess Memory. In addition, the Dynamic Host ConfigurationProtocol (DHCP) provides flexible IP address assignment for theSLC-5/05 processor Channel One Ethernet port as well as theBootstrap Protocol.

For more information, visit:www.ab.com/programmablecontrol/plc/slcsystem/controllers.html

Architecture. In addition, the CompactLogix 1768-L43 platformwill support the 38 embedded motion instructions and preloaded motion parameters currently offered on theControlLogix controllers. What’s more, it employs RockwellSoftware® RSLogix™ 5000 programming software so users canmove easily from one Logix application to another with noadditional program development or training.

In the end, customers can leverage all the benefits of KintexIntegrated Motion while cost-effectively integrating their smallmotion applications with the rest of the enterprise.

For more information, visit:www.ab.com/programmablecontrol/pac/compactlogix/index.html

The latest addition to the Rockwell Automation® Kinetix®

Integrated Motion offering is the Allen-Bradley® CompactLogix™1768-L43 controller. Featuring a small, modular footprint, itcontrols up to four axes of motion in material handling,packaging, metal forming and other applications in which speed,motion synchronisation and information-sharing are required.

The controller combines the benefits of a SERCOS interfaceand EtherNet/IP™ with a powerful, cost-efficient processor. Italso supports DeviceNet™ and ControlNet™, enabling a seamlessflow of information from the smallest device up through theenterprise business system.

The CompactLogix 1768-L43 platform eliminates the need fora battery, reducing maintenance and support issues. It alsosupports removable CompactFlash memory that can be used as aprogramme and firmware storage area, providing users with theability to archive projects that can be loaded into multiplecontrollers.

CompactLogix leverages the same Logix control engine,motion, networking technology and communications services asthe Allen-Bradley ControlLogix® and SoftLogix™ controllers,making it part of Rockwell Automation’s scalable Integrated

CompactLogix 1768-L43 Combines Motion and Sequential Control in Small Footprint

Improve Network Messaging and Security with SLC 500-Series Controllers

PRODUCT FOCUS


Allen-Bradley PLCs


PRODUCT FOCUS

• High-speed oscillographyThe power-metering hardware combines with Rockwell

Software® RSEnergyMetrix® power management software andsystem integration services to provide a complete energymanagement package that helps achieve proactive demandmanagement.

For more information, visit:www.ab.com/PEMS/pm3000/pm3_idx.html

Rockwell Software® RSEnergyMetrix® is a new web-enabledenergy-management solution that combines data communicationtools, client-server software and advanced web technology tocapture, analyse and store energy information, enablinginformation-sharing across the enterprise.

The energy-management solution can track energy usage, costand power quality data. Load-profiling, cost-allocation and billingcapabilities allow users to correlate energy costs to productioncosts and provide accurate cost-accounting based on energyconsumption. Users can view real-time data, create historicaltrend reports and charts to develop energy budgets andforecasts, negotiate better rates and make decisions on electricalcapacity and quality to help avoid unscheduled shutdowns.

RSEnergyMetrix includes a core energy manager that acts asthe data-logging, reporting, charting and billing package.Connectivity to Allen-Bradley power monitors and programmablecontrollers is standard, with optional third-party deviceconnectivity. The energy manager runs on the Microsoft®

Windows Server™ and uses Microsoft .NET™ and XML webservices and technologies so users can access, configure andshare management information via the web.

The manager can be configured for any energy- and production-related inputs, including electricity, gas, water andsteam meters. Legacy meters can be added manually. UsingMicrosoft .NET security, meter configuration values can be set upand changed remotely via the web, with multi-level passwordprotection and privileges.

A real-time communications, configuration and data-displaypackage allows users to configure and view real-time andhistorical power monitoring data. It displays waveforms andharmonics in a graphical or log format to provide acomprehensive electrical system view.

For more information, visit:www.rockwellautomation.com/rockwellsoftware/assetmgmt/energymetrix/


The Allen-Bradley® Powermonitor™ 3000 digital power meterenables facility engineers to monitor and collect energy usageinformation. Designed for industrial process applications withhigh electrical demands – such as food, beverage and processapplications – the compact meter provides vital information fordocumenting and tracking energy consumption, enablingelectrical usage load-profiling and supplying delivery data neededfor activity-based accounting. Information also allows facilityengineers to manage load requirements to increase systemperformance and achieve energy cost savings.

The digital power meter is equipped with a standard RS-485DF1 half-duplex and Modbus™ RTU communication port with theability to accept one additional communications option, providinga cost-effective method for gathering energy usage information.The Powermonitor 3000 can be mounted in a motor controlcentre, eliminating the need for an external enclosure andsimplifying installation.

Additional features of the Powermonitor 3000 include:• Real-time power monitoring with 50 ms update rates• Configurable snapshot data logs that store more than 45,500

data points• Event logs that are 50 records deep• Calculation of total harmonic distortion• Projected energy demand based on trending data

Powermonitor 3000 Monitors and Collects Energy Usage

Optimise Energy Consumption with RSEnergyMetrix

PRODUCT FOCUS

The 42CM is a family of metal-bodied, cylindrical photoelectricsensors intended for heavy-duty industrial applications inindustries such as packaging, assembly, material handling andautomotive. The 42CM LaserSight™, the most recent addition tothe line, is a laser-based version ideal for long-rangeapplications, the detection of small objects andthe detection of registration marks.

The 42CM LaserSight offers three sensingmodes – transmitted beam, diffuse andpolarized retroreflective. This allows thesensor to be used in a variety of complexapplications.

In addition, the sensor addresses long-rangeapplications that standard photoelectric sensors cannot, offeringsensing ranges up to 50 metres in Transmitted Beam, 30 metresin Polarized Retroreflective mode and 300 mm at two timesmargin for the Standard Diffuse. What’s more, the eye-safe Class1 visible red laser simplifies sensor alignment, especially whencompared to traditional photosensors that use an invisibleinfrared beam.

The sensor includes the following features:

• Reverse polarity, output short-circuit (SCP) and overloadprotection

• Small spot size – 0.1 mm at 100 mm sensing distance• NPN or PNP outputs• Fast response time – less than 0.7 ms• Rugged 18 mm cylindrical metal housing, IP67• 2-metre cable or micro QD connector

For more information, visit:www.ab.com/sensors/products/photoelectric_sensors/42CM.html

modules support applications requiringreal-time monitoring of overallvibration levels. These three modulesare compact, easy to install and easy

to maintain. Each measures andreports the overall vibration levelbetween selected high and lowpass filters, as well as the bias(gap) voltage per channel.For stand-alone applications, the

XM-160 series includes comprehensivealarm logic per channel. It also supports the

linking of up to two XM®-441 expansion relaymodules, providing a total capacity of up to eight relays.

XM-161 overall vibration module offers the same capabilitiesas the standard XM-160 but also includes a 4-20mA output foreach channel. The XM-162 incorporates a DC power supplysuitable for powering standard -24V eddy current (proximity)probe drivers.

For more information, visit:www.rockwellautomation.com/xm.

The XM®-160 series of overall machineryprotection modules is a new addition tothe Allen-Bradley® XM series of intelligent,distributed I/O modules. Deployed as eitherstand-alone monitors or as part of abroader networked solution, theXM-160 series is a complete andcost-effective solution fordetecting system deterioration,providing maintenancedepartments with the intelligencenecessary to correct issues beforeproductivity is impacted.

The Allen-Bradley XM overall vibrationmodules can be deployed on an open, standard industrial bus,allowing plant engineering and maintenance personnel tocontinuously and cost-effectively monitor and protect criticalplant-floor assets. Modules can be easily integrated withDeviceNet™ and other XM Protection Modules, PLCs, distributedcontrol systems and condition monitoring systems, and displaydevices.

Specifically, the Allen-Bradley XM-160, XM-161 and XM-162

XM Series Vibration Modules Reduce Unplanned Downtime


Laser-Based Sensor Operates Under Unexpected Conditions

Allen-Bradley PLCs


atap feb. 2005 - ucc.colorado.eduucc.colorado.edu/allen-bradley/atap-sea_2007-03.pdf · intelligent...

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