Functional Design Specification

HAIL WATER SUPPLY SYSTEM

Rev. 2 Date: 23.08.09

RTCC
PROJECT NO CSP#1200

Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 1 of 13

HAIL WATER SUPPLY SYSTEM PROJECT

(Vibration Monitoring System)

Vendor Reference Contractor P.O. Vendor Document No.

: : :

AEE2007-RTCC-HAIL SY-PU-EM-CSP1200-PO-EL-013-09 AEE2007-RTCC-HAIL-FDS-000

CONTRACTOR SUPPLIER

: AL RASHID TRADING & CONTRACTING CO (RTCC) : ROCKWELL AUTOMATION

THE DESIGN OR PART THEREOF CONTAINED IN THIS DOCUMENT WAS DEVELOPED FOR TAKREER AND MAY BE UTILISED BY TAKREER FOR ANY PURPOSE RELATING TO THE CONSTRUCTION, MAINTENANCE OR OPERATION OF THE PROJECT.

ELECTRONIC DOCUMENTS, ONCE PRINTED, ARE NON-CONTROLLED AND MAY BECOME OUTDATED

Functional Design Specification

HAIL WATER SUPPLY SYSTEM
Rev. 2 Date: 23.08.09

RTCC
PROJECT NO CSP#1200

Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 2 of 13
Rev 00 01 02 Date Reason For Issue Prep AS AS AS Chkd SG SG SG Apprd SG SG SG Approved EM PM PMC COMPANY

07.06.09 For Approval 16.06.09 For Approval 23.08.09 For Approval

NOTES:
1. Revisions are denoted as follows: (a) By a vertical line in the right-hand margin against the revised text. (b) By a triangle symbol for graphics, the revision number being denoted within the symbol. Revision symbols are positioned adjacent to the revision. 2. Prep = VENDOR/SUPPLIERs specialist

Chkd = Checked by VENDOR/SUPPLIERs specialist Apprd = Approval by VENDOR/SUPPLIERs specialist, if required as per job quality plan EM PM = CONTRACTORs Engineering Manager = CONTRACTORs Project Manager

Functional Design Specification

HAIL WATER SUPPLY SYSTEM
Rev. 2 Date: 23.08.09

RTCC
PROJECT NO CSP#1200

Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 3 of 13
PARAGRAPHS REVISED IN THIS ISSUE Para. No. 5 Added the Customer Supplied drawing Para. No. Para No. Para. No.

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

Functional Design Specification

HAIL WATER SUPPLY SYSTEM
Rev. 2 Date: 23.08.09

RTCC
PROJECT NO CSP#1200

Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 4 of 13
TABLE OF CONTENTS 1. 1.1 1.2 2 2.1 3 4 5 INTRODUCTION ............................................................................................................................5 PURPOSE OF THE DOCUMENT ..................................................................................................5 REFERENCE DOCUMENTS .........................................................................................................5 BILL OF MATERIAL ......................................................................................................................6 HARDWARE...................................................................................................................................6 SYSTEM ARCHITECTURE............................................................................................................7 SENSOR MOUNTING DETAILS....................................................................................................9 DRAWINGS..................................................................................................................................13

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

Functional Design Specification

HAIL WATER SUPPLY SYSTEM
Rev. 2 Date: 23.08.09

RTCC
PROJECT NO CSP#1200

Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 5 of 13 1. INTRODUCTION 1.1 PURPOSE OF THE DOCUMENT

The purpose of the Functional Design Specification is to provide a general configuration for the Vibration Monitoring System applied to the Hail Water Project This document defines the functional requirements for the Vibration Monitoring System to be supplied by M/s Rockwell Automation Middle East This FDS incorporates, and expands upon, information contained in the RFQ documents, as issued at the Project tender stage, and will be used to validate the Vibration Monitoring System functionality This document will be supported by further specifications and design documents forming the contents of the total system documentation. The purpose of this document is not intended to address how functions will be designed and implemented but to address what functions are available.

1.2

REFERENCE DOCUMENTS

This document is best understood with the listed documents available, and they will be referenced to in this document text when relevant. Rockwell Auutomation offer ref QS09/12 rev 3.0 dated April 12, 2009

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

Functional Design Specification

HAIL WATER SUPPLY SYSTEM
Rev. 2 Date: 23.08.09

RTCC
PROJECT NO CSP#1200 2 BILL OF MATERIAL 2.1 HARDWARE
CAT NO. Power Supply System 1606-XL60DR Description

Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 6 of 13

Bazakha Pumps

Tawaren Pumps

Total Qty

SWITCH MODE POWER SUPPLY, N+1 REDUNDANCY, INPUT: SINGLE PHASE 100..120, 200..240V AC MANUAL SELECT, 160-375V DC, OUTEST PLUGOUT: 24V DC 2.5A, EK-46804I: SPLASH PROOF CABLE ASSEMBLY, 32FT; 3SOCKET CONNECTOR TO BLUNT CUT; SHIELDED 3CONDUCTOR; TEFLON JACKET 9842V2 4VELOCITY PROCESS SENSOR STUD 1/4 -28 TO 1/4 - 28 WITH BASE FOR SCREW MOUNTING INDUCTIVE PROXIMITY SENSORS, ST ST FACE/THREADED ST ST BARREL, SHORT BODY, DC, 2WIRE, 18 MM DIA, SHIELDED, LENGTH 55.4 MM, SENSING RANGE 5 MM, NO, TOUGHLINK CABLE 2 M, MOUNTING BRACKET FOR 'INDUCTIVE PROXIMITY SENSORS TEFLON END CAPS FOR INDUCTIVE PROXIMITY SWITCH, SHIELDED, DIA. 18 MM SHIELDED, INDUCTIVE PROXIMITY SENSORS, ACCESSORY, MOUNTING NUTS FOR CYLINDRICAL SENSOR, PLASTIC, DIA. 13 MM, NICKEL PLATED BRASS, INDUCTIVE PROXIMITY SENSORS, ACCESSORY, LOCK WASHERS, DIA. 18 MM, PLATED METAL,

16

Vibration sensors & Studs EK-46804I EK-48956 EK-44153+EK-44156 16 16 16 16 16 16 32 32 32

Proximity Sensor & Accesories 871TM-DH5NE18-H2 871A-BRS18 871A-KT18 871T-N4 871A-LWN18 8 8 8 8 8 8 8 8 8 8 16 16 16 16 16

XM 220 Speed Protection Modules 1440-SPD02-01RB 1440-TB-B XM-220 DUAL CHANNEL SPEED MONITOR, XM POSITION MODULE TERMINAL BASE, 4 4 4 4 8 8

NEMA 4 X Enclosure with Glass Window 1440-E6P600N4XW XM ENCLOSURE 6 POSITION NEMA4x RATED ENCLOSURE with window 4 4 8

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

Functional Design Specification

HAIL WATER SUPPLY SYSTEM
Rev. 2 Date: 23.08.09

RTCC
PROJECT NO CSP#1200 3

Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 7 of 13 SYSTEM ARCHITECTURE

Refer System Architecture drawing Below

Junction Box

4-20mA signals

PLC
VIBRATION SENSORS

Scope of supply = Power Supply Proximity SENSOR S

= XM-220

Vibration & Reverse rotation protection system for HAEL Villages

The main intention of the Vibration Monitoring System is to monitor the Hail Water Project Pumping Station Pumps Vibration Levels and Speed. The Vibration System deployed in this project consists of : a. Model 9842V Velocity Sensors with 4-20 mA output for Vibration Monitoring b. Model 871A Non-Contact Pick-ups for Speed Measurement c. XM-220 Speed Measurement module d. Power Supplies with Redundancy e. Enclosure

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

Functional Design Specification

HAIL WATER SUPPLY SYSTEM
Rev. 2 Date: 23.08.09

RTCC
PROJECT NO CSP#1200

Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 8 of 13
Two 24 V DC Power Supplies, for input supply of 220/110V AC with Redundancy are mounted along with XM-220 Speed Measurement Module in the enclosure. The enclosure to be located at the site within a distance of 10 Meters of the Pumps. The 24 V DC redundant supply is also powers the XM-220 Module. The Vibration Sensors Mounted on the Motor/Pump bearing housing as recommended by the client are connected to 24V DC redundant power supply from the System Enclosure. The 4-20 mA output from each Sensor is directly connected to the PLC as shown in Drawing Ref. # AEE2009RTCC-HAIl-06 for Alarm and Trip purposes. For Speed measurement System two (2) Non-Contact pick-ups for each pump are mounted. The first one is meant for the Speed Measurement and the Second one mounted at 90 Deg.to the first one is used for Reverse Rotation sensing. XM-220 Speed measurement module supplies 24DC Power Supply to both the Sensors. For Sensing the speed, the gap between the Key Phaser/Key Hole and the Sensor face to be adjusted to 5 mm approximately. From XM-220 module, a 4-20 mA Signal is available for the speed measurement and one Change Over Relay Contacts available for the Reverse Rotation Speed Monitoring.

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

Functional Design Specification

HAIL WATER SUPPLY SYSTEM
Rev. 2 Date: 23.08.09

RTCC
PROJECT NO CSP#1200

Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 9 of 13 4 SENSOR MOUNTING DETAILS

Vibration Sensor Mounting The sensor mounting is the most important consideration in getting accurate readings from the sensor. Mounting sensors directly on the case The actual frequency range of a sensor depends on how well it is attached to the machine. Mounting sensors directly to the machine is the most common mounting technique for many vibration sensors. Sensors designed for stud mounting have a base that is drilled and tapped for that purpose. There are two common methods of stud mounting a sensor. In both cases, it is crucial to prepare a flat, smooth, and clean area at least as large as the base of the sensor. If the surface is not prepared properly, some of the vibration energy will be lost, and will not be transmitted to the sensor. Improper mounting can also allow chatter, creating false data. Note: Rocwell recommends following the API 670 requirements for surface finish and flatness, even for non-API installations. If the surface is not properly prepared, it can reduce the detection of higher frequencies. 1. The first method is to spot face the surface, then drill and tap a hole in the machine case or bearing housing where you want to install the sensor. Per the requirements of API 670 appendix C.2.1, the surface finish should be within 0.8 micrometers (.032 mil, or 32 inches) and the flatness should be below 25 micrometers (1 mil). 2. Clean the finished area to remove any rust, dirt, paint, or grease. 3. Insert a set screw leaving enough of the screw above the case to attach the sensor, 4. Typically 1/4 inch. Some sensors come with captive mounting screw and do not need a separate set screw. 5. Apply a thin coating of grease or silicone lubricant to the surface. 6. Use a torque wrench to attach the sensor. Refer to the following table. 7.

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

Functional Design Specification

HAIL WATER SUPPLY SYSTEM
Rev. 2 Date: 23.08.09

RTCC
PROJECT NO CSP#1200

Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 10 of 13

XM-220 Dual Speed Module for Reverse Rotation Monitoring: The XM-220 Dual Speed module is a member of the Allen-Bradley XM series, a family of DIN rail mounted condition monitoring and protection modules that operate both in stand-alone applications or integrate with programmable Logic Controllers (PLCs) and control system networks. The XM-220 is a two channel module that accepts input from any two tachometers of any standard type including eddy current probes, magnetic pickups, optical tachometers, and TTL output devices. It measures speed, rotor acceleration, and peak speed and is capable of detecting zero speed, locked rotor, and reverse rotation conditions. It is also used as a component of the XM Electronic Over speed Detection system. The XM-220 will be configured (using the configuration software) to operate in reverse rotation mode. Reverse Rotation Mode - The two sensors are used to monitor speed and direction of a single shaft. The two sensors must be mounted out of phase from each other so that the rotational direction can be determined by monitoring which sensor the shaft keyway passes first. Position the sensors so that: The keyway passes Channel 1 sensor before it passes Channel 2 sensor as the machine rotates in the forward direction. The sensors are more than 10 degrees apart and less than 170 degrees apart in the direction of forward rotation; 90 degrees is optimum

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

Functional Design Specification

HAIL WATER SUPPLY SYSTEM
Rev. 2 Date: 23.08.09

RTCC
PROJECT NO CSP#1200

Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 11 of 13

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

Functional Design Specification

HAIL WATER SUPPLY SYSTEM
Rev. 2 Date: 23.08.09

RTCC
PROJECT NO CSP#1200

Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 12 of 13

Inductive Proximity Sensor and its accessories dimensions details

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

Functional Design Specification

HAIL WATER SUPPLY SYSTEM
Rev. 2 Date: 23.08.09

RTCC
PROJECT NO CSP#1200

Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 13 of 13 5 DRAWINGS

See attached drawing AEE2009-RTCC-HAIL-01 Total 7 pages Sheet 01 Sensor Mounting Arrangement Overview Sheet 02 Vibration Sensor Mounting Arrangement Sheet 03 Speed Sensor Mounting Arrangement Sheet 04 NEMA4 X Enclosure General Arrangement with Enclosure BOQ Sheet 05 AC Power Distribution Sheet 06 DC Power Distribution Sheet 07 - System Wiring Diagram See attached drawing 091013548-GA updated for location of Sensors

AEEE2009-RTCC-HAIL-FDS-000 Rev 02