Siemens tiastar TM Motor Control Center (MCC) Siemens All rights reserved.

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2 tiastar Arc Resistant MCCs UL Validated Testing of Arc-Resistant Motor Control Centers page 2

3 tiastar Arc Resistant MCCs Statistics Arc flashes are responsible for about 80 percent of electrical accidents in the U.S. each year 1. In human terms, they are responsible for hundreds of deaths, thousands of serious injuries, and significant lost work time every year. 2 Bureau of Labor Statistics Census of Fatal Occupational Injuries page 3

4 tiastar MCCs Arc Flash Arc flashes are responsible for about 80 percent of electrical accidents in the U.S. each year. Personal Protective Equipment (PPE) can help avoid or reduce the severity of injuries Electrical equipment manufacturers have applied strengthened structural design to improve the safety potential of its Switchgears. Standards for performance-testing arc-resistant features defined for switchgear not MCCs. Manufacturers are using those standards for testing arc-resistant MCCs. page 4

5 tiastar Arc Resistant MCCs Prevention The simplest and most effective measure to prevent an arc flash is to shut off all power to the equipment to be worked on. Siemens advises that individuals should only work on MCCs or other electrical equipment after all power to the equipment has been turned off. Arc flash prevention, safety training and PPE can only go so far in keeping workers out of harm s way should an arc fault occur. Although PPE can provide protection from an arc flash, it still cannot protect an operator from being struck by enclosure doors blown off or open from an arc flash or from fragments ejected from a disintegrating enclosure. page 5

6 tiastar Arc Resistant MCCs Arc Mitigation & Arc Resistant Equipment Arc flash hazard mitigation and arc-resistant features. Designed to complement each other. Arc flash mitigation features: To keep the workers beyond the Arc Flash Boundary To shorten the arc flash duration Arc resistant equipment: To make sure that, in the event of an arc flash when the MCC s doors are closed and latched, the equipment will contain the explosion, directing the arc blast, including its heat, plasma and pressure, away from workers. page 6

7 tiastar MCCs Arc Flash Mitigation Arc Flash Hazard Mitigation Features available in tiastar MCC: Dynamic Arc Flash Sentry (DAS): This is a patented feature available in both Siemens MCCs and type WL Low Voltage Switchgear. DAS (alternate parameter settings) can be activated using a variety of activation methods (keyed switch, occupancy sensors, light curtains, etc.). Visual verification of DAS activation can be as simple as a pilot light or more elaborate such as horn and strobe light. page 7

8 tiastar Arc Resistant MCCs Arc Flash Mitigation Normal Operation Parameter A Maintenance Operation Parameter B page 8

9 tiastar Arc Resistant MCCs Arc Flash Mitigation page 9

10 tiastar Arc Resistant MCCs Siemens is the first manufacturer in the industry to have Underwriters Laboratories (UL) observe and validate the testing of its arcresistant tiastar TM MCC model. The tiastar arc-resistant MCC successfully met the testing criteria required by the standards, and a qualified, independent third-party has confirmed this satisfactory performance. page 10

11 The new tiastar product family: tailor made feature sets focused on your industry Base HD H2O Smart Your Industry Construction Commercial Offshore O&G Real estate Warehouses Municipal W/WW Process Industries Pharmaceuticals Why Tiastar Fastest shippingat lowest price point Smallest footprint with highest safety and performance Arc-Resistant MCC Always-on reliability, industryleading asset protection Always on, autonomous backup (failover), automatic process adjustments page 11

12 tiastar Arc Resistant: Features that reach farther Arc Flash Resistant Setting a new safety standard, tiastar is the first IEEE C compliant arc resistant motor control center with UL-witnessed testing. Decrease the risk of exposure to arc flash incidents to better protect personnel. page 12

13 tiastar Arc Resistant: Protecting your most valuable asset your personnel Reinforced enclosure and doors, with bolted rear covers: Increased hinge and latching locations combined with additional structural supports ensure sections will withstand, contain and re-direct internal arcing fault incident energy. Insulated vertical bus bar system: Isolates energized components preventing inadvertent contact and propagation of arcing faults. Automatic shutters in plug-in unit compartments: Isolates the plug-in location to prevent inadvertent access and lowers the risk to personnel. Internal venting system: The structure components are designed to vent and channel arc flash gasses to the back and out the top of the MCC. page 13

14 tiastar Arc Resistant MCCs Features ANSI/IEEE Type 2 arc resistance to protect personnel at the front, back and sides of the equipment Reinforced enclosure to withstand pressure from internal arcing faults Internal venting system with pressure vents to channel the flow of arc fault gases and vent these gases out the top of the gear and away from personnel page 14

15 tiastar Arc Resistant MCCs Features Reinforced front with doors with extra hinges and stronger latching systems Reinforced bolted rear covers page 15

16 tiastar Arc Resistant MCCs Features Insulated bus bar system Automatic Shutters page 16

17 tiastar Arc Resistant MCCs Features Arc flashes present a serious safety risk. The best protection is prevention by enforcing strict safety rules, mandate proper maintenance, and support that with regular safety training. Advances in technology have enabled electrical equipment the means to design and engineer much more arc flash safety features into their products and systems such as switchgear and MCCs. While standards continue to evolve, they inherently follow these kinds of innovations. It is important that the application testing of new safety features be validated by a qualified third-party like UL to ensure that the safety features work as intended and to prevent tragic accidents. page 17

19 Smart MCCs What is a Smart MCC? A smart MCC can communicate via a network by incorporating intelligent devices to: control motors monitor motor operation monitor energy consumption monitor power quality monitor system operation communicate with a data network page 19

20 Smart MCCs Monitoring System Operation Historically MCCs have played a limited roll in monitoring system operation. providing basic information to the PLC M OL Example - start-stop motor control circuit PLC inputs are connected to normally open auxiliary contacts. M contact closes when the motor starter coil energizes. OL contact closes when an overload occurs. page 20

21 Smart MCCs Monitoring System Operation Historically basic information to the adding to the initial cost of the system Conventional Wiring for 1 motor starter (5 wires minimum) ON OFF FAULT Motor RUN Output Motor Starter Run and Trip Input Signals Remote PLC /DCS page 21

22 Smart Motor Control Centers: What is the cost? Motor Starter 5 Motors 25 Wires Remote PLC / DCS Motor Starter Remote PLC / DCS Motor Starter Remote PLC / DCS Motor Starter Remote PLC / DCS Page page Motor Starter Remote PLC / DCS

23 Smart Motor Control Centers: What is the cost? Page page Motors 125 Wires

24 Smart Motor Control Centers: What is the cost? Page page 24 24

25 Smart MCCs Monitoring System Operation Historically basic information to the PLC adds to the initial cost of the system PLC wiring labor page 25

26 Smart MCCs Monitoring System Operation Historically Increase system complexity Increase the number of wires Increase cost to gain limited information NOW Smart MCCs incorporate intelligent devices Providing expanded protection to motors Communicate information previously difficult to obtain or unavailable Motor Operation Power Conditions Status of External Events page 26

27 tiastar Smart MCCs Network Communication PROTOCOL Many different protocol exist PROFIBUS PROFINET Industrial Ethernet AS-Interface PROFIBUS DP is the primary network used internal to a tiastar SMART MCC PROFIBUS DP is an open network based on the IEC 61158/61784 standard. page 27

28 Smart Motor Control Centers: What is the cost? Page page Assuming 25 starters and 100 between mcc units and the PLC/DCS: (25) SIMOCODEs (0) Starter aux. contacts (0) Overload alarm contacts (0) Digital PLC input points (0) Digital PLC output points 200 feet PROFIBUS cable and connectors Approximately $12500

29 tiastar Smart MCCs Monitoring System Operation Intelligent Components Simocode VFD Power Meter WL CB RVSS page 29

30 tiastar Smart MCCs Pro C The compact system for: Direct starters Reversing starters SIMOCODE Siemens Motor Management and Control Device Pro V The variable system for: all control functions extendable additional functions page 30

31 tiastar Smart MCCs Monitoring System Operation Conventional Information Additional desirable information, such as ON WARNING FAIL TO START UNDER LOAD OFF JAM PHASE LOSS OVER TEMP FAULT AUTO CONTROL POWER??? Typically not provided on most motors due to cost page 31

32 tiastar Smart MCCs Application: Electrical + Spannungserfassung pump (up to 550 kw) Configuring Operator Station of the application within SIMOCODE pro possible Application remains available during fails of the automation or communication system Profibus interface is the standardized interface between Engineering Station Maintenance Station Power Management application and automation system SIMOCODE pro Basic unit - Protection - Control - Interlockings - Monitoring - Communication Temperature module Analog module Digital modules Protection against overload, stall, phase failure, Monitoring of power, Cos-Phi motor idling, rotational direction Temperature monitoring e.g. of the bearings, windings, medium, cooling fluid Monitoring e.g. of the filling level, filter dirt, flow rate, run dry protection, Pressure of the cooling fluid or gear oil Monitoring/Status e.g. overflow, run dry protection, Check-back signals: Open, Closed, On, Off page 32 Pump Flow rate Filter

33 tiastar Smart MCCs Siemens Motor Management and Control Device PARTIAL LIST OF INFORMATION AVAILABLE MOTOR OPERATION POWER CONDITIONS STATUS OF EXTERNAL EVENTS OPERATIONAL STATUS PHASE CURRENTS DISCRETE INPUTS NUMBER OF STARTS PHASE VOLTAGES ANALOG INPUTS OPERATING TIME PHASE FAILURE RESULTS OF INTERNAL LOGIC STOP TIME NUMBER OF FORWARD STARTS NUMBER OF REVERSE STARTS MOTOR/BEARING TEMPERATURE NUMBER OF OVERLOAD TRIPS TIME TO TRIP PHASE IMBALANCE GROUND FAULT ENERGY CONSUMED REAL POWER APPARENT POWER POWER FACTOR LAST TRIP CURRENT COOL DOWN PERIOD page 33

34 tiastar Smart MCCs Process Visualization and Control integration to a larger system SIMATIC WinCC SCADA system Configurable to provide complete operating and monitoring functionality SIMATIC PCS 7 uniform data management, communication, and configuration capabilities open platform for solutions in batch, continuous, and hybrid process applications page 34

35 Data Record Capability with Simocode ES software or S7300 PLC page 35

36 Data Record Capability with S7400 PLC with PCS7 Limits -current limits Maintenance -Local/Remote Standard -Control Statistic Alarm - PCS7 Alarm logging Trend Faults Warnings Batch Control - PCS7 Batch Control page 36

37 tiastar Smart Start A truly plug-n-play option for tiastar Smart. Fully operational the moment you switch it on. Faster Start: Pre-programmed, pre-configured and pre-tested PLC and HMI combination reduces field engineering and commissioning times for quicker installation. Fast Access: Standardized PLC and HMI offer instant access and control of all the information in every PROFIBUS device from the moment the unit is switched on. Users can start, stop, test and verify all motor operations immediately after installation. page 37

38 Smart Start Elevation Configuration page 38

39 Smart Start Main Screen, SIMOCODE View page 39

40 Smart Start Main Screen, Variable Frequency Drive View page 40

41 Smart Start Main Screen, RVSS View page 41

42 Siemens tiastar Motor Control Centers Base HD H2O Smart Arc-Resistant Designed to meet your application requirements page 42

43 The new tiastar product family Base Attractive Price Point & Lead Times HD Smallest Footprint Arc Resistant Increased Operational Safety H20 Integrated Drives Smart Diagnostics & Fast Start up page 43

44 Totally Integrated Automation and Totally Integrated Power Field instrumentation Process analyzers Process control system SIMATIC PCS 7 PLC (SIMATIC S7) HVAC MES (SIMATIC IT) TIA Drives (SINAMICS) Medium Voltage Switchgear WL Low Voltage Switchgear TIASTAR Motor Control Centers ACCESS Power Monitoring TIP ERP Enterprise Resource Planning MES Manufacturing Execution Systems Automation >=110kV Medium Voltage Low Voltage page 44

45 Smart Motor Control Centers: What is the cost? Assuming 25 starters and 100 average per wire length, the traditional wiring solution requires: (25) Starter aux. contacts (25) Overload alarm contacts (50) Digital PLC input points (25) Digital PLC output points 12,500 feet interconnect wire Approximately $12500 (components, wire, installation) Page page 45 45