Lowering Lifecycle Costs with Intelligent Motor Control Centers - - PowerPoint PPT Presentation

▶
lowering lifecycle costs with intelligent motor control
SMART_READER_LITE
LIVE PREVIEW

Lowering Lifecycle Costs with Intelligent Motor Control Centers - - PowerPoint PPT Presentation

Sep 14, 2023 143 likes •554 views

Lowering Lifecycle Costs with Intelligent Motor Control Centers (iMCCs) 2016 NC AWWA-WEA Spring Conference in Asheville, NC Tuesday, April 19 th at 11:20a.m. Presented by Jeff M. Miller , PE, ENV SP Authored by Jeff M. Miller , PE, ENV SP Speaker

slide-1
SLIDE 1

Lowering Lifecycle Costs with Intelligent Motor Control Centers (iMCCs)

2016 NC AWWA-WEA Spring Conference in Asheville, NC

Tuesday, April 19th at 11:20a.m. Presented by Jeff M. Miller, PE, ENV SP Authored by Jeff M. Miller, PE, ENV SP

slide-2
SLIDE 2

Speaker Bio: Jeff M. Miller, PE, ENV SP

Water Wastewater Competency Center | Solutions Architect

Jeff M. Miller is a Water Segment Manager for Schneider Electric’s Water Wastewater Competency Center. Jeff has a B.S. in Electrical Engineering with over 25 years of experience. Jeff has the unique perspective of having worked for engineering consultants, systems integrators, and utilities where he delivered on projects ranging in size from small lift stations to 370 MGD treatment plants. Jeff is the co- founder and past chair of the NC AWWA-WEA Automation Committee and is also an active member of several national and regional Automation and Plant O&M related committees.

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 2

slide-3
SLIDE 3

Lowering Lifecycle Costs with Intelligent Motor Control Centers (iMCCs)

  • Who has heard of iMCCs?
  • Who has iMCCs?
  • Who is using them for more than RIO?
  • Energy Monitoring? Power Quality? Load

Control? Load Protection? Asset Management? Condition Management?

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 3

How come you don’t have comfortable seats like ours? If I answer questions will I get free stuff?

slide-4
SLIDE 4

Typical SCADA Architecture

Role of Motor Control Centers

  • MCCs
  • iMCCs
  • Smart MCCs

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 4

slide-5
SLIDE 5

Intelligent Motor Control Centers - iMCCs

Industry Trends

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 5

0% 5% 10% 15% 20% 25% 30% 35% 2000 2002 2004 2006 2008 US iMCC Market

slide-6
SLIDE 6

Conventional vs. Intelligent Motor Control Centers

What’s the Difference?

Page 6

slide-7
SLIDE 7

Conventional Hardwired Motor Control Centers

MCC with a Typical SCADA Control Panel

  • Hardwired components
  • Stand alone control panel

typically with PLC or Remote I/O

  • Multiple field connections

needed installation, startup, and testing

  • Minimal data pulled from MCC
  • Start/Stop, Run, Fail, HOA

Position

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 7

Standard MCC

PLC or Remote I/O Drop SCADA Network

Control Panel

slide-8
SLIDE 8

Smarter Networked Intelligent Motor Control Centers

iMCC Connected Directly to SCADA or Fieldbus Network

  • Smart Components
  • Metering, CBs, Motor Controllers, Process Controllers, etc.
  • Industrial Communications
  • Smart Devices, Controllers, Remote I/O
  • iMCC Benefits
  • Enhanced Functionality
  • Lower Costs
  • Increased Reliability
  • Less Risk

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 8

SCADA Network

slide-9
SLIDE 9

Unnecessary Hardwired Elements When Using iMCCs

  • Network connection instead of

hardwiring to controller(s)

  • Eliminate need for signal

terminals, power supplies, surge protectors, fuses, etc.

  • Eliminate need for controller I/O

modules

  • Less hardwired logic components
  • Shrink enclosure and MCC

compartment sizes

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 9

Standard MCC

PLC or Remote I/O Drop SCADA Network

Control Panel

slide-10
SLIDE 10

Overly Simple Capital Cost Analysis

Not All Savings Considered

  • Cost Analysis
  • Many MCC components are now smart but unused in

conventional MCCs

  • Not all savings or schedule impacts considered
  • Additional functionality can greatly increase savings

from >30% to more than 3,000%

  • Many different configurations will vary savings
  • All Costs Needing to be Considered
  • Capital Costs
  • Operational Costs
  • Maintenance Costs
  • Cost of Risk / Safety

Conventional MCC $650,000 (+ )Smart MCC Components $105,000 (+) iMCC Networking $35,000 (+) iMCC Configuration and Testing $95,000 iMCC Additional Cost $235,000 (-) PLC I/O, Pwr, Supplies, etc. $95,000 (-) PLC Hardwiring and Terminals $25,000 (-) PLC Enclosure Size $3,000 (-) Field Wiring and Conduit $130,000 (-) MCC Hardwiring and Logic $7,000 iMCC Savings $0.00 Difference (See Explanation and Exceptions) 0% ±15%

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 10

slide-11
SLIDE 11

Adoption of Intelligent Motor Control Centers

Why Are They Not Being Used More?

  • Stigma of Early iMCC Issues
  • Lack of integrated intelligence in many devices
  • Internal MCC network cabling issues
  • Concerns on reliability and common points of failure
  • Advantages Misunderstood and Poorly Applied
  • Used mainly for RIO and energy monitoring but nothing else
  • Designs and implementation copied from conventional MCCs
  • Using same procurement methods as conventional MCCs
  • Electrical safety and ease of worker access not considered
  • Too Many Choices from Simple to Complicated
  • What smart components or controllers are integrated?
  • What network protocols to use?
  • What network topology to use?

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 11

slide-12
SLIDE 12

Benefits of Intelligent Motor Control Centers

Enhanced Functionality | Lower Costs | Increased Reliability & Less Risk

Page 12

slide-13
SLIDE 13

Increased Functionality

Enhanced Functionality | Lower Costs | Increased Reliability & Less Risk

  • Equipment Protection
  • Motor Protection
  • Energy Management
  • Process Optimization
  • Asset Management
  • Condition Management
  • Power Quality
  • Diagnostics
  • Statistics, Tracking and Trending
  • Accessibility of Information
  • Integration of Components and Levels of Engagement
  • Access to more Data for Big Data Applications

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 13

slide-14
SLIDE 14

Lower Costs

Enhanced Functionality | Lower Costs | Increased Reliability & Less Risk

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 14

  • Fewer Components and Wiring
  • Fewer Cables and Conduit
  • Smaller Footprint
  • Less Field Installation, Startup and Testing
  • Lower Change Costs
  • Energy Efficiency
  • Equipment Protection
  • Common spares
  • Cost of Risk
slide-15
SLIDE 15

Increased Reliability and Less Risk

Enhanced Functionality | Lower Costs | Increased Reliability & Less Risk

  • Better Equipment / Motor Protection
  • Simpler and Fewer Configurations
  • Fewer Components and Wiring
  • Less Mechanical Components
  • Longer Mean Time Between Failures (MTBF)
  • Enhanced Safety through remote configuration, operation, and

troubleshooting

  • Faster Issue Identification and Repair
  • Detailed Diagnostic and Statistical Information
  • Predictive Maintenance
  • Flexible Configurations
  • Soft vs. Hard Changes

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 15

slide-16
SLIDE 16

Municipal Energy Consumption

Typical Energy Savings and Importance of Energy Management

  • Municipal Energy Improvements
  • Efficient devices and installation (10 to 15%)
  • Optimized usage via automation (5 to 15%)
  • Monitoring & Maintenance (2 to 8%)
  • W/WW Utility Optimization
  • Up to 30% in Energy Consumption
  • Up to 25% in Operational Efficiency
  • Up to 20% in Cost of Ownership
  • Lack of Energy Management
  • Up to 12% per year is lost without regulation and control systems
  • Up to 8% per year is lost without monitoring and maintenance program

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 16

Municipal Energy Consumption

slide-17
SLIDE 17

Asset and Condition Management

Importance of Proper Monitoring, Protection and Management of Assets

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 17

Misc. 9% Contaminants 19% Bearing Failures 13% Rotor Failures 5% Overload 30% Age 10% Voltage Conditions 14%

44% of motor failures are preventable by monitoring power and loading

slide-18
SLIDE 18

Narrowing Down the Choices for Implementing iMCCs

~ Ethernet Communications

A Proposal for Keeping it Simple and Getting the Most Benefits out of your Investment

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 18

slide-19
SLIDE 19

Ethernet

Choosing a Communications Protocol

  • Open protocol used by many

smart devices

  • Numerous topologies
  • High speed
  • No special tools or proprietary

expertise

  • Product evolution and cost driven

by market

  • Easy to use and maintain with

minimal training needed

  • Access to many tools and apps

for enhanced functionality

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 19

Most Frequently Named Protocols

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Profibus-DP Proprietary HART Modbus TCP WiFi (IEEE 802.11b) ControlNet OPC Modbus DeviceNet 0-10 Volt EtherNet/IP RS-485 RS-232 4-20 mA Ethernet TCP/IP

slide-20
SLIDE 20

Choosing a Network Topology

Ethernet Network Topologies

  • Primary Selection Criteria
  • Level of Availability
  • Performance
  • Cost

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 20

Ring Ring / Dual ring Bus Cost Reliability Star Tree Mesh

slide-21
SLIDE 21

Single Ring Routing

Network Connection and Routing within an iMCC

Ethernet Network Ring Construction

  • Smart Devices
  • Integrated Ethernet Ports
  • Some have integrated daisy chain

ports for ring

  • Network Cable Barriers
  • Not needed with 600V shielded

cable

  • Cable Routing and Ethernet

Switches

  • Shipping Splits or field wired

network cables?

  • Number and placement of

switches

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 21

600V Cable

Intelligent Motor Protection Relay (IMPR)

slide-22
SLIDE 22

Narrowing Down the Choices for Implementing iMCCs

~ Intelligent “Smart” MCC Components

A Proposal for Keeping it Simple and Getting the Most Benefits out of your Investment

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 22

slide-23
SLIDE 23

Intelligent “Smart” Ethernet Components

Typical Smart Devices within an iMCC

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 23

AC Drives Network Cabling and Switches Intelligent Motor Protection Soft Starters Automation Controllers or RIO Electronic Circuit Breakers Power Metering & Monitoring Operator Displays Harmonic Filters & Power Factor Correction Motor Starters

slide-24
SLIDE 24

Typical Examples

iMCC Unit Compartments

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 24

Intelligent Full Voltage Starter with IMPR Variable Frequency Drive Intelligent Circuit Breaker Ethernet Switches and Power Supply

slide-25
SLIDE 25

Process Controllers and Remote I/O

iMCC Unit Compartment Examples

  • When smart components are

not available or when it is desired to integrate a process controller (PLC) into an iMCC, process controllers or remote I/O may be provided in buckets with fold down racks, terminals, power supplies, etc.

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 25

slide-26
SLIDE 26

Narrowing Down the Choices for Implementing iMCCs

~ Intelligent Motor Protection

A Proposal for Keeping it Simple and Getting the Most Benefits out of your Investment

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 26

slide-27
SLIDE 27

Intelligent Motor Protection

Sensing | Protection | Logic | Remote I/O

  • Integrated Sensing
  • Equipment / Motor Protection
  • Integrated Inputs and Outputs
  • Integrated Communications
  • Energy Management
  • Flexible Starter Logic
  • Local and Remote Operator Interface
  • Remote Access and Configuration
  • Automated Replacement Configuring
  • Diagnostics, Statistics and Trending
  • Scalable for Fewer Parts

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 27

slide-28
SLIDE 28

Intelligent “Smart” Starter

Example of Integrated Intelligence into a Motor Starter

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 28

Upto 50% maintenance cost savings. Upto 60% of wiring

  • ptimization.

Commissioning time saving due to easier process tuning. Impact of modification & evolution divided by 2 Upto 70% downtime reduction Alarms give time to solve problems before trip Upto 90% fewer motor burnouts. Thanks to more accuracy of tripping characteristics. Upto 40% surface saving compared to traditional motor starters.

3 functions in 1

  • device. Just 6

part numbers for starters upto 15kW

Totally Coordinated

motor starter. Zero downtime even when at a 50kA short .

slide-29
SLIDE 29

Intelligent Motor Protection Relay (IMPR)

Example of Integrated Intelligence into an IMPR

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 29

Current Rating (internal CT)

  • 0.4 to 8 A or
  • 1.35 to 27 A or
  • 5 to 100 A

Control Power supply

  • 24 VDC or
  • 100-240 VAC 50/60Hz

Operating mode

  • Overload
  • Independent
  • Reverser
  • Two-Step
  • Two-Speed
  • Custom Mode

Motor Protection

  • Thermal Overload
  • Over/Under current
  • Long Start / Jam
  • Ground current
  • Motor temperature sensor

Inputs & Outputs

  • 6 discrete inputs
  • 4 relay outputs
  • Ground fault input
  • Temperature sensor

Network Communication

  • Modbus or
  • CAN Open or
  • Profibus DP or
  • Device Net or
  • Ethernet

Additional Motor Protection

  • Over / Under Voltage
  • Voltage phase reversal
  • Over / Under Power Factor
  • Over / Under Power
  • Load shedding

Additional Input

  • 4 discrete inputs

Base Unit Expansion

slide-30
SLIDE 30

Intelligent Motor Protection Relay (IMPR)

Example of Integrated Intelligence into an IMPR

Remote Access and Configuration

  • Webserver Access
  • Configuration and Monitoring Software Tools

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 30

slide-31
SLIDE 31

Narrowing Down the Choices for Implementing iMCCs

~ Design, Procurement and Construction

A Proposal for Keeping it Simple and Getting the Most Benefits out of your Investment

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 31

slide-32
SLIDE 32

Design, Procurement and Construction

  • iMCC Design
  • Electrical Schematics with Soft Logic Incorporated
  • k

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 32

slide-33
SLIDE 33

Goal of iMCC Motor Controls

The Universal Starter Example

  • Simple Hardware Design
  • Low Part Count
  • Consolidated Spares
  • Quick Troubleshooting
  • Flexible Design
  • Future
  • More Industry Specific Functions
  • Wireless
  • Lower Cost
  • Availability of older technologies

will decrease

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 33

slide-34
SLIDE 34

Design, Procurement and Construction

  • iMCC Procurement and Construction
  • Furnished by Control System Integrator vs. Electrical Contractor
  • Integrated SCADA/iMCC Factory Testing for Minimal Field Issues
  • Integration of Field, Plant, Operational and Enterprise Systems
  • k

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 34

slide-35
SLIDE 35

Summary for Implementing Intelligent Motor Control Centers

Keeping it Simple and Getting the Most Benefits out of iMCCs

  • Ethernet Communications
  • Industrial Ethernet/IP and/or Modbus TCP Protocols
  • Cost Effective Ring(s) topologies
  • Smart Ethernet Components
  • Eliminate need for separate I/O devices
  • Intelligent Motor Protection Relay
  • Asset Protection and Condition Management
  • Energy Management
  • Flexible Soft Logic self contained within iMCC starter unit
  • Design, Procurement and Construction
  • Electrical Schematics with Soft Logic Incorporated
  • Furnished by Control System Integrator vs. Electrical Contractor
  • Integrated SCADA/iMCC Factory Testing for Minimal Field Issues
  • Integration of Field, Plant, Operational and Enterprise Systems
  • c

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 35

slide-36
SLIDE 36

Questions?

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 36

slide-37
SLIDE 37
slide-38
SLIDE 38

APPENDIX

Note: The additional material presented hereafter is not part of the oral presentation, but is provided for reference within this document.

slide-39
SLIDE 39

Lowering Lifecycle Costs with Intelligent Motor Control Centers

Presentation Abstract

Intelligent motor controllers have been around for many years in the water / wastewater industry but, more often than not, their advantages have been misunderstood and poorly applied. When Intelligent Motor Control Centers (iMCCs) were first introduced, the issues facing early adopters may have placed a stigma on iMCCs preventing widespread adoption of the technologies. Now

  • ver 15 years later, technologies have matured and they offer outstanding advantages in terms of reducing costs, gaining
  • perational efficiency, and construction execution. This presentation will provide a summary of the benefits and lessons learned

that would be of interest to engineering, maintenance, and management. There are many ways to implement iMCCs, and too many choices may have been one of the issues that limited adoption. These

  • ptions will be summarized but focus will be on the methods trending today in the industry to provide the most benefits for the

majority of utilities. So why iMCCs? iMCCs reduce lifecycle costs not only of themselves but also of the equipment they control; they reduce footprint of equipment; they reduce the work and testing needed for installation and commissioning; they allow soft changes in starter control logic without worry of a PLC failure; they provide lower part count, spares and reduction in MTBF (failures); they provide better equipment protections and asset management; they provide enhanced diagnostics for predictive maintenance; they lower risk; and most of all they enable energy savings by the measurement and control of energy. Many of these benefits were never achieved when implemented because the motor starters were designed and operated mainly the same way as a basic starter with hardwiring of monitoring and control signals, but iMCCs are much more and to fully achieve the benefits an understanding of how to leverage these technologies is needed.

Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 39