Turbine Supervisory Instrumentations

8/2/2019 Turbine Supervisory Instrumentations

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TURBINE SUPERVISORY INSTRUMENTATIONSELECTION GUIDE

MEASUREMENT MODULES

RELAY MODULES

POWER SUPPLY

COMMUNICATIONS

SOFTWARE

GRAPHIC TERMINALS

PROGRAMABLE CONTROLLERS


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1

Introduction

In the past, the primary concern for companies that depend on turbomachinery was simply protecting the asset from catastrophic failure. In today'scompetitive environment, companies must not only protect their turbomachinery but they must also protect the people that operate it whilemaximizing production availability by detecting changes early and takingcorrective action.

Rockwell Automation - a global leader in industrial automation with more than100 years of experience serving the changing needs of our customers inindustries such as power generation, oil and gas, and others - understands theimportance of turbo machinery as a primary mover for critical applications and

offers solutions specifically designed to meet the unique requirements ofsteam, gas, and hydro turbines.

For a solution that includes both protection and monitoring of your criticalturbo machinery, Rockwell Automation's proven hardware, software andservices include everything you need to be successful.

XM Condition Monitoring and Protection modules

Our XM condition monitoring and protection system gives you the ability todetect changes and faults as early as possible so that uptime and maintenance

planning are optimized. In addition to this capability, the modular design andopen industry network protocol of XM give you flexibility that results in themost cost effective design, installation and information sharing available.

Emonitor and RSMACC Enterprise Online software

Emonitor and RSMACC Enterprise Online expert data analysis and CMMSintegration software makes storage and analysis of data easy, while making itpossible to integrate this information into CMMS systems so that the databecomes actionable. Emonitor software also integrates data from portabledata collectors and online surveillance systems, giving you a complete pictureof plant asset health.

Services

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


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2 Introduction

TSI System Integration Our integrated solution lowers your total cost by utilizing your existing plantinformation and control platform as well as open industry standard protocols.

Integrated Architecture

Below is an illustration of a typical Rockwell Automation integrated TSIsystem.

Ethernet

DeviceNetVersa View

Emonitor

Enterprise

PanelView

CMMS

RSMACCEnterprise Online

Reliability

OnLineDCS

Proprietary Serial,OPC, Modbus, etc.

Controller


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TSI System Selection Guide 3

Retrofit Integration

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

retrofit system.


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4 Introduction

Turbine System Comparison

Recommendation is in bold text.

Monitoring SystemComponents Steam Turbine Gas Turbine Hydro Turbine

Measurements Radial Vibration - ShaftRelative

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



4-20mA I/O


ControlLogix

OPC Gateway



4-20mA I/O

Reliability Emonitor

RSMACC EOL

ROL

Emonitor

RSMACC EOL

ROL

Emonitor

RSMACC EOL

ROL


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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 tomonitor on your turbine system.

Steam turbine system

Gas turbine system

Hydro turbine system

page 7

page 19

page 25

2 Select modules based on measurement

Match the measurements and the XM modules. Steam turbine system

Gas turbine system

Hydro turbine system

page 11

page 21

page 27

3 Select integration strategy

Choose the HMI and control hardware for yoursystem.

HMI products

Control systems

page 31

page 33

4 Select software

Choose the software product you need toconfigure and manage your system.

XM Serial Configuration Utility

RSLinx software

RSNetworx for DeviceNet software

Emonitor Enterprise software

RSMACC EOL software

page 37

page 38

page 38

page 39

page 40

5 Select project services

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

Engineering design services

Turnkey projects

Reliability Online Service programs

Available product services

TrainingRepair, Exchange & Renewal parts

page 41

page 41

page 42

page 42

page 43page 43

6 Select optional accessories

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

Sensors

Power Supplies

Cables

Junction Box

Enclosures

Sensor Adhesives / Mounting Tools

Portable Data Collectors

Surveillance Monitoring

page 45

page 46

page 46

page 46

page 46

page 47

page 47

page 48


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6 Introduction


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7

Steam Turbine System

Measurements This section describes the recommended vibration monitoring for a steamturbine. Use this information to help you select the measurements that youwant to monitor.

Radial Vibration Measurement - Shaft Relative

Radial vibration measures the radial motion of the rotating shaft relative to thecase. This measurement gives the first indication of a fault, such as unbalance,misalignment, cracked shaft, oil whirl or other dynamic instabilities. Vibrationmeasurements can be made in a single plane or a two plane (X-Y) arrangementwhere the sensors are 90 degrees apart and perpendicular to the shaft. Eddycurrent probes are usually installed in a hole drilled through the bearing capand are held in place by either a bracket or a probe holder.

EXCITERGENERATORLOW PRESSURE

TURBINEHIGH PRESSURE

TURBINE

VALVE

POSITION

SPEED/OVERSPEED

ROTOR ACCELERATION

DIFF. EXPANSION

1 SET TO MONITOR

1 SET SPARE

"A""B"

"A""B"

ROTOR/THRUST

POSITION

"A" & "B"

CASE

EXPANSION

RIGHT

CASE

EXPANSION

LEFTBRG #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


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8 Steam Turbine System

Absolute Shaft Measurement

Absolute Shaft Vibration is a measure of the shafts motion relative to freespace. The measurement is typically applied when the rotating assembly is five

or more times heavier than the case of the machine. Absolute shaft motion isproportional to the vector addition of the casing absolute motion and the shaftrelative motion.

Phase Measurement

Phase is defined as the angle between a reference mark (usually a keyway onthe shaft) and the heavy spot on the rotor. Phase measurement is required foraccurate 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. Duringstart-up, speed is a critical measurement as it allows the operator to: increasespeed quickly through shaft critical frequencies; hold the speed stable duringheat soak plateaus; and, for electric generators, to accurately match thesynchronous frequency before connecting the generator to the power grid.

Acceleration measures how fast speed is increasing or decreasing. It ismonitored by the operator during turbine roll up, so that a steady increase inmachine 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 mayalso provide indication of a bent shaft. This measurement is used by theoperator to indicate when the machine can safely be brought up to speedwithout causing rubs or damage to the seals.

W

D GAP

APPROX.

.060

PREFERRED

(PROTRUSION)

D=1/4W=3/8

OR LARGER

D

W

GAP

(DEPRESSION)

ALTERNATE

AXIAL DRILLED HOLE

3/8"DIA.x 1/4" DEEP SHIM STOCK

EPOXIED STEEL


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Differential Expansion (DE) Measurement

Differential expansion is the difference between the thermal growth of therotor compared to the thermal growth of the case. Differential expansion

monitoring is most critical during a turbine "cold" start-up. A common steamturbine has a thick, heavy case, and a lighter, hollow rotor. Due to the mass ofthe case it will grow slower than the rotor, so the operator must make sure thecase has expanded enough to keep it from making contact with the rotor. Tomonitor, transducers can be placed on a collar or ramp that have beenmachined onto the turbine.

Rotor/Thrust Position Measurement

The primary purpose of the thrust position measurement is to monitor thrustbearing wear and to ensure against axial rubs. Dual (redundant) thrust motiondetection should be used when the machine is required to shutdown. Thismethod requires two transducers mounted on each bearing. When bothindependent set points cross the shutdown limit the machine will be turnedoff. Single thrust motion detection should be used when the machine does nothave to be shutdown and there is another means of verifying thrust bearingfailure. Thrust position measurements are taken within 12 inches of the thrustbearing, monitoring the thrust collars movement between the active andinactive thrust shoes and their subsequent wear. Measurements taken outsideof the thrust bearing area (greater than 12 inches) are generally effected by therotors 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, usuallya throttle valve. It provides the operator with an idea of the current load on amachine 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 ANGLE

a = DETECTED RANGE

c = INDICATED RANGE

Ramp


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Overspeed - Triple Redundant Protection Measurement

Overspeed is one of the most dangerous conditions that can occur in aturbine, and is defined when a machine accelerates beyond its maximum

permissible rotational speed. It is monitored by an Electronic OverspeedDetection 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 expandsfrom its fixed point outward as it is heated. Continuous indication of shellthermal 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 isoperating. These measurements may provide a secondary validation ofoperation or maintenance problems. An increase in a temperature reading maybe due to excessive bearing loading, insufficient clearances, or misalignment.

9-1/23

10-3/16

3-1/44-1/2

15/163/8

2-5/8

3-1/2

3/4

Figure 9-1


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XM Modules The XM series is a group of intelligent, specialty I/O modules designed formachinery protection and condition monitoring. The XM modules monitorcritical machinery parameters such as vibration, temperature, position, andspeed. The XM modules may be applied as a standalone system, or they can beintegrated with existing automation and control systems, including PLCs anddisplays, to provide maintenance and operations with intelligent informationto aid in protecting machinery from catastrophic failures and planningproduction and maintenance activities.

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

If you want to measure select description

Radial Vibration - ShaftRelative

Phase

XM-120 Standard DynamicMeasurement Module

The XM-120 Standard Dynamic Measurement Module is an intelligent,2-channel, general-purpose monitor. The module supports monitoring ofshaft, casing or pedestal vibration in rotating equipment by accepting

input from any eddy current probe, standard accelerometer, or any voltageoutput measurement device such as a velocity or pressure transducer. Inaddition to dynamic inputs, the module accepts one tachometer input toprovide speed, phase and order analysis functions making it capable ofcalculating over 14 critical parameters per channel simultaneously.

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

Absolute Shaft XM-121 Low FrequencyDynamic Module

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

Many of the specifications are similar to the XM-121 Low FrequencyModule. The HPFs available in the XM-121 allow for measurements to beas low as .2 Hz (12 CPM).

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

Speed

Acceleration

XM-220 Dual Speed Module The XM-220 Speed Module is an intelligent 2-channel measurementmodule that accepts input from two tachometers of any standard typeincluding eddy current probes, magnetic pickups, optical tachometers andTTL output devices. The module measures speed, rotor acceleration andpeak speed and is capable of detecting zero speed, locked rotor andreverse rotation. The module may also serve as a component of anElectronic Overspeed Detection System (EODS).


Eccentricity XM-120 Standard DynamicMeasurement Module

The XM-120 Standard Dynamic Measurement Module with alternativeXM-120E firmware, enables eccentricity monitoring, critical for steamturbine operation. The XM-120E firmware is included on the distributionCD with every standard XM-120.

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


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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. Themodule can be configured to measure any of: Axial Position, ValvePosition, Case Expansion or Differential Expansion. The XM-320 supportsmultiple single and dual-probe methods of measuring differentialexpansion. The appropriate method is machine specific and requiresreview of the installation.


Temperature XM-361 Universal TemperatureModule

or

XM-362 Isolated TemperatureModule

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

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

For more information on the temperature modules, see publication

ENMON-TD361.

Triple RedundantOverspeed

XM-220 Dual Speed Module

XM-442 Voted EODS RelayModule

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

For more information on the XM-220 module, see publicationENMON-TD220. For more information on the XM-442 module, seepublication GMSI10-TD048.For more information on the Electronic

Overspeed Detection System, see publication GMSI10-UM015.



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Typical Configurations The following configurations are examples of a typical system. ReferenceOEM specifications and existing sensor dimensions before selectingreplacement 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/mountingtools, 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 Modulewith 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


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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




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Eccentricity Configuration

Differential Expansion (DE) Configuration

Eccentricity Configuration Parts


1440-VST02-01RA XM-120 Standard Dynamic Measurement Module withXM-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 & 1meter armored cable

(1) 8.0 meter armored extension cable

(1) Drive calibrated for 25mm probe 9 meterelectrical length

1


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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 1400Ohm

1

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

1


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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



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19

Gas Turbine System

MeasurementsThis section describes the recommended vibration monitoring for a gasturbine. Use this information to help you select the measurements that youwant 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 theshaft. Eddy current probes are usually installed in a hole drilled through thebearing 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

THRUST

POSITION

"A" & "B"

PHASE

SPEED

SPEED

Typical Gas System Overview

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

Two Plane

Arrangement


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20 Gas Turbine System

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

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

Phase Measurement

Phase is defined as the angle between a reference mark (usually a keyway onthe shaft) and the heavy spot on the rotor. Phase measurement is required foraccurate balancing of any rotor. It also provides an indication of shaft cracks,misalignment, mass loss (such as throwing a blade), and other faults.

Speed Measurement

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

Thrust Position Measurement

The primary purpose of the thrust position measurement is to monitor thrustbearing wear and to ensure against axial rubs. Dual (redundant) thrust motiondetection should be used when the machine is required to shutdown. Thismethod requires two transducers mounted on each bearing. When bothindependent set points cross the shutdown limit the machine will be turnedoff. Single thrust motion detection should be used when the machine does nothave to be shutdown and there is another means of verifying thrust bearingfailure.



Case Mounted

Arrangement

W

D GAP

APPROX.

.060

PREFERRED

(PROTRUSION)

D=1/4W=3/8

OR LARGER

D

W

GAP

(DEPRESSION)

ALTERNATE

AXIAL DRILLED HOLE


EPOXIED STEEL

Dual Thrust

Single Thrust


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


Radial Vibration

Phase

XM-123 Aeroderivative Module

Note: For FFT, TWF andadditional calculatedparameters, the XM-120module (1440-VST02-01RA)should be used in conjunctionwith the XM-123 module.

The XM-123 Aeroderivative Module is an intelligent 2-channelspecial-purpose monitor that is uniquely suited for monitoringAeroderivative Gas Turbines. The XM-123 can be configured, per channel,

to perform either tracking filter or band pass style measurements while italso continuously measures each channels broad band overall level.These capabilities, along with its extraordinary configurability, enable theXM-123 to meet the demanding monitoring requirements of almost anyengine in service today.

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

Speed XM-220 Dual Speed Module The XM-220 Speed Module is an intelligent 2-channel measurementmodule that accepts input from two tachometers of any standard typeincluding eddy current probes, magnetic pickups, optical tachometers andTTL output devices. The module measures speed, rotor acceleration andpeak speed and is capable of detecting zero speed, locked rotor andreverse rotation. The module may also serve as a component of anElectronic Overspeed Detection System (EODS).


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


Temperature XM-361 Universal Temperature

Moduleor


The XM-361 Universal Temperature Module is a 6-channel general

purpose temperature monitor. Each channel can be configured to measureeither an RTD or an isolated thermocouple.


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


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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 OperatingTemperature 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 +350F (-40 to+177C)

2

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

2

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

2

Option 2: Case Absolute

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

1

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

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


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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


EK-2170-0-80 8mm extension cable, 8m 1EK-2108-9-001 8mm probe driver, 9m system 1

Option 2



Thrust Position Configuration Parts


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






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Option 1: Thermocouple or 2 or 3 Wire RTD







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25

Hydro Turbine System

Measurements This section describes the recommended vibration monitoring for a hydroturbine. Use this information to help you select the measurements that youwant 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 theshaft. Eddy current probes are usually installed in a hole drilled through thebearing cap and are held in place by either a bracket or a probe holder.

Shaft

Turbine

SPEED/PHASE

TEMP

TEMPTHRUST

POSITION

"A" & "B"

Generator

CAVITATION

R

A

D

I

A

L

M

E

A

S

U

R

E

M

E

N

T

S

Typical Hydro Turbine System Overview


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26 Hydro Turbine System

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

Vibration measurements can be made by a transducer mounted on themachines 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 oneither the draft tube or turbine head cover.

Phase/Speed Measurement

Phase is defined as the angle between a reference mark (usually a keyway onthe 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 is a measurement of shaft rotation in revolutions per minute. Speed is acritical 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 motiondetection should be used when the machine is required to shutdown. Thismethod requires two transducers mounted on each bearing. When bothindependent set points cross the shutdown limit the machine will be turnedoff. Single thrust motion detection should be used when the machine does nothave to be shutdown and there is another means of verifying thrust bearingfailure.



Cavitation

W

D GAP

APPROX.

.060

PREFERRED

(PROTRUSION)

D=1/4

W=3/8OR LARGER

D

W

GAP

(DEPRESSION)

ALTERNATE

AXIAL DRILLED HOLE


EPOXIED STEEL

Dual Thrust

Single Thrust


29/52



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


Radial Vibration

Phase

XM-121 Low FrequencyDynamic Module

The XM-121 Low Frequency Vibration Module is identical to the XM-120Standard Vibration Module except for the available high pass filter (HPF)selections. The HPFs available in the XM-121 allow for measurements to

be as low as .2 Hz (12 CPM) making it ideal for monitoring low speedmachinery 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 measurementmodule that accepts input from two tachometers of any standard typeincluding eddy current probes, magnetic pickups, optical tachometers andTTL output devices. The module measures speed, rotor acceleration andpeak speed and is capable of detecting zero speed, locked rotor andreverse rotation. The module may also serve as a component of anElectronic Overspeed Detection System (EODS).


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


Temperature XM-361 Universal TemperatureModule

or


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


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


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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


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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


EK-2170-0-80 8mm extension cable, 8m 1EK-2108-9-001 8mm probe driver, 9m system 1

Option 2



Thrust Position Configuration Parts








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Option 1: Thermocouple or 2 or 3 Wire RTD







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31

Integration Products

This section describes the integration strategy. Select the human machineinterface (HMI), control system, and reliability products that best fit yourneeds.

XM systems use the DeviceNet open standard for all communications.DeviceNet is an open, low-level network that provides connections betweensimple industrial devices (such as sensors and actuators) and higher-leveldevices (such as HMIs, PLCs, and computers). The DeviceNet network usesthe 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 monitorsolutions, comprised of integrated display computers, workstations,non-display computers, and flat panel monitors. VersaView products offereffortless management of changing technology, a rugged but cost-effectivedesign, and easier product configuration. All VersaView products provide thelatest 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 Windowsdesktop environments - bringing together features of operator interfaces andindustrial computers. It is a high performance computer with a compact flash

drive and integrated RSView Machine Edition runtime (no activationrequired). Theres no hard disk, no fan, and no moving parts, which meansmaximum reliability on the plant floor. Easy to set up and maintain, VersaViewCE means an open system thats rugged and economical, offering highfunctionality in an easy to use package.


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32 Integration Products

RSView Enterprise Series Software

RSView Enterprise Series software from Rockwell Software is a line of HMIsoftware products designed with a common look, feel, and navigation to help

speed HMI application development and training time. With RSViewEnterprise Series 3.0, you can reference existing Logix data tags. Any changesmade to these referenced tags are automatically inherited by RSView software.RSView Enterprise Series software includes:

RSView Studio lets you create applications in a single designenvironment. It configures RSView Supervisory Edition, RSViewMachine Edition, VersaView CE, and PanelView Plus applications. Itsupports editing and reusing projects for improved portability betweenembedded machine and supervisory HMI systems.

RSView Machine Edition (ME) is a machine-level HMI product that

supports both open and dedicated operator interface solutions. Itprovides a consistent operator interface across multiple platforms(including Microsoft Windows CE, Windows 2000/XP, and PanelViewPlus solutions), and is ideal for monitoring and controlling individualmachines or small processes.

RSView Supervisory Edition (SE) is an HMI software forsupervisory-level monitoring and control applications. It has adistributed and scalable architecture that supportsdistributed-server/multi-user applications. This highly scalablearchitecture 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 maximumperformance in space saving flat panel designs. These electronic operatorinterfaces feature pixel graphics capabilities and high-performancefunctionality in color, grayscale, and monochrome displays. The PanelViewStandard family offers a complete line of rugged electronic operator interfacesolutions in a variety of sizes and configurations to meet specific application

requirements, all with a rich collection of hardware and software featuresdesigned to simplify programming and improve operator productivity. Thehigh performance functionality of the PanelView Standard line includesadvanced alarm handling, screen security, analog gauges, ATA PC memorycard, universal language support, and online printing for more intuitiveoperator control.


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


The XM module may be linked directly to a PLC or other control system viaindustry standard DeviceNet scanner cards. Host controllers can then scanXM modules for data, alarm and relay status information in real-time.Prioritizing messaging insures that changes to any alarm or relay status isimmediately communicated to network controllers.

ControlLogix

The ControlLogix system provides sequential, process, motion, and drivecontrol 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, andmodify it efficiently - with significant savings in training and engineering. Asimple ControlLogix system consists of a standalone controller and I/Omodules in a single chassis.

You can also use the ControlLogix system as a gateway. Include thecommunication modules you need for connectivity to other networks. For thisuse, a controller is not required. The ControlLogix Gateway integrates intoexisting PLC-based systems so that users with existing networks can send orreceive messages to or from other networks.

For more information on the ControlLogix products, see publication1759-SG001.

OPC Gateway

OPC (OLE for Process Control) is a set of industry-standard specificationsthat allow plant floor devices such as DCSs and PLCs to communicate and

exchange data with software applications such as HMIs and ProcessHistorians. The OPC standards allow different automation and controlapplications, field systems and devices, and business and office applicationssupplied by different vendors to work with one another.

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


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XM-500 Ethernet Gateway

The XM-500 Ethernet Gateway provides a powerful bridge between an XMDeviceNet network and Ethernet. The Gateway provides complete DeviceNetMaster functionality and support for a fully populated DeviceNet networkwith up to 63 devices. On the Ethernet side, the XM-500 offers a standardTCP/IP interface and support for the Ethernet protocol. Recommended forsystems designed primarily to communicate with RSMACC EOL andEmonitor.

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 thecapability to bridge explicit messages from an Ethernet/IP network to aDeviceNet network, or scan the DeviceNet network via Ethernet/IP. Can beused with any Logix controller or third party controller with Ethernet/IPsupport. Recommended for systems requiring integration with automationenvironments, 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 forhandling 500 bytes of data in and out from DeviceNet compliant devices. The

other side is a ControlNet scheduled adapter with redundant mediacommunications and a Network Access Port.

XM-440 Master Relay Module

The XM-440 Master Relay Module combines four relay outputs with XM busmaster capabilities to provide remote, shared and voted relay operation fordistributed XM measurement modules. The XM-440 module offers highpower relays suitable for use in most protection applications.

IMPORTANT Rockwell Automation's Encompass Partners provideadditional gateways for almost any network; seehttp://www.rockwellautomation.com/encompass/ forfurther details.


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XM-442 Voted EODS Relay Module

The XM-442 module is designed to mate with three XM-220 Dual SpeedModules to provide an API compliant triple redundant Electronic Overspeed

Detection System (EODS). The XM-442 provides four high power relays thatserve as the EODS alarm and shutdown relays.

4-20mA Outputs

The XM modules offer a 4-20mA isolated analog output per channelproportional to the selected measurement. Each output is independentlyprogrammed to represent any measured parameter, from either channel with amaximum load of 300 ohms. The 4-20mA outputs can interface directly with

existing strip chart recorders and LED indicators to monitor and control thehealth of your turbine system.


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37

Software Products

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

XM Serial ConfigurationUtility Software

The XM Serial Configuration Utility software is an easy to use Windowsapplication for installing and configuring the XM Series modules. The tool canread, write, and modify configurations stored on disk, upload configurationfrom 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 ConfigurationUtility CD that is packaged with the XM modules.

IMPORTANT To use the XM Serial Configuration Utility, connect the PCto a modules 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-floordevice connectivity for a wide variety of Rockwell Software applications suchas RSLogix 5/500/5000, RSView32, RSView Enterprise Series, andRSMACC Enterprise Online Condition Monitor (RSMACC EOL). Inaddition, several open interfaces are provided for third-party HMI, datacollection 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 newproduct within the RSLinx family that provide unparalleled connectivity toLogix processors. RSLinx Enterprise software currently can support workingas a data server for widely distributed RSView Supervisory Edition products,RSSql, RSBizWare Historian, and RSBizWare PlantMetricsapplications, RSView Machine Edition including PanelView Plus andVersaView 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 XMmodules.

RSNetWorx for DeviceNetSoftware

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


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

Emonitor EnterpriseSoftware

The Emonitor suite is a complete machinery information software systemfor Condition Based Maintenance programs. By incorporating multiple datasources, 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 logicallows you to quickly and easily identify problem areas among large amounts of

data.


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40 Software Products

Emonitor historical data can be accessed via any application utilizing thefollowing data access standards:

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

MIMOSA - MIMOSA is an open standard in which equipment assetsoftware components are able to communicate and exchange dataautomatically without propriety or supplier-specific interface protocols.

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

RSMACC Enterprise OnlineSoftware

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

Third Party SoftwareProducts

Rockwell Automation offers connectivity solutions allowing our products tointegrate with a variety of third party data sources directly via OPC, DeviceNetStandard and Scanner Bridges.


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41

Project Services

A TSI system retrofit begins with a walk down of the machine and the creationof a project scope document. From this, a bill of material and quotationdocument will be generated.

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

Engineering Design

Services

Rockwell Automation has the engineering resources and specific TSIknowledge 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 Automations performance history and depth of knowledge help todeliver 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 formost 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 andmaintenance 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 actionableCondition-based Maintenance information.

The TSI system can be designed to be accessed over a phone line orthrough a secure internet connection

Regular or on demand analysis expertise is provided remotely

Asset health information is accessed through the internet with an easyto use web portal (see illustration below)

Select the Product Services Services Menu

Cat. No. Description

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

1443-S-DOC Documentation Service - Reports, Drawings and SystemSpecifications

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

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

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


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Training Utilizing the Rockwell Automation training offerings can significantly improvethe productivity and efficiency of the plant f loor staff by giving them theknowledge, skills and learning aids to maintain both legacy automation systemsand todays 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 forover 12,000 Allen-Bradley catalog products, and renewal parts for many legacyAllen-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


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44 Project Services


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45

Optional Accessories

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

Accelerometers bare the workload in vibration monitoring and data collectionprocessing. Designed for use in a broad range of applications, various types ofaccelerometers including high frequency, low frequency, high temperature, andspecialty sensors offer a variety of frequency ranges and reference sensitivitiesto provide the best selection for each measurement concern.

9000 Series Accelerometers

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

For more information on 9000 series accelerometers, see publicationGMSI10-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 stringentrequirements of the American Petroleum Institute (API) Standard 670. Thesensors are non-contacting eddy-current type transducers that measure thedynamic and/or static displacement of the target relative to the mountingfixture. The system consists of a non-contact pickup probe,oscillator/demodulator (probe driver) and interconnecting cable. Thesesystems are typically used to measure shaft radial and axial vibration, shaft

eccentricity, shaft axial position, case expansion, differential expansion andother instances where non-contacting, relative measurements must be made.

We also provide a variety of probe holder options. For more information on2100 series non-contact pickups and probe holder options, see publicationENACC-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. Thefollowing Allen-Bradley 1606-XLP power supplies are recommended for usewith 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 loadrequired by the XM system. If the total system power requirement exceeds the1606-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 systemfor critical applications. All XM modules provide redundant power supplyinput terminals so if the primary 24V power supply fails, the secondary powersupply 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 industrialvibration sensors to termination and switch boxes, portable data collectors,readout devices, and recording and analysis instruments. For individualproduct offerings, see publication GSMG10-PL001.

Junction Box Rockwell Automation offers a 20 terminal junction box to house electricalcomponents and facilitate wiring. For individual product offerings, seepublication GMSG10-PL001.

Enclosures Rockwell Automation offers a broad line of UL approved NEMA enclosuresto house and protect your XM system. NEMA enclosures are rated by theNational Electrical Manufacturers Association (NEMA) and designed forhazardous 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


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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 preparethe machinery surfaces for installation of the sensors. For individual productofferings, see publication GMSG10-PL001.

Portable Data Collectors A portable data collector is capable of performing condition monitoring datacollection, analysis, and root cause correction. The Enpac portable datacollectors are Windows CE based, high performance, data collectors and signalanalyzers. Their comprehensive measurement capability, analysis functions andease of use make them the perfect tool for a portable predictive maintenancestrategy.

The Enpac 2500 is an easy to use, cost effective, scalable solution that meetsthe 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 arugged 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 windblowndust and rain, splashing water, and hosedirected water; undamaged by theformation of ice on the enclosure.

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

NEMA 12 Indoor use primarily to provide a degree ofprotection against dust, falling dirt, anddripping noncorrosive liquids.


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48 Optional Accessories

Surveillance Monitoring The Enwatch is a cost-effective solution for monitoring the condition of theimportant machines in a plant. It bridges the gap between portable datacollectors with manual periodic update capabilities and more expensivecontinuous monitoring systems.

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


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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.

Documents

Turbine Supervisory Instrumentations