New Approach for Intelligent Motor Control Centers
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As steel operations rely heavily on low-voltage motors, the introduction of new technologies which target motor performance have a direct impact on energy, commissioning and maintenance costs. Networking allows for easy monitoring of critical data of each motor or load connected to the intelligent motor control center (iMCC), enabling precise process control. However, the iMCC concept isn’t a new technology. Networked protection relays and speed drivers are mature technologies with consolidated acceptance. Explore new trends for iMCCs including new Ethernet technologies, Web, wireless, biometric devices, and new technologies for metering and motor branch circuit protection. Copyright AIST Reprinted with Permission
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New Approach for Intelligent Motor Control Centers
- 1. New Approach for Intelligent Motor Control Centers Terry L. Schiazza Business Development Mgr. Schneider Electric
- 2. What we will cover today ● Introduction ● Why Intelligent Motor Control ● Basic requirements for an Intelligent Motor Control Center ● Emerging Technology ● Summary ● Audience Questions
- 3. Introduction Why Intelligent MCCs Conventional MCC Intelligent MCC ● Maintenance ● Maintenance ● Lots of cabling ● Based on networks (more points of failure) (“Just one cable”) ● Restrict remote access or Pre-assembled cabling ● Remote access (including Internet) ● Information availability ● Poor information access ● Information availability ● Real time information ● Richness of information ● Future Expansion ● Limitations ● Future Expansion ● Flexible
- 4. Introduction Intelligent MCC Basic Requirements ● Cost-effective solution ● Networking solution from plant floor to board room ● Scalability from simple solutions to advanced requirements ● Maintenance ● Reduce system downtime ● Easy to identify and resolve problems ● Access locally and remotely ● Asset management
- 5. Introduction Intelligent MCC Basic Requirements ● Connectivity ● Open for best-in-class products ● Interoperability and Transparency with control systems ● Easy migration from legacy systems ● User Interface ● Graphical and friendly interface tools
- 6. Intelligent Motor Control Centers Main Components Motor Starters Power Monitoring Network Cabling Intelligent Overload Relays AC Drives
- 7. Predictive Maintenance Asset Management Strategy ● Advanced Monitoring ● Informed Control ● Repair-Focused to Reliability-Focused
- 8. Intelligent Motor Protection Relay Backbone of the MCC ● Full functionality, protection and monitoring availability by means of configurable control ● Accurate measurement ● Numerous alarms & trip thresholds ● Sharp analysis of motor operating conditions
- 9. Industrial Ethernet ● Standards reduce cost ● No special tools or proprietary expertise required ● Product evolution and cost reduction driven by the market ● Simple and efficient network ● Easy to use and maintain ● Common network for all enterprise levels (Device/Control/Supervision) ● Performance guaranteed by the hi-speed network combined with a switched priority network
- 10. Industrial Ethernet ● No vendor dependence ● Same network standards, installation rules and guidelines (applied from the IT level to factory level) ● Wide infrastructure and product offer (market)
- 11. Emerging Technology Embedded Web Servers ● Information accessible by simple Web browsers - multi-access easily supported ● Pre-defined screens “ready-to-use” ● Product health status ● I/O and data values AC Drives Motor Starters ● User customizable pages to integrate images and live data ● Replaces some low end SCADA or HMI ● Email servers
- 12. Emerging Technology Wireless Push Buttons ● No wiring and no battery 1 The energy is provided 3 … and sends a .. … by pressing the button… radio signal only once… 2 … which converts a mechanical energy into electrical energy Transmitter Receiver 4 … this signal … activates the receiver output Just one momentary push to send a radio signal
- 13. Emerging Technology Advanced Circuit Breakers ● Energy measurement ● Capability for front display module ● Communications
- 14. Emerging Technology Arc Flash Mitigation System Design De-energize Equipment Site Safety Procedures Avoidance Intelligent MCCs Remote Racking Electric Operation of CBs Passive Protection Passive Containment Virtual Mains Installation Considerations Zone Selective Interlocking - Plenums (ductwork) Bus Differential Relays - Size of Equipment Low Arc Flash CB AF - Equipment location High Resistance Grounding Arc Flash Sensing Relay Active Protection Interactive Arc Flash Sensing Relay Arc Flash with Arc Quenching technology Energy-Reducing Maintenance Switches
- 15. Summary Experience the Benefits of an Intelligent Network ● Remote monitoring capability ● Reduced downtime and system interwiring ● Control to every bucket ● Lower commissioning costs ● Flexible configuration ● Cabling system compliant to applicable standards
- 16. Thank You Terry L. Schiazza Business Development Manager Schneider Electric
Editor's Notes
- Fabio Mielli Business Development Mgr. – Mining, Metals & Minerals Program Segment Located in Alpharetta ----------------------------------------------------------------------------------------- Users need to protect motors the best they can due to their large utilization. The protection of motors is not because of the motors themselves, but because an inoperative motor can mean that the entire process becomes unavailable. It can cause loss of production, higher maintenance costs and unacceptable risks in any critical process. Thus, by better protecting the motors, you are, in fact, better protecting the plant processes. [CLICK]
- Protection is a critical issue in metal and steel industries. It includes not only the protection of the motors and of the process, but also personnel protection, including operators and maintenance staff. Traditional motor protection solutions, based on thermal overload relays, are unable to communicate with a higher level process control system. These conventional solutions are no longer able to answer to the requirements of continuous process industries and infrastructures. [CLICK]
- From Control Evolution to Control Revolution [CLICK] MCCs are used where a central control point is needed to remotely operate multiple loads. [CLICK] In industrial facility applications, the central control point is usually an environmental control system, with an HVAC pump and fan loads. Industrial process applications include many different and varied load types. [CLICK] These loads often require coordinated control and can be the source of important process or machine diagnostic information. Distributed control systems or PLCs are used normally to provide this control and data acquisition functionality. [CLICK] In today’s competitive business environment, the definition of an intelligent MCC is: “An integrated system that provides equivalent or greater functionality more economically than a standard MCC.” In other words, an intelligent MCC is simply an MCC that maximizes the value of the components in a given application. [CLICK] But how does one determine maximum value? Is it based on the cost of the equipment? Certainly not. The cost to design, specify, purchase, install, commission, operate, maintain, and upgrade an MCC are all factors that affect the total product cost. But “value” is measured differently. [CLICK] Every person in the chain is likely to define intelligence according to his perception of value. For example, consultants that design and specify equipment are interested in the reliability and performance of the components. A contractor may be primarily concerned with equipment and installation costs. A facility manager is likely to be concerned about the ease of operation and amount of maintenance costs. Operations personnel are focused on the functionality and durability of the entire system. [CLICK] Regardless of job function, every person’s perception of value regarding MCC intelligence has a common underlying solution: a design that fully optimizes every component of the equipment specific to that function. [CLICK]
- [CLICK] When specifying intelligent MCCs for your application you should consider cost, capability, and complexity; assess your capabilities and objectives realistically; and keep in mind that additional functionality usually comes with additional cost or complexity that you may not need. [CLICK] Before diving in, ask yourself the following questions: • Will I maximize my return on investment by lowering the installed cost of the MCC equipment or by providing significant additional functionality? • Will last minute changes be likely? • Is future expansion or modification likely? • How valuable is a reduction in installation and commissioning time? • Can the equipment be integrated into my overall control and information architecture? • Does my control system or network have enough capacity to handle the data provided? Do I have a technical staff capable of maintaining the system? • What are the cabling and connection requirements of the system? [CLICK]
- A good MCC supplier will offer a range of options; one size does not fit all. The manufacturer should be able to help you answer these questions, so you can select the best approach for your application. The supplier should be able to integrate with multiple networks and existing control systems. They must work with third parties and system integrators that can add value. And should provide total solution packages, where appropriate. [CLICK] Finally, a complete, functional test of the equipment before shipment is essential to realizing reductions in commissioning time. Be sure the vendor intends to conduct the test by actually energizing the I/O, not with simple point-to-point wiring checks. So what is an intelligent MCC? It all comes down to a design that is intelligent in form and function. [CLICK]
- [CLICK] In the 1990s, the revolution took off. The use of electronic components in MCCs grew dramatically. [CLICK] Solid state overload relays provided the traditional electromechanical starter with increases in protective and diagnostic features. [CLICK] Drives and soft starts offered additional functionality and protective features. [CLICK] Today, the most complex systems actually delegate control, diagnostic information acquisition, and advanced protection tasks to these electronic devices. [CLICK] Communications are now incorporated directly at the device level through a variety of cabling solutions. [CLICK]
- [CLICK] You can’t control or manage what you can’t measure. What do you want to know about a tripped circuit? …..Think if you could add the why to the what, or when did the circuit trip, or where and how often. How much more would you know about that tripped circuit? Utility and equipment level metering is not good enough anymore. Protection information, Internal and External data, real-time and historical trending aids in the troubleshooting process versus human detection [CLICK] Automate your process with informed decisions. You can get protection information and Internal and External Data with an intelligent MCC, as well as monitoring data and data storage. This can be done at the device level or supervisory level, remotely or locally. [CLICK] Predictive Maintenance moves you from a Repair-focused asset management strategy to a Reliability-focused plan. You now have Actionable intelligence – there is now a correlation of downtime event with the time of day, the specific machine operator, or equipment set-up procedure. It is a shift from Preventative Maintenance , done per a schedule not a need; to Predictive Maintenance , based on a feedback loop, that reduces unnecessary downtime, saves on equipment costs, maintenance time and overall cost, for the life of your process. Predictive maintenance allows you to efficiently schedule maintenance shutdowns and increase performance or “speed” of the operation or process. Let’s look at a very simple example of preventative maintenance that we have all experienced, changing your oil. Every 3000 miles or 3 months whether you need it or not. But a shift to predictive maintenance is now possible with today’s technology, same thing with an intelligent MCC. [CLICK]
- [CLICK] The microprocessor-based controller is the central component in the system that manages the control, protection and monitoring functions of single-phase or 3-phase AC induction motors. These devices are typically current and voltage sensing devices. They have full functionality, protection and monitoring availability by means of configurable control. [CLICK] More accurate sensors and solid-state full motor protection ensures better utilization of the motor. [CLICK] The devices monitor current, ground-current and motor temperature sensor parameters, they can also monitor voltage and power measurement functions. This is very a critical aspect of these type of components. The controller uses these parameters in protection functions to detect fault and warning conditions. The controller’s response to fault and warning conditions is fixed for the predefined operating modes. [CLICK] You can configure these motor protection functions to detect the existence of undesirable operating conditions that, if not resolved, can cause motor and equipment damage. All motor protection functions include fault detection, and most protection functions also include warning detection. The devices can be designed to work over various fieldbus protocols and s hould have multiple communication capabilities like Profibus, DeviceNet, Modbus and Ethernet [CLICK]
- [CLICK] The paper highlighted the major differences between an Office Ethernet and the Industrial Ethernet in various comparative areas including the Environment, Layout and Performance. Ethernet refers to the way that data accesses the network, how the messages are framed for transmission and reception and the physical characteristics of the network: topology, cables, connectors and infrastructure. Industrial Ethernet is the commercial name adopted by the industrial automation market segment to refer to the use of Ethernet in an industrial environment. The term is now so generic that other Internet technologies are included even if Ethernet itself is not present. For example, Ethernet is not used in an industrial wireless 802.11 communication, but it is still considered an industrial Ethernet application. [CLICK] A star topology with home runs from each communicating device to an Ethernet switch mounted in the equipment is recommended due to the compartmental design of the MCC. Manual or protective disconnection of a unit removes all power to any communicating components, leaving a daisy chain or ring topology susceptible to loss of large sections of the network. Equipment ordered with Ethernet cabling and switches provide a connected, tested and documented system from the factory ready for one customer connection. [CLICK]
- Ethernet network has consolidated its use into the industrial environment; the technology evolution addressed some initial concerns about ruggedness and performance (determinism). Even driven by commercial technologies, the industrial Ethernet and its components were designed to address industry requirements. It is a classical example of open technology not limited to proprietary/supplier control. This approach allows constant technical evolution and aggregation of commercial technologies into industrial applications. [CLICK]
- [CLICK] The Ethernet version of many devices have a built in web server which can provide you with basic diagnostics data. This service can be used with a simple Internet Browser supporting Java. This unique feature will again help ease your maintenance costs. Additionally, dedicated display hardware is NOT required, which further adds to cost savings. [CLICK] In addition to providing direct, high speed Ethernet connectivity the protection relays, variable speed drives and power meters may also include embedded web pages. This web access allows real-time power system information from the device through a standard web browser . [CLICK] Users are able to view this information from home or a remote location through a company’s virtual private network connection. These systems are also able to trigger email notification if an event occur or conditions are outside normal parameters. [CLICK]
- [CLICK] Biometric Switches and Wireless Push Buttons you can reduce maintenance and machine downtime resulting from unauthorized operation. Simple and efficient, it enables you to restrict access to sensitive areas and machine functions – including, start-up, adjustments, and maintenance – to only authorized personnel. Eliminate costs associated with the administration or loss of keys, cards, and badges. [CLICK] The advances and level of performance achieved in biometric technology has now enabled manufacturers to offer a robust, cost-effective solution, which is essential in industrial environments . [CLICK] Utilizing wireless technology, new battery-less push buttons no longer requires cables through the panel structure or cabling tray to connect the push button to the electrical panel. [CLICK] Key features of this technology are typically: quick and easy installation, eliminates wires and cables, flexible due to its mobility, greater control and mobility for operators and virtually maintenance-free. [CLICK] Similar to other products of this type, the wireless, battery-less push button is well-suited for harsh industrial environments where added protection of people and systems is vital, allowing them to remotely control machines at a distance of up to 25 meters in a factory environment. [CLICK]
- New-generation circuit breakers, as low as 15A, are able to provide other functions beyond just protection and power disconnection. [CLICK] The energy data from an electronic trip unit will help you study consumption patterns, compare the performance of different facilities, and isolate where energy is being wasted. Exposing the associated energy cost at the building, department, or machine level will drive efficiency. Having integrated metering in your breakers can also complement existing metering systems, helping you validate utility billing, or verify that consumption at upstream feeders matches the sum of the associated meters. [CLICK] These breakers are simple to use, convenient, local data access through a high visibility front display module provides maintenance personnel convenient access to all measurements, history, and circuit breaker maintenance indicators directly from the front of an MCC bucket. [CLICK] Remote data access: Easy, remote data access to anyone that needs it, supporting energy management strategies, as well as remote maintenance and troubleshooting. This type of technology is an all-in-one device; protection, metering, and communications, in one device. [CLICK]
- Intelligence. We’re all striving for it. Achieving it requires information that answers the big questions and leads to smart choices. [CLICK] The metal/steel industry in the U.S. is already recognized for its best in class, technology, productivity and safety performance, however, there is room for improvements and technical evolutions. [CLICK] Intelligent Motor Control Centers are strong allies for metal/steel producers since they address the main critical points for operations: personnel and equipment safety, downtime reduction, productivity (operations and maintenance) and energy efficiency. [CLICK] The Intelligent Motor Control Center offers solutions to address your questions. [CLICK] • How do I eliminate the cost of field wiring hundreds of I/O points? • Is there a way to streamline troubleshooting? • How do I predict unscheduled downtime? • Do procedures exist for proper wire labeling and documentation? • Can I utilize an existing PLC or factory network? [CLICK] Factory wiring, popular network protocols, and extensive testing and documentation can make your MCC installation simple. [CLICK] An intelligent MCC can deliver the integrated package while reducing acquisition, installation and commissioning costs. Thank you [CLICK]