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 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
Lowering Lifecycle Costs with Intelligent Motor Control Centers (iMCCs) How come you • Who has heard of iMCCs? don’t have • Who has iMCCs? comfortable • Who is using them for more than RIO? seats like ours? • Energy Monitoring? Power Quality? Load Control? Load Protection? Asset Management? Condition Management? If I answer questions will I get free stuff? Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 3
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
Intelligent Motor Control Centers - iMCCs Industry Trends 35% 30% 25% 20% US iMCC 15% Market 10% 5% 0% 2000 2002 2004 2006 2008 Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 5
Conventional vs. Intelligent Motor Control Centers What’s the Difference? Page 6
Conventional Hardwired Motor Control Centers MCC with a Typical SCADA Control Panel • Hardwired components Control Panel • Stand alone control panel Standard SCADA typically with PLC or Remote MCC Network I/O • Multiple field connections PLC or needed installation, startup, Remote and testing I/O Drop • Minimal data pulled from MCC • Start/Stop, Run, Fail, HOA Position Page 7 Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m.
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 SCADA Network Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 8
Unnecessary Hardwired Elements When Using iMCCs • Network connection instead of hardwiring to controller(s) Control Panel Standard SCADA • Eliminate need for signal MCC Network terminals, power supplies, surge protectors, fuses, etc. PLC or • Eliminate need for controller I/O Remote modules I/O Drop • 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
Overly Simple Capital Cost Analysis Not All Savings Considered Conventional MCC $650,000 • Cost Analysis (+ )Smart MCC Components $105,000 • Many MCC components are now smart but unused in conventional MCCs (+) iMCC Networking $35,000 • Not all savings or schedule impacts considered (+) iMCC Configuration and Testing $95,000 • Additional functionality can greatly increase savings iMCC Additional Cost $235,000 from >30% to more than 3,000% (-) PLC I/O, Pwr, Supplies, etc. $95,000 • Many different configurations will vary savings (-) PLC Hardwiring and Terminals $25,000 • All Costs Needing to be Considered (-) PLC Enclosure Size $3,000 • Capital Costs (-) Field Wiring and Conduit $130,000 • Operational Costs (-) MCC Hardwiring and Logic $7,000 • Maintenance Costs iMCC Savings $0.00 • Cost of Risk / Safety 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
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
Benefits of Intelligent Motor Control Centers Enhanced Functionality | Lower Costs | Increased Reliability & Less Risk Page 12
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
Lower Costs Enhanced Functionality | Lower Costs | Increased Reliability & Less Risk • 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 Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 14
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
Municipal Energy Consumption Typical Energy Savings and Importance of Energy Management • Municipal Energy Improvements Municipal Energy Consumption • 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
Asset and Condition Management Importance of Proper Monitoring, Protection and Management of Assets 44% of motor failures are preventable by monitoring power and loading Voltage Age Conditions 10% 14% Misc. 9% Overload 30% Contaminants 19% Bearing Rotor Failures Failures 5% 13% Schneider Electric | Lowering Lifecycle Costs with iMCCs | 2016 NC AWWA_WEA Spring Conference | Tuesday, April 19th at 11:20 a.m. Page 17
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
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