Siemens make Motor control center' SIMOCODE

1. 1
NEW GENERATION MOTOR
CONTROL CENTER
-SIMO CODE SYSTEM

2. 2
Conventional MCC
Parts on Conventional MCC Feeders
Main Switch (Switch Fuse Unit / Circuit Breaker)
Power Contactor & Control Contactor
Thermal Over Load Relay
 Transducers with Analogue Signals
for Measurement (Optional)
 I/O Communication through Hardware (Control Cable)
Outgoing Terminals for Power & Control Cable

3. 3
Local Stop
MCC Stop
Interlock
Start
C
O/L relay
230V AC
C
Isolator
Overload
relay
Contactor ©

4. 4
Local Stop
MCC Stop
Interlock
O/L to DCS
Local Stop to DCS
MCC Stop to DCS
Control supply Healthy
ON Remote ONDCS ON
Local
DCS
Selector Switch
C
230V AC
Drive 1 to Remote
C

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Intelligent MCC
Parts on Intelligent MCC Feeders
Main Switch (Switch Fuse Unit / Circuit Breaker)
Power Contactor & Control Contactor
SIMOCODE pro & Complete Accessories
 I/O Communication through Profibus
Outgoing Terminals for Power Cable
SIMOCODE pro : Sirus Motor Management & Control Devices with a Profibus
DP interface

6. 6
Intelligent MCC
90 KW Motor Feeder with Internal Parts

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Intelligent MCC
SIMOCODE & Accessories
4 I / 3 O binary
Thermistor
PROFIBUS DP
24 V DC /
110 – 240 V AC/DC
Basic Unit
Current Measuring Module
0.3 A – 630 A Straight-Through/Busbar Connection Technology
Expansion Modules
 Additional binary I/Os
 3 x 0/4 – 20 mA I/Os
 3 x sensors Pt100/ Pt1000
 External earth fault via
summation current
transformer

8. 8
Operator Panel
with display
Operator Panel
5 buttons / 10 LEDs
Intelligent MCC
SIMOCODE & Accessories
Current/Voltage Measuring Module
0.3 A – 630 A /690 V Straight-through/ busbar connection technology
Connection Cable
In various lengths (up to 2.5 m)

9. 9
Intelligent MCC
Sub Divisions of SIMOCODE pro:
SIMOCODE pro C : A Compact System for Direct & Reversing Starter with
Monitoring & Communication of Current related Parameters only.
Typical SIMOCODE pro C Hardware Configuration

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Intelligent MCC
SIMOCODE pro V : A Variable System, which offers numerous in addition to all of
the SIMOCODE pro C Functions.
1. Expandable Binary Input / Output Modules
2. Current / Voltage / Power Related Measurements
3. Expandable Analogue Input / Output Modules
4. Earth Fault Detection
Typical SIMOCODE pro V Hardware Configuration

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Intelligent MCC
Applications of SIMOCODE / Intelligent MCC Feeder Module
Controlling, Protection, Measurement & Communication for
 Direct Online Starters
Star Delta Starters
Reversible Starter
Actuation through Soft Starters

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Intelligent MCC
Functions of SIMOCODE / Intelligent MCC Feeder Module
Protection Functions
 Thermal Over Load
 Unbalance Protection
 Stalled Rotor Protection
 Thermister Protection Based on Actual Temp. Measurement
 Upper Current Limits & Lower Current Limits
 Earth Fault Protection
 Under Voltage / Over Voltage Protection
 External Interlocking Through Digital Inputs

13. 13
Intelligent MCC
Functions of SIMOCODE / Intelligent MCC Feeder Module
Measurement Functions
 3 Phase Voltage
 3 Phase Current
 Active Power
 Apparent Power
 Power Factor
 Unbalance Current
 Thermal Model Memory
 Drive Operation Hours
 No. of Over Load Trips
 Last Trip Current
 Drive Stop Time

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Intelligent MCC
Simplified Hardware Wiring – By Graphic Editor in the SIMOCODE

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Intelligent MCC
Profibus Networking – Line View

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Intelligent MCC
Profibus Configuration
Each Profibus Network shall have Maximum 126 Nodes (SIMOCODES).
DCBL, Kadappa Selected Max. 60 Nodes in a Network as Internal Standard.
For Each 30 Nodes (or) the Cable Length is more than 1500 Mtr., A Profibus
Repeater is Essential
2 3 30 31 32 60Nodes
Repeater
From Processor
EndTo
Work
Station SIMOCODE
Work Station

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Intelligent MCC
Monitoring of Last Trip Current – 498% of the Motor Rated Current

18. 18
Intelligent MCC
Monitoring of Measured Values

19. 19
Intelligent MCC
Maintenance Date / Statistical Data

20. 20
Intelligent MCC
Events List

21. 21
Intelligent MCC
Control Signals /Drive Status Indications & Digital Signals Status

22. 22
Intelligent MCC
Detailed Fault & Warning Information
Faults Warnings

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Intelligent MCC
Trend View of Measuring Parameters – For Close Monitoring & Detailed
Analysis
KVA
KW
Voltage
Max. Current
L1 Current

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Intelligent MCC Motor Protection Settings

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Intelligent MCC
Merits
 Sensitive Protection to the Motors like Over Current, Unbalance, Earth Fault, Starting
Current…
 Direct Communication to DCS & Load Center Workstation by Profibus (Controlling,
Measurement & Annunciations). Hence no Instrument I/O Panel is required.
 Reduces the Commissioning Time of 3 Weeks due to no I/O Panel and its Cabling /
termination
 Online Monitoring of all Motors like Running Status, Current and Power Datas at CCR
and Load Center Workstation.
 Retrieving of motor Trip Records
 Reduced Hardware wiring and hence reduced Maintenance & Breakdowns.
 Vide Range of Feeder Components, hence reduced inventory.

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Intelligent MCC
Demerits
 High Initial Cost
 Required Air Conditioned Substation
 Required UPS Power Supply for SIMOCODE Aux. Power
 If Profibus Communication Fails, Entire MCC Feeders will be affected.
 Delayed Communication in responses / feedbacks.
 Required High Skilled Man Power

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Sl.
No.
Description
Standard
MCC
Intelligent MCC
1
Total cost of the motor control centre
in a cement project
487.00 Lacs 567.00 Lacs
2
Total cost of DCS System in complete
Cement Plant
903.00 Lacs 886.00 Lacs
A) Sub Total - I 1390.00 lac 1453.00 lac
1
Cost of cables, cable trays (from MCC
panel to I/O panel) , cable glands and
other Hardwares
43.58 7.98
B) Sub Total - II 43.58 7.98
Total (A+B) 1433.58 1460.98
Increase in Total Cost 27.4 Lacs
Intelligent MCC
Cost Benefit Analysis – Ordering Stage

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Intelligent MCC
Cost Benefit Analysis – Commissioning Stage
Sl.
No.
Description
Standard
MCC
Intelligent MCC
1
Project Execution Time for Installation,
Testing & Commissioning of MCC’s and
Plant DCS system.
75 days 45 days
2
Per day loss due to delay in Plant
commissioning @ 50% Capacity
22 Lacs
3
Loss due to delay in Plant
Commissioning as above
660 lac 0
Hence, it is recommended that we shall go with Intelligent MCC for Cement Plant,
which is not impacting the project cost but tendering significant reduction in
Execution, Commissioning, Operation and Maintenance Cost

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Intelligent MCC
Problem Faced during Commissioning
 Feedback Fault due to Delayed Communication
Problem drastically reduced by fine tuning the Execution Time & Feedback Time Settings
 Communication Error
Solved by Ensuring Earthing Connectivity of Profibus Cable Shield at all Terminals
 Failure of Digital Expansion Modules
• Solved by Connecting all Earth Terminals of SIMOCODE to separate Earth Pit
• Solved by Connecting Surge Suppressors to the Power & Control Contactor Coil
Terminal and Suppressed the Surges during Switching.
• Tested all the Digital Modules (Measured Digital Input Energizing Current) and replaced
the Defective Digital Expansion Modules


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