Upgrading of Legacy Drives to PowerFlex

Upgrading of legacy 1336 Drives

Overview

Obsoleted 1336 Drive which is not a low harmonic drive.

Challenges

1. 336 Drive is difficult to commission, lack of software to commission thus requires manual work to commission the drives, and long process required.
2. No ADC function, parameters of the drives have to be manually key in after every replacement, thus delay in the downtime.
3. 1336 Drive is not a low harmonic drive.
4. No self-diagnosis function to alert the users if there’s any problem.

Solutions

1. The solution was to advise and share with the xxx company the benefits of upgrading the 1336 Drives to PowerFlex
2. HoST pursued and engaged on this
3. Hardware and services were fronted by HoST Pte Ltd. Rockwell CSM team were the ones that carry out the installation and commissioning.
4. Installation and removal of the 1336 Drives were done during the plant shut down period, a total of 4 days of downtime was
5. The total cost was about SGD200K
6. Prior to the job, a couple of things were done;
   • A kick-off meeting was held to align all scope of work. Including Mechanic and Process
   • Prior study of existing programs, circuit diagrams, and existing drives
   • Project milestone planning to meet xxx company requested
   • Managing manpower and lead time of the
7. Scope during installation:
   • During the shutdown window, we only have about 7 to 8 days for the project
   • Dismantling of existing drives and reinstalling of the new PowerFlex
   • PowerFlex 755TR procedures were submitted to the xxx company
   • SAT and FAT were carried out prior to
   • No Load Test and Load Test were carried
   • Test and Commissioning were done
   • PowerFlex 755TR drive parameters were provided to the company

Conclusion

1. The solution improves satisfaction, production, pleasure, work comfort. In terms of ROI and justification, PowerFlex 755 provides the xxx company the following:
   • Predictive Maintenance, faster troubleshooting to help maximum uptime with advance diagnostic
   • Increased motor control performance by High Bandwidth & Torque Smoothness/Accuracy
   • Studio 5000® is the single software tool to configure devices for a Logix architecture
   • Premier Integration provides;
   • Single software tool for controller and drive setup
   • Faster configuration with full access to device data
   • Interface to streamline device configuration and programming
   • Device parameters, control tags, device properties
   • Elimination of mismatch errors
   • Automatic Device Configuration
   • Provides more energy-efficient solution than resistive braking
   • Reduce energy expenses and return energy back to the incoming power supply
   • Reduce the need for braking resistors and associated equipment—save on acquisition, installation and maintenance costs
   • Active front end technology with regeneration and lower harmonics provides means for
   • Provides regeneration and low harmonics with an active front end technology
   • A complete solution that includes, line side converter with regeneration, harmonic filter, and inverter
   • Recover dissipated energy and re-use that energy for other applications
   • Eliminate braking resistors and costs associated with installation, cooling, and
   • Built-in regeneration helps reduce energy consumption by returning energy back to the incoming power supply