Intelligent MCCs

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Intelligent MCCs

• Hans Meulenbroek Product Manager LV Systems
• Botlekgroep 27 October 2005

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Intelligent MCCsTopics covered
Definitions Conventional versus
Intelligent Impact serial communication Advantages
and Disadvantages New developments
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Intelligent MCCsDefinitions
Definition of Shell (DEP 33.67.01.31-GEN, January
1998) Integrated Motor Control System A system
comprising control modules, central units, a
serial bus connecting the control modules to the
central unit and a serial communication facility
enabling connection of central unit to a
Distributed Control System (DCS).
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Intelligent MCCsDefinitions
Definition of Shell (DEP 33.67.01.31-GEN, January
1998) MCU (Motor Control Unit) a micro-processor
based device with integrated control, monitoring
and protection functions and communication
facility serving a single motor starter. FCU
(Feeder Control Unit) a micro-processor based
device with integrated control, monitoring and
protection functions and communication facility
serving a single contactor, circuit breaker or
fused feeder. CCU (Central Control Unit) a
micro-processor based interface device used to
monitor and control a number of MCUs and FCUs
via a serial bus and enabling communication with
a higher level of control.
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Intelligent MCCsDefinitions
Simplified IMCS block diagram (Shell)
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Intelligent MCCsDefinitions
Definition of Exxon (Use and evaluation of smart
MCC equipment IEEE PCIC-98-32 / Exxon) Smart
MCC MCC in which the conventional starter
overload protection and other protection and/or
auxiliary relays are all replaced by one standard
microprocessor based unit, and may be connected
to a Communications Interface unit (CI). This
Motor Starter Device (MSD) can be programmed to
provide the electrical protection functions
needed. In addition it provides maintenance data,
sends data to the operators, and/or accepts start
and stop signals from a remote Digital Control
System (DCS) via the CI.
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A typical configuration for an Intelligent Motor
Control System (Exxon)
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Intelligent MCCsDefinitions

• SCU Starter Control Unit
• FCU Feeder Control Uint
• LCU Local Control Unit
• CIU 1 Central Interface Unit
• CIU 2 Redundant Central
• Interface Unit
• - - - Redundant network

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Intelligent MCCsDefinitions

• SCU Starter Control Unit
• FCU Feeder Control Uint
• LCU Local Control Unit
• CIU 1 Central Interface Unit
• CIU 2 Redundant Central
• Interface Unit
• - - - Redundant network

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Intelligent MCCsConventional vs intelligent
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Intelligent MCCsConventional vs intelligent
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Intelligent MCCsConventional vs intelligent
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Intelligent MCCsConventional vs intelligent

• Integrated functionality Starter
• Protection
• Monitoring
• Control
• Maintenance
• Integrated functionality Feeder
• Measurement
• Control
• Protection

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Intelligent MCCsImpact serial communication
Redundancy

• Failure reduced to minimum
• Worst case loss of control of one Starter
  Control Unit or one Feeder Control Unit
• Increased availability
• Dual network i.e.redundant CIU, DeviceNet,
  serial links to SCU and FCU
• Redundant power supply for SCU, FCU and DeviceNet

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Intelligent MCCsAdvantages and disadvantages
Disadvantages Dependant on quality of serial
communication More expensive if not all
functionality is needed? More knowledge/ training
needed Not exchangeable with conventional MCCs
Costs for software upgrades / making backups
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Intelligent MCCsAdvantages and disadvantages
Advantages Less downtime Less expensive (less
DCS I/O, relais and wires) A lot of functionality
is available (e.g. energy measurement) A lot of
data is available (e.g. for predictive
maintenance) Better authorisation Standard
starters for larger range of kWs Open
system Proven technology (large installed base)
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Intelligent MCCsAdvantages and disadvantages
Less downtime Pre-alarms allow the process
automation to act on it (switch over to a spare
motor) Less incorrect trips (bi-metal protection
is ambient temperature dependent, smart
protection has a number of parameters so you can
the protection setting for the motor) High MTBF
(Eaton Clink is built in the wire way resulting
in a better temperature and EMC behaviour) Low
MTTR (Eaton Clink PCBs are easily exchanged
without having to download settings) Spare
starter can be used for several kW ratings (only
settings need to be changed)
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Intelligent MCCsAdvantages and disadvantages
Advantages Less downtime Less expensive (less
DCS I/O, relais and wires) A lot of functionality
is available (e.g. energy measurement) A lot of
data is available (e.g. for predictive
maintenance) Better authorisation Standard
starters for larger range of kWs Open
system Proven technology (large installed base)
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Intelligent MCCsAdvantages and disadvantages
Less expensive less DCS I/O, relais and
wires) Example Number of motors 100 Per
motor 2 DI (on/off,trip), 1 DO (on/off), 1 AI
(current) Distance MCC - DCS 55m Conventional
MCC connected via IRP to DCS
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Intelligent MCCsAdvantages and disadvantages
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Intelligent MCCsAdvantages and disadvantages
Advantages Less downtime Less expensive (less
DCS I/O, relais and wires) A lot of functionality
is available (e.g. energy measurement) A lot of
data is available (e.g. for predictive
maintenance) Better authorisation Standard
starters for larger range of kWs Open
system Proven technology (large installed base)
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Intelligent MCCsAdvantages and disadvantages
A lot of functionality is available For
starters Control (DOL / SD / FR, manual/serial,
automatic restart) Protection (thermal,
earthfault, phase unbalance, undervoltage) Measure
ment (current, voltage, power factor, power,
energy) For feeders Control (automatic restart
for contactor feeders) Protection
(earthfault) Measurement (current, voltage, power
factor, power, energy)
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Intelligent MCCsAdvantages and disadvantages
Advantages Less downtime Less expensive (less
DCS I/O, relais and wires) A lot of functionality
is available (e.g. energy measurement) A lot of
data is available (e.g. for predictive
maintenance) Better authorisation Standard
starters for larger range of kWs Open
system Proven technology (large installed base)
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Intelligent MCCsAdvantages and disadvantages
A lot of data is available (e.g. for preventive
maintenance use) Number of operating
hours Number of contactor operations Number of
contactor operations last hour Starting
current Starting time Trip current Trip
indication Time to trip Time to reset
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Intelligent MCCsAdvantages and disadvantages
Advantages Less downtime Less expensive (less
DCS I/O, relais and wires) A lot of functionality
is available (e.g. energy measurement) A lot of
data is available (e.g. for predictive
maintenance) Better authorisation Standard
starters for larger range of kWs Open
system Proven technology (large installed base)
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Intelligent MCCsAdvantages and disadvantages
Better authorisation Need password to change
settings (no screwdriver) Need password for
manual control
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Intelligent MCCsAdvantages and disadvantages
Advantages Less downtime Less expensive (less
DCS I/O, relais and wires) A lot of functionality
is available (e.g. energy measurement) A lot of
data is available (e.g. for predictive
maintenance) Better authorisation Standard
starters for larger range of kWs Open
system Proven technology (large installed base)
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Intelligent MCCsAdvantages and disadvantages
Standard starters for large range of kWs Typical
schematics Typical protection settings
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Intelligent MCCsAdvantages and disadvantages
Advantages Less downtime Less expensive (less
DCS I/O, relais and wires) A lot of functionality
is available (e.g. energy measurement) A lot of
data is available (e.g. for predictive
maintenance) Better authorisation Standard
starters for larger range of kWs Open system
Proven technology (large installed base)
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Intelligent MCCsAdvantages and disadvantages
Open system Open interface contactor brand
independent Open internal network DeviceNet
(ODVA certified) Open communication to process
control Modbus/Profibus/Ethernet
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Intelligent MCCsAdvantages and disadvantages
Advantages Less downtime Less expensive (less
DCS I/O, relais and wires) A lot of functionality
is available (e.g. energy measurement) A lot of
data is available (e.g. for predictive
maintenance) Better authorisation Standard
starters for larger range of kWs Open
system Proven technology (large installed base)
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Intelligent MCCsAdvantages and disadvantages
Proven technology Eaton (Holec) history 1985
CIT 1993 Clink 1999 ClinkII
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Intelligent MCCsAdvantages and disadvantages

• Proven technology some Eaton (Holec) Clink
  references
• ADMA-OPCO Abu Dhabi
• BSP Brunei
• Isla Refinary Curacao
• Ceska Czech Rep.
• Khalda Egypt
• Phillips Great Britain
• SSB Malaysia
• Lyondell Netherlands
• SPDC Nigeria
• PDO Oman
• PSPC Philippines
• SEPC Singapore
• GNOPC Sudan
• Thai Shell EP Thailand
• Qatar Kentz Qatar

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Intelligent MCCsNew developments
Communication on device level Ethernet
communication Wireless communication Advanced
diagnostics Smart maintenance solutions Energy
management
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Intelligent MCCsNew developments
Communication on device level Eaton IT
contactor 24VDC control voltage Small
footprint DeviceNet communications
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Intelligent MCCsNew developments
Communication on device level Ethernet
communication Wireless communication Advanced
diagnostics Smart maintenance solutions Energy
management
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Intelligent MCCsNew developments
Ethernet communication Modbus TCP Ethernet
IP Profinet Other..
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Intelligent MCCsNew developments
Communication on device level Ethernet
communication Wireless communication Advanced
diagnostics Smart maintenance solutions Energy
management
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Intelligent MCCsNew developments
Wireless communication Suitable for use in
industrial environment
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Intelligent MCCsNew developments
Communication on device level Ethernet
communication Wireless communication Advanced
diagnostics Smart maintenance solutions Energy
management
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Intelligent MCCsNew developments
Advanced diagnostics Harmonics
measurement Vibration monitoring Trending
(logging) facilities Recording of events with
date/time stamps
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Intelligent MCCsNew developments
Communication on device level Ethernet
communication Wireless communication Advanced
diagnostics Smart maintenance solutions Energy
management
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Intelligent MCCsNew developments
Smart maintenance solutions Easy exchange of
data with - spreadsheet programs (e.g. decide to
exchange motor bearings based on running hours,
replace contactors when number of contactor
operations exceeds a limit) - existing
Maintenance systems/programs (e.g. Maximo)
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Intelligent MCCsNew developments
Communication on device level Ethernet
communication Wireless communication Advanced
diagnostics Smart maintenance solutions Energy
management
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Intelligent MCCsNew developments
Energy management Integrate Automatic
Change-Over functionalities (e.g. change over
from transformer to generator in case) Integrate
Load-shedding functionalities (switch of loads if
insufficient power is available)
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Intelligent MCCsSummary
Commercial benefits (down time, wiring costs) A
lot of functionality standard avaialable (kW,
kWh,..) A lot of data is available (process
automation, maintenance) Better authorisation (no
screwdrivers but passwords) Standard schematics
and settings Proven technology (large installed
base)
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Intelligent MCCsQuestions?