APPLICATION CONDITION GUIDEMONITORING

THE XM SOLUTION
If youve ever driven a car with a tachometer then you are familiar with the premise of overspeed. You may or may not understand the mechanical detail, but you know that if the engine speed is allowed to pass the red line on the gauge, then engine damage, at some point, will surely follow. Overspeed of industrial turbines isnt much different: Go too fast, wreck the machine. But there are differences. Overspeed your car and you will ruin your engine, and probably your day. Do the same to the 30,000 HP steam turbine at the nearby power plant and you may well incur millions of dollars worth of machinery damage, plus untold costs due to fire, and possibly even loss of life. The above scenario can and has happened. Steam and gas turbines can and do overspeed. And when they do, the results can be catastrophic. For this reason these machines all include systems to protect them from these events. While there are many types of overspeed protection systems their basic function remains the same: Operate independently of the machines control systems and, in the event that the machine speed exceeds a predefined set point, shut it down.

XM OVERSPEED DETECTION SOLUTIONS

This solution should be applied when the requirements specify either an API-670 overspeed or a TRIPLE REDUNDANT overspeed system.

In most cases two independent overspeed systems are applied. The first system is always mechanical. These typically involve a weighted plunger attached to the shaft. As speed increases the plunger, installed offset from center, is forced outward against a spring. When the centrifugal force is sufficient, usually at about 10% above rated speed, the plunger trips a lever that dumps trip throttle holding oil pressure and the valve slams shut. Most modern engines are fitted with electronic overspeed detection systems (EODS). In these, the EODS uses a magnetic speed sensor to measure shaft speed, continually performs the appropriate comparisons, and trips a relay when the overspeed set point is exceeded. Generally, the EODS relay interrupts power to a solenoid valve that, when opened, dumps the same holding oil from the trip throttle as the mechanical overspeed system. The Allen-Bradley XM family intelligent, distributed I/O modules includes condition monitoring and protection modules with speed measurement capability that serve an overspeed detection application. Selecting the right module will depend on what the requirements of the overspeed application. Non Redundant EODS Dual Redundant EODS Triple Redundant EODS

NON REDUNDANT EODS

If applied, the overspeed function must be implemented independent1 of any other system. This means that the overspeed function must be entirely contained within the single module and not rely on another system or communications network to perform its function. In addition, any applicable standards or manufacturers specifications must be considered before selecting any specific overall architecture.
YOU WILL NEED:
Catalog # Description Qty

1440-SPD02-01RB and 1440-TB-B 1440-VST02-01RA and 1440-TB-A 1440-VLF02-01RA and 1440-TB-A 1440-VAD02-01RA and 1440-TB-A 1440-REX00-04RD and 1440-TB-D 1606-XLP-30E

XM-220 Dual Speed Module and Terminal Base - OR XM-120 Standard Dynamic Module and Terminal Base - OR XM-121 Low Frequency Dynamic Module and Terminal Base - OR XM-123 Aeroderivative Module and Terminal Base XM-441 Expansion Relay 1 Power Supply

1 1 1 1 1 1

DUAL REDUNDANT EODS

Determine the specific applicable standards or manufacturers specifications before choosing. In either case, as with the Non Redundant EODS, the overspeed function must be implemented independent of any other system.
YOU WILL NEED:
Catalog # Description Qty

1440-SPD02-01RB and 1440-TB-B 1440-VST02-01RA and 1440-TB-A 1440-VLF02-01RA and 1440-TB-A 1440-VAD02-01RA and 1440-TB-A 1440-REX00-04RD and 1440-TB-D 1606-XLP-30E

XM-220 Dual Speed Module and Terminal Base - OR XM-120 Standard Dynamic Module and Terminal Base - OR XM-121 Low Frequency Dynamic Module and Terminal Base - OR XM-123 Aeroderivative Module and Terminal Base XM-441 Expansion Relay 1 and Terminal Base Power Supply

1 2 2 2 1 or 2 1

TRIPLE REDUNDANT EODS

The XM EODS is a highly reliable, redundant system that fully meets the performance, measurement and relay requirements of API 670.
YOU WILL NEED:
Catalog # Description Qty

1440-SPD02-01RB and 1440-TB-B 1440-REX03-04RG and 1440-TB-G 1606-XLP-30E 1440-TMR-EODS-K

1 2

XM-220 Dual Speed Module and Terminal Base XM-442 Expansion Relay and Terminal Base Power Supply - OR XM EODS KIT

3 1 2 1

An XM-441 Expansion Relay Module may be added to provide additional relays. If you choose the XM-220 module, only one XM-441 module is needed. If you choose the XM-120, -121, or -123 modules, two XM-441 modules are needed.

STANDARDS
Electronic Overspeed Detection Systems (EODS) range from simple single channel relay devices to sophisticated highly redundant safety systems. The specific EODS selected for a machine is determined by the specification of the engine manufacturer plus any standards that the applicable industry or facility is required to adhere to. Some of the many standards include: API Standard 611 General-Purpose Steam Turbines for Refinery Service API Standard 612 Special-Purpose Steam Turbines for Petrochemical, Chemical, and Gas Industry Services ISO 10436 Petroleum, petrochemical and natural gas industries Steam turbines General-purpose applications ISO 10437 Petroleum, petrochemical and natural gas industries Steam turbines Special-purpose applications

MORE INFORMATION
The XM series of intelligent, distributed I/O modules for machinery protection and condition monitoring can be ordered by contacting your local authorized Allen-Bradley distributor or Rockwell Automation sales office. For further information go to: http://www.rockwellautomation.com/go/xm

If you are installing a new on-line condition monitoring system, or refurbishing an existing one, Project Services provides the expertise needed to ensure your success. From setting up and commissioning standalone, on-line monitoring systems to complete installation of large, complex monitoring solutions, youll receive experience that has proven to be invaluable to customers worldwide. From start to finish, Rockwell Automation will provide a solution for your needs. Our track record and depth of knowledge help us to deliver successful Turn Key projects of all shapes and sizes. Well make sure: Your project needs are properly defined Your solution is planned, designed, built and installed, making sure it integrates with your plant Your project is tested, commissioned before it is turned over to you For more information on Condition Monitoring Services, go to: www.rockwellautomation.com/services

These standards apply to steam turbines, each, slightly different. There are other standards for gas turbines, reciprocating engines, and so on. Also, the standards cover far more than the overspeed protection system as their purpose is far broader. What they do cover, with regards to overspeed, is the systems mechanical components as well as the actual speed limits (10% above rated speed). Most do not cover the details of any Electronic Overspeed Detection System that might be provided. That however is covered by one specific standard: API Standard 670 Machinery Protection Systems API 670 section 5.4.8 specifies the requirements for a triple redundant overspeed detection system. The standard does not permit less capable, single channel systems. However, many engine manufacturers do permit single channel solutions, particularly on some small gas turbines. Ultimately it is the end users responsibility to insure that an appropriate overspeed detection system is provided for the turbo machinery within any facility.

Publication GMSI10-AP041A-EN-E July 2006

Copyright 2006 Rockwell Automation, Inc. All Rights Reserved. Printed in U.S.A.