intelligent mcc-white paper

8/8/2019 Intelligent Mcc-white Paper

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Intelligent Motor Control Centers

INTRODUCTION

Todays Industry demands more from its equipment to meet the needs of theCompetitive environment. Electronics have changed the way things are done andno part of our lives is excluded from the use of Microprocessors to make thingsmore efficient.

Lately, interest in the Intelligent Motor Control Centers (IMCCs) has increasedsignificantly. Intelligence is the ability to use & share Information Globally soas to continuously ensure desired control and Motor protection cost effectively.

Intelligent MCCs represents a New and Functional approach to the switchgeararchitecture, utilizing new technologies without the limitation of the conventionalcomponents.

To elaborate, we present this White Paper

MOTOR CONTROL CENTER EVOLUTION

Motor Control originally had independent Starters located & operated near theMotors. The need to have centralized Control, Monitoring and Maintenancecreated the concept of Motor Control Center. The role of MCC, was and is, toprovide a Compact, Modular, Centralized factory Built and cost effective Control.The Basic devices of MCC include a Power Switching, Short Circuit & OverloadProtection, actuation and device status indication.

MCCs grew as a concept in 1970s because it offered many advantage over theseparate Starters located near the Motors.

Less Power Distribution on line side.

Cost effective.

Single Source Pre-assembled and Factory Tested.

Space Saving.

Excellent fault containment.

Centralized operation and maintenance.

Remote Control with interlock.

Even today these original demands remain but business environment want moreout of the equipment to manage the total factory more economically withpreventive approach rather than post event related and less dependent onmanpower.

Hence the need to pack the MCC with more Intelligence to satisfy theManagement needs of today and tomorrow.

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Motor Control Center evolution has been limited. Originally Control was basedon Relay Logic until the PLCs arrived. The development and use of PLCs withMCCs has shifted the complex circuits from Hardwiring to Software within the

Processor. The I/O modules are generally kept in a separate I/O Panel afterusing a marshalling Panel. This segregates Electrical & Instrumentationdepartment responsibility.

An end user or his consultants generally decide the MCC Feeder ratings,equipment / component supplier, fault level and other specific design featuresrelevant to the application. An intelligent MCCs can be designed using thesepreferences but at the same time, embrace the new technology using newintelligent components.

These new technologies and components offer at the minimum

1. Intelligent devices with live performance Data2. Better Control and Protection with Communication3. Point level Diagnostics for Digital & Analog values4. Open Network Connectivity at Device level5. Pro-active and Predictive maintenance capability6. Fewer inventories7. Common Operator Panel on MCC instead of discrete Lamp & Push Button

TOMMOROWS EXPECTATION

Industry has realized and sensed that better utilization and management of their

Assets will improve their bottom line. In the best of plants worldwide, EnterpriseAsset Management System has become a critical component of their on goingbattle of optimizing maintenance and operation cost.

Consider the following findings:

The single largest controllable expenditure in a plant is maintenance.

In many plants maintenance budget exceeds annual net profit.

Industrial maintenance averages 14 per cent of the cost of goods sold inmany industries.

An estimated one-third of maintenance budget is wasted due to improper

or unnecessary practices. One major U.S. automotive manufacturer has a maintenance staff of

between 15,000 and 18,000, all plants combined. They say, 85 per centto 90 per cent is crisis work (breakdown).

Simple, but chilling statistics!!

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In a highly productivity oriented manufacturing setup, keeping the equipmentrunning is the only thing that matters. As companies explore and seek to remedyhigh cost areas such as productivity optimization, automation and supply Chain

management, maintenance is considered the next big frontier to cost saving.

In the Electrical arena, Motors account for about 80% the Electrical load asprime-movers. Intelligent MCC, with the technology available today, can offer anexcellent Engineered solution to achieve Preventive, Predictive and Proactivemaintenance by managing root cause of breakdown and extending the life cycleof the equipment.

With this a realization, a well-designed and integrated Intelligent MCC shouldinclude the following capability.

1. Individual equipment should be equipped with a device capable to Control,Protect and provide relevant Data via a Communication Port.2. A Device level Network able to transfer Data-periodically, conditionally or on

request, to a Central Processing Unit.3. An extremely reliable Open Network with Diagnostic available on-line, to

advise failure and status of individual point and node. On-line replacement ofnodes / modules should be possible.

4. Network interface to pass the Data of all the connected Devices to differentNetworks or CPUs.

5. A Central Processor Unit either mounted locally on Intelligent MCC to form apart of Distributed Control or connected on the Network to a Central PlantDCS and MMI Control Station.

6. A MMI Operator Station dedicated to connect the related Intelligent MCCs,Control Desks, and Push Button Stations.

Central Work Station(s) common for complete Plant should offer as aminimum:

Overview of the Power System.

Front view of each Intelligent MCC with status of each feeder.

Individual feeder Data available by a click on Compartment or SLD symbol.

Capability to record Data to give trends and historical performance data ofindividual feeders.

Capability of automatic event based generation of message or reports to KeyPersonal on email, Phone, Pager, Audio System, Mobile etc.

Maintenance Planning & Scheduling.

Bill of Material, Component specification, Vendor & Commercial information.

AutoCAD Drawing of all Feeders.

Important Product User Manuals & Technical information On-line.

Capability of MIS Reports for Operation, Costing, Maintenance etc.

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Connectivity with Enterprise Resource Management System (e.g. SAP,

BAAN).

POWERGEAR INTELLIGENTMCCs

Engineered MCC CPRI tested with over two decades of experience.

World renowned Intelligent devices to Monitor, Protect & Communicate.

Open Local Network to connect devices DeviceNet

CPU Control, Programmable logic if desired, to have distributed Controlwith Communication link to upstream hierarchy of Different Makes /Networks.

In case its a part of centralized Control, fast Communication link-up withCentralized CPU.

A Graphic Operator Terminal to be able to Monitor and Control and give

Alarm & Event Summary, Help Screen, Event recording etc.

POWERGEAR AND PIMA CONTROLSare companies of the same group andmanagement. POWERGEAR since 1975 is an established name manufacturingCustom-built equipment covering a range of LT and MV Motor Controls. PIMACONTROLS PVT.LTD., incorporated in 1985, is a reputed company offeringAutomation solutions in all sectors of industries. Pima Controls Pvt. Ltd. offersengineering solution with their partner agreements for products and technicalsupport of MNCs like Rockwell Automation (Allen Bradley), Prosoft, and DVT etc.Combining these Engineering strengths and Technological products, Powergear

offers an Intelligent Motor Control Centers packed with all feature listed in thisPaper and many more, Custom-built for your needs and imagination.

POWERGEAR also undertakes study and offers to upgrade existing MCCsinstallation to a level that can achieve a System as described herein so as tosave your investments and get use todays technology for Motor Control & itsmonitoring.

Madhukar ParikhAuthor

Please contact for more details to:

POWERGEARDivision of Pima Controls Pvt. Ltd.A4-New York Corner, Bodakdev,Ahmedabad380015, INDIAPhone No.: +91-79-2687 2201 / 2 / 3

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Fax No.: +91-79-2687 1126E-Mail: [email protected]

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mailto:[email protected]:[email protected]

intelligent mcc-white paper

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