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Considerations for Designing an

Intelligent Motor Control Center

PUBLIC INFORMATION

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.


Agenda

IntelliCENTER® Technology
What is it and how does it improve the design and operation of an MCC?

Embedded Systems and Intelligent Motor Control

Software and Controller Integration

IntelliCENTER® MCC Return on Investment Case Study


How does it lower the installation and operating costs of an MCC?

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.


IntelliCENTER Technology Overview

 Integrated, preconfigured
network infrastructure
 Order specific,
customized support
materials
 Preconfigured user
interface software for
monitoring, diagnostics
and configuration

Leverage IntelliCENTER to enable and strengthen enterprise solutions


Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Value of IntelliCENTER Technology
 Faster integration
 Network is preconfigured (node number, IP address, baud
rates, functionality verified)
 Faster installation compared to hardwired I/O
 Control and diagnostics
 State of the art intelligent motor controls provide crucial
feedback from motors
 Precise control with intelligent motor control devices
 Wide array of device level components
 More information – where you need it, when you need it
 Enhances your plant asset management system
 Improved uptime
 Warnings in advance of failure
 Troubleshooting tools and information at your fingertips
Lowest total cost of ownership
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Agenda

IntelliCENTER Technology
What is it and how does it improve the design and operation of an MCC?

Embedded Systems and Intelligent Motor Control

Software and Controller Integration

IntelliCENTER MCC Return on Investment Case Study


How does it lower the installation and operating costs of an MCC?

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.


EtherNet/IP for Seamless Integration

 A single network for all Automation and Process control equipment


 Seamlessly linked to the front office for increased access to information
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
EtherNet/IP Design

 Design consistent with DeviceNet IntelliCENTER


 Cables are behind the vertical wireway
 Does not take up any additional space
 24V power supply required
 Easy to install in the field
 All nodes preconfigured with the IntelliCENTER database pre-built at the factory
 Robust, noise immune network solution
EtherNet/IP Structure EtherNet/IP Units

 600V UL-listed Ethernet cable  PowerFlex® Drives


(Rockwell Automation exclusive)  SMC™ Flex Soft Starters
 Stratix 5700™ Industrial Switch  E1 Plus™ Overload Relays for Starters
 E3 Plus™ Overload Relays for Starters
 Point I/O™

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.


EtherNet/IP Design

The EtherNet/IP network in CENTERLINE® MCCs has been tested to the


most rigorous standards for electrical noise immunity.
Lightning Strike Industrial Noise
 +/- 2KV, 40A surge repeatedly  +/- 1KV high voltage burst
applied to the network cable applied to the network cable
 IEC 61000-4-5  IEC 61000-4-4

No communication failures!
No dropped packets!
Less down time!

Radio Frequency Interference Static Discharge


 150kHz … 80MHz interference  +/- 8KV ESD event at 12 locations
applied to the network cable on the MCC and network cable
 IEC 61000-4-6  IEC 61000-4-2

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.


CENTERLINE® 2100 MCC
IntelliCENTER EtherNet/IP Layout

Power Supply

SMC™ Flex
193-ETN
(E1 Plus)

PowerFlex® 755

EtherNet/IP Connections
2100-ENET
(E3 Plus) 24V DC Connections
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
CENTERLINE® 2500 MCC
IntelliCENTER EtherNet/IP Layout

Power Supply

2100-ENET PowerFlex 755


(E3 Plus)
193-ETN
(E1 Plus)

EtherNet/IP Connections
SMC Flex 24V DC Connections
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER® EtherNet/IP Topology #1
MCC Sections Connected via Switch-Level Linear Topology
Enterprise-wide
Business Systems Levels 4 and 5 – Data Center
Enterprise Zone

Level 3.5 - IDMZ

Level 3 - Site Operations


Cell/ Area Zone # 1 Plant-wide Physical or Virtualized Servers Industrial Zone
Machine Site-wide •

FactoryTalk® Application Servers & Services Platform
Network Services – e.g. DNS, AD, DHCP, AAA
Operation Systems • Remote Access Server (RAS)
• Call Manager Levels 0-2
• Storage Array
Cell/Area Zones

Cell/Area Zone # 3
Electrical Distribution System
Power Control Room MCC Sections

Section 1 Section 2 Section N

Cell/ Area Zone # 2


Industrial Automation & Control System

Motor
Control
Center

IEC 61850 Switchgear


CIP/MMS
Gateway Substation
MMS E-House
Security Reporting Co-Gen
Appliance
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
IntelliCENTER EtherNet/IP Topology #2
MCC Sections Connected via Switch-Level Ring Topology
Enterprise-wide
Business Systems Levels 4 and 5 – Data Center
Enterprise Zone

Level 3.5 - IDMZ

Level 3 - Site Operations


Cell/ Area Zone # 1 Plant-wide Physical or Virtualized Servers Industrial Zone
Machine Site-wide •

FactoryTalk Application Servers & Services Platform
Network Services – e.g. DNS, AD, DHCP, AAA
Operation Systems • Remote Access Server (RAS)
• Call Manager Levels 0-2
• Storage Array
Cell/Area Zones

Cell/Area Zone # 3
Electrical Distribution System
Power Control Room MCC Sections

Section 1 Section 2 Section N

Cell/ Area Zone # 2


Industrial Automation & Control System

Motor
Control
Center

IEC 61850 Switchgear


CIP/MMS
Gateway Substation
MMS E-House
Security Reporting Co-Gen
Appliance
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Agenda

IntelliCENTER Technology
What is it and how does it improve the design and operation of an MCC?

Embedded Systems and Intelligent Motor Control

Software and Controller Integration

IntelliCENTER MCC Return on Investment Case Study


How does it lower the installation and operating costs of an MCC?

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.


IntelliCENTER Software

System Level Dashboard Component Configuration


 Virtual view of the MCC  Parameter editor
 Simple dashboard presentation  Device monitoring and
configuration
 Customer configurable
 Remote diagnostic support
 Exclusive functionality for
MCCs  Support for all IMC devices
in the MCC
 Trending and event logging

HMI Support Asset Management


 ActiveX and IMC faceplates provided Key customer documentation:
 Enables simple integration with On-Machine™ HMIs  User manuals
 Customized wire
diagrams
 Spare parts lists

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.


IntelliCENTER® Energy

IntelliCENTER Energy is a premier software package with all the features of IntelliCENTER®
PLUS additional energy management benefits powered by FactoryTalk® EnergyMetrix™:

 Real-time energy consumption and historical


trending down to the device level, all across the
network
 Ability to monitor and manage energy usage for
substantial cost savings

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.


IntelliCENTER Integration Assistant

 Provides valuable integration features


1. Automatically build the I/O tree for all Intelligent Motor Control devices in the MCC
2. Auto-generate the device tags using Device Add-On Profiles (AOPs)
 Full integration between power and control for Rockwell Automation products
 Exclusive integration capabilities

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.


IntelliCENTER Integration Assistant –
Rockwell Software Studio 5000 ®

Simple integration of devices into Studio 5000


Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Rockwell Software Studio 5000 –
Premier Integration
 Premier Integration via
Device Add-On Profiles
(AOPs)
 Device parameters
automatically mapped to
controller tags in Studio 5000
 Configure and program all
intelligent motor control devices
in Studio 5000
 Configuration stored in the
controller to simplify device
replacement (in ACD file)

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.


Agenda

IntelliCENTER Technology
What is it and how does it improve the design and operation of an MCC?

Embedded Systems and Intelligent Motor Control

Software and Controller Integration

IntelliCENTER MCC Return on Investment Case Study


How does it lower the installation and operating costs of an MCC?

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.


IntelliCENTER Motor Control Center
Value Statement

 A Rockwell Automation IntelliCENTER Motor Control Center can help to


reduce installation and first year operating costs by up to 20%
 Four key areas of value:
 Installation time
 Integration
 Energy use
 Downtime avoidance

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.


Unintelligent MCC Example

 Example unintelligent MCC, price is $50,000


 4 columns
 5 units/columns PLC
 5 I/O points per unit
Control Room
 5 drives
 15 starters
For this example
ACME UNINTELLIGENT MCC MCC, we will
estimate the
IntelliCENTER
equipped price to be
$56,000
Factory Floor
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Do-It-Yourself Integration

 Hardware
 Conduit installation
 Wire cutting, stripping, preparation,
and pulling
 Labeling, updating drawings
 Testing, possible rework
 Programming
 I/O mapping
 Tag creation
 Device configuration
 HMI integration
 Testing, troubleshooting

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.


Example - Materials

 Material costs for hard-wiring:


 Wire:$0.65 per meter / wire
 Conduit: $46 per meter
 Logic I/O Cards: $20.34 on average per point
 Calculations:
 20 meters * $46/meter = $920 in conduit
 20 meters * 100 wires * $0.65/meter = $1,300 in wire
 100 points * $20.34/point = $2,034 in I/O cards

$4,254 for cost of materials


Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Example – Labor

 Labor costs for hard-wiring:


 Including wiring, terminating, labeling, updating drawings, and testing we estimate
30 mins per I/O point
 50 hrs for 100 I/O points
 Assuming low-cost resources at $25/hr, $1,250 in electrician labor

 Labor costs for Integration/Testing:


 Including programming, testing, and troubleshooting
 5 days = 40hrs
 Assuming $44/hr, $1,760 in engineering labor

$3,010 in labor costs and 11 persons / days of work


Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Total Costs Before Startup

 Total material costs:


 $4,254
 Total Labor costs:
 $3,010
 Total person-days of startup time:
 Approximately 11 days

Time is money.
Are your projects ever behind?

$7,264 estimated in total costs prior to startup


Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Cost Correction

 With the IntelliCENTER package, you will need an EtherNet/IP card for
your controller
 Since we took the cost of the discrete I/O cards into account earlier, we
will subtract the cost of the EtherNet/IP card to give us a real cost
comparison:
 $7,264 – $1,410 = $5,854

$5,854 in corrected costs prior to startup


Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Initial Savings

 $5,854 is roughly equivalent to 10% of the price of the unintelligent MCC


 Since the IntelliCENTER option typically only accounts for an estimated
10% of the unintelligent MCC cost (or 12% in our example), we have
illustrated savings that account for almost its entire cost
 The cost savings when compared to the cost of the IntelliCENTER MCC
is roughly 9% in our example

In our example, the IntelliCENTER option almost pays for itself


before you even turn it on for the first time!
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Energy

 A 1600A, 480V MCC will draw 614.4kW running at 80% efficiency


 At $0.07/kWh, this correlates to $43.00/hr in energy
 Running 2 shifts a day (16 hours), 280 days a year, this means
$192,640 in energy each year is passing through your MCC, almost 4
times the original purchase price!

An MCC will distribute multiples of its purchase price in energy


each year!
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Energy Savings

 Through energy-monitoring enhancements in IntelliCENTER, we can


provide you with pre-configured access to the following information:
 Real-time energy consumption information for the MCC down to the unit level including
historical trending - Most manufacturers monitor at the line level, rarely do they monitor at
the load level (more granular insight) to make energy decisions
 Power-quality analysis - Power factor penalties can add 10-30% to your electric bill
 Alarms for when energy consumption at the MCC or a particular unit is beyond a set level
- Peak demand charges can be 20% or more of your electric bill!
 Using this information to make smart decisions about your process, you
can potentially save on your energy bill. Imagine being able to save
even just 2%... that correlates to a savings of $3,852 each year – which
is almost 10% of the purchase price of the MCC in our example!

The savings that can be gained through energy monitoring and


smart decisions can be huge!
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Maintenance Costs – Motor Example
Motors seldom fail instantly. Through intelligent monitoring of drive
parameters, you can give your maintenance personnel insight that can
help them catch motor problems before they become expensive motor
failures.
Failure distribution statistics
Source: IEEE Petro- Chemical Paper PCIC-94-01

75% of motor
failures can be
prevented

Device failures can be prevented


Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Maintenance Costs – Motor Exam

 Can you afford to have your line down for even one unexpected hour?
 Knowledge is power, take advantage of the insight gained through
intelligent monitoring of your MCC system to reduce your downtime
Average downtime costs per hour by industry
Electronics $500,000 Paper $36,000
Rubber $25,000 Plastic $12,000
Automotive $1.6M Oil& Gas $3M
Pharma $1.1M Food & Bev $8,000
Chemicals $700,000 Metals $600,000

Saving even just 15 minutes of downtime at a very conservative cost of $2,000/hr


each year is almost 4% of the initial purchase price of our example MCC!
If you can eliminate even just one downtime event, you’ve paid for IntelliCENTER
and then some!
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Summing it all up

 This example has illustrated the following cost savings over the course
of one year
 $5,854 in material and labor costs
 $3,852 in potential energy savings
 $2,000 in potential downtime savings

 Approximately 21% in cost savings in the first year using


conservative numbers

 Over a typical 20-year lifecycle the savings can add up to $50k in


today’s dollars for our example

An IntelliCENTER® MCC can help you achieve a cost savings of at


least 20% on integration and first year operation!
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Calculate your Potential Savings

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.


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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 34
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