Smart Motor Management

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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”
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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.
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When the overload trips ….
what happens to the process??
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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”
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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?
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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”
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A tripped overload relay
causes:
• Unexpected shut downs
• Unidentified reason for the trip
• Potentially hazardous conditions
• Potential scrapped material
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page 4
• Potential lost production
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Time Based or Preventive Maintenance
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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
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Traditional motor maintenance relies
on traditional motor protection devices.
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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
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Traditional motor maintenance
• Relies on traditional motor load protective
devices.
• Offers little help in troubleshooting the cause of
the trip.
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• Does little to prevent unwanted shut downs
caused by dynamic changes to the protected
loads.
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page 7
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
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Condition based, or Predictive
Maintenance is based on historical
load information, such as:
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• Operating hours
• Number of starts
• Number of trips
• Load data ($$$)
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page 8
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
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Condition based, or Predictive
Maintenance requires gathering
information. But how?
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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.
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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.
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page 10
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
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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.
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page 11
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
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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.
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• 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.
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SIMOCODE pro C
V
Current
Current
Voltage
Power
Power Factor
(Motor Overload)
Inputs
Local Logic
I/O Expansion
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page 13
PROFIBUS
Outputs
Digital
Analog
Temperature
Ground Fault
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
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SIMOCODE pro V in a typical tiastar™ unit
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page 14
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
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SIMOCODE pro Standard Protective Functions
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page 15
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
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SIMOCODE pro Standard Protective Functions
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page 16
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
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SIMOCODE pro Optional Protective Functions – Voltage Based
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page 17
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
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SIMOCODE pro Optional Protective Functions – Analog
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page 18
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
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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)
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Device Operating Hours
Motor Voltage
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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
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page 19
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance
Condition Based (Predictive) Maintenance.
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There are significant benefits from
employing a Condition Based Predictive
motor maintenance program:
• Smart motor management provides real time, dynamic motor and load
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data to facilitate Predictive motor and load maintenance.
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• Smart motor management includes enhanced monitoring and
protective functions.
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• 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
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