Transcript Smart Motor Management: How data-driven visibility can help protect both processes and motors in key industrial applications

s
Smart Motor
Management
How data-driven visibility can help
protect both processes and motors
in key industrial applications
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
“Wait ‘til it trips”
Item
Item
Item
Traditional motor control circuits use
thermal, or electronic, overload relays to
protect electric motors from the effects
of heat generated from mechanical or
electrical overload conditions.
Item
Item
Item
Item
When the overload trips ….
what happens to the process??
Item
Item
Item
page 2
When the overload relay detects an
overload condition of sufficient
magnitude and duration, a normally
closed contact on the overload relay
opens, turning the protected motor off.
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
“Wait ‘til it trips”
Item
Item
Item
Item
Item
Item
When the overload trips ….
• Was it caused by a mechanical load
problem? (bearing, poor maintenance, etc.)
• Was it caused by a motor problem?
• Was it caused by an electrical power
problem?
Item
Item
Item
Item
page 3
• What was happening when the motor
tripped?
What needs to be corrected to
restore the process?
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
“Wait ‘til it trips”
Item
Item
Item
Item
Item
Item
Item
Item
A tripped overload relay
causes:
• Unexpected shut downs
• Unidentified reason for the trip
• Potentially hazardous conditions
• Potential scrapped material
Item
Item
page 4
• Potential lost production
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Time Based or Preventive Maintenance
Item
Item
Item
Item
Item
Item
Item
Item
Item
Item
page 5
Time based maintenance does not
“wait ‘til it trips”. It is:
• based on a presumed schedule, much like the
maintenance schedule for a car.
• often scheduled around planned shut downs.
• can lead to unnecessary maintenance.
• not able to identify parts that are nearing the end
of their service life.
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
“Wait ‘til it trips” or Preventive Maintenance
Item
Item
Traditional motor maintenance relies
on traditional motor protection devices.
Item
Item
Item
Item
Item
Item
Item
Item
page 6
Thermal overloads
(bimetallic) and basic
electronic overloads
(ESP200) provide
limited protective
functions. The
additional protective
functions on ESP200 do
not annunciate the
reason for the trip.
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
“Wait ‘til it trips” or Preventive Maintenance
Item
Item
Item
Item
Item
Traditional motor maintenance
• Relies on traditional motor load protective
devices.
• Offers little help in troubleshooting the cause of
the trip.
Item
Item
Item
• Does little to prevent unwanted shut downs
caused by dynamic changes to the protected
loads.
Item
Item
page 7
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
Item
Item
Item
Condition based, or Predictive
Maintenance is based on historical
load information, such as:
Item
Item
Item
Item
Item
Item
• Operating hours
• Number of starts
• Number of trips
• Load data ($$$)
Item
page 8
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
Item
Item
Item
Condition based, or Predictive
Maintenance requires gathering
information. But how?
Item
Item
Item
Item
Item
Item
Item
page 9
Traditional devices only indicate the
present condition of the connected
load.
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
Item
Item
Item
Item
Item
Item
Item
Item
Item
Condition Based, or Predictive
Maintenance requires that operating
information for the connected load be
gathered and stored to identify
conditions that require maintenance.
More information leads to more
effective predictive maintenance.
Item
page 10
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
Item
Item
Item
Intelligent, communicating overload devices offer a
wide range of selectable protective functions.
Siemens SIMOCODE pro Motor Management
device can provide all of the functions listed below.
Item
Item
Item
Item
Item
Item
Item
page 11
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
Item
Item
Item
Item
Item
Item
Item
Enhanced capabilities allow the user to:
• tailor protective functions to
the load.
• get warnings of developing
problems before a trip occurs.
• gather dynamic load
information.
Item
Item
Item
• select the response of the
protective device.
• know why the device tripped.
page 12
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
Item
Item
Item
Item
SIMOCODE pro C
V
Current
Current
Voltage
Power
Power Factor
(Motor Overload)
Inputs
Local Logic
I/O Expansion
Item
Item
Item
Item
Item
Item
page 13
PROFIBUS
Outputs
Digital
Analog
Temperature
Ground Fault
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
Item
SIMOCODE pro V in a typical tiastar™ unit
Item
Item
Item
Item
Item
Item
Item
Item
Item
page 14
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
Item
SIMOCODE pro Standard Protective Functions
Item
Item
Item
Item
Item
Item
Item
Item
Item
page 15
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
Item
SIMOCODE pro Standard Protective Functions
Item
Item
Item
Item
Item
Item
Item
Item
Item
page 16
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
Item
SIMOCODE pro Optional Protective Functions – Voltage Based
Item
Item
Item
Item
Item
Item
Item
Item
Item
page 17
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
Item
SIMOCODE pro Optional Protective Functions – Analog
Item
Item
Item
Item
Item
Item
Item
Item
Item
page 18
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
Item
Item
SIMOCODE pro
Available Data
Number of Overload Trips
Individual Event Messages (62)
Number of Parameterizations
Individual Warning Messages (33)
Motor Stop Time
Individual Trip Messages (48)
Operating Hours
Motor Current (%FLA)
Item
Device Operating Hours
Motor Voltage
Item
Number of Starts
Motor Power (W & VA)
Number of Starts Left
Power Factor (COS Phi)
Number of Starts Right
Time to Trip
Consumed Energy (kWh)
Cool Down Period
Individual Status Messages (29)
Last Trip Current
Item
Item
Item
Item
Item
Item
page 19
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
Item
Item
Item
Item
There are significant benefits from
employing a Condition Based Predictive
motor maintenance program:
• Smart motor management provides real time, dynamic motor and load
Item
data to facilitate Predictive motor and load maintenance.
Item
• Smart motor management includes enhanced monitoring and
protective functions.
Item
Item
Item
Item
• Smart motor management allows selected responses to monitored
motor or load conditions.
• Smart motor management can alert the user to an impending problem
and prevent unwanted shutdowns.
•Smart motor management alerts the user as to the cause of a trip or
warning, simplifying maintenance.
page 20
© Siemens Industry, Inc. 2011