Lowering Lifecycle Costs
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1 Lowering Lifecycle Costs with Intelligent Motor Control Centers Standards Certification Education & Training Publishing Conferences & Exhibits Speakers: Presented and Authored by Jeff M. Miller, PE, ENV SP 2016 ISA Water / Wastewater and Automatic Controls Symposium August 2-4, 2016 Orlando, Florida, USA
2 Presenter ~ Jeff M. Miller, PE, ENV SP Jeff M. Miller is the Water Segment Manager for Schneider Electric s Water Wastewater Competency Center. B.S. in Electrical Engineering Over 25 years of experience Co-founder and past chair of the NC AWWA- WEA Automation Committee Headshot photo 2
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? How come you don t have comfortable seats like ours? If I answer questions will I get free stuff? 3
4 Typical SCADA Architecture Role of Motor Control Centers MCCs imccs Smart MCCs 4
5 Intelligent Motor Control Centers-iMCCs Industry Trends 35% 30% 25% 20% 15% 10% US imcc Market 5% 0%
6 What s the Difference? CONVENTIONAL VS. INTELLIGENT MOTOR CONTROL CENTERS 6
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 SCADA Network Control Panel PLC or Remote I/O Drop Standard MCC 7
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 SCADA Network 8
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 SCADA Network Shrink enclosure and MCC compartment sizes Control Panel PLC or Remote I/O Drop Standard MCC 9
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% 10
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? 11
12 Enhanced Functionality Lower Costs Increased Reliability & Less Risk BENEFITS OF INTELLIGENT MOTOR CONTROL CENTERS 12
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 13
14 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 14
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 15
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 Municipal Energy Consumption 16
17 Asset and Condition Management Importance of Proper Monitoring, Protection and Management of Assets 44% of motor failures are preventable by monitoring power and loading Misc. 9% Age 10% Voltage Conditions 14% Contaminants 19% Bearing Failures 13% Rotor Failures 5% Overload 30% 17
18 A Proposal for Keeping it Simple and Getting the Most Benefits out of your Investment NARROWING DOWN THE CHOICES FOR IMPLEMENTING imccs ~ ETHERNET COMMUNICATIONS 18
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 Most Frequently Named Protocols Ethernet TCP/IP 4-20 ma RS-232 RS-485 EtherNet/IP 0-10 Volt DeviceNet Modbus OPC ControlNet WiFi (IEEE b) Modbus TCP HART Proprietary Profibus-DP 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 19
20 Cost Ethernet Network Topologies Choosing a Network Topology Primary Selection Criteria Level of Availability Performance Cost Star Mesh Ring / Dual ring Tree Ring Bus Reliability 20
21 Ethernet Network Ring Construction Network Connection and Routing within an imcc Single Ring Routing 600V Cable Intelligent Motor Protection Relay (IMPR) 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 21
22 A Proposal for Keeping it Simple and Getting the Most Benefits out of your Investment NARROWING DOWN THE CHOICES FOR IMPLEMENTING imccs ~ INTELLIGENT SMART MCC COMPONENTS 22
23 Intelligent Smart Ethernet Components Typical Smart Devices within an imcc Harmonic Filters & Power Factor Correction Power Metering & Monitoring Intelligent Motor Protection Motor Starters Network Cabling and Switches Automation Controllers or RIO AC Drives Electronic Circuit Breakers Operator Displays Soft Starters 23
24 imcc Unit Compartments Typical Examples Variable Frequency Drive Intelligent Full Voltage Starter with IMPR Intelligent Circuit Breaker Ethernet Switches and Power Supply 24
25 imcc Unit Compartment Examples Process Controllers and Remote I/O 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. 25
26 A Proposal for Keeping it Simple and Getting the Most Benefits out of your Investment NARROWING DOWN THE CHOICES FOR IMPLEMENTING IMCCS ~ INTELLIGENT MOTOR PROTECTION 26
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 27
28 Intelligent Smart Starter Example of Integrated Intelligence into a Motor Starter Upto 40% surface saving compared to traditional motor starters. Totally Coordinated motor starter. Zero downtime even when at a 50kA short. Upto 50% maintenance cost savings. Upto 60% of wiring optimization. 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 3 functions in 1 device. Just 6 part numbers for starters upto 15kW Upto 90% fewer motor burnouts. Thanks to more accuracy of tripping characteristics. 28
29 Intelligent Motor Protection Relay (IMPR) Example of Integrated Intelligence into an IMPR Operating mode Overload Independent Reverser Two-Step Two-Speed Custom Mode Current Rating (internal CT) 0.4 to 8 A or 1.35 to 27 A or 5 to 100 A Motor Protection Thermal Overload Over/Under current Long Start / Jam Ground current Motor temperature sensor Additional Motor Protection Over / Under Voltage Voltage phase reversal Over / Under Power Factor Over / Under Power Load shedding Control Power supply 24 VDC or VAC 50/60Hz Inputs & Outputs 6 discrete inputs 4 relay outputs Ground fault input Temperature sensor Base Unit Network Communication Modbus or CAN Open or Profibus DP or Device Net or Ethernet Expansion Additional Input 4 discrete inputs 29
30 Intelligent Motor Protection Relay (IMPR) Remote Access and Configuration Examples of Integrated Intelligence into an IMPR Webserver Access Configuration and Monitoring Software Tools 30
31 A Proposal for Keeping it Simple and Getting the Most Benefits out of your Investment NARROWING DOWN THE CHOICES FOR IMPLEMENTING IMCCS ~ DESIGN, PROCUREMENT AND CONSTRUCTION 31
32 Design, Procurement and Construction imcc Design Electrical Schematics with Soft Logic Incorporated k 32
33 The Universal Starter Example Goal of imcc Motor Controls 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 33
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 34
35 Summary for Implementing Intelligent Motor Control Centers 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 35
36 Questions? 36
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