Optimizing Energy Consumption and Executive Summary
The escalating price of fossil
fuels marked by fierce global
Improving Operational Efficiency competition is driving process
industry decision makers to
Through the Use of Smart MCCs in rethink the way their
businesses will perform in the
Process Automation Systems future. In order to stay
competitive, manufacturers will
have to develop strategies to
conserve energy and limit their
usage of depleting fossil fuel
reserves. However, the
challenge in achieving this goal
is to do so without disrupting
production. This is where the
integration of Smart Motor
Controls (MCCs) into a process
automation system can play a
vital role in your energy
conservation strategy.
In 2005, the Energy
Information Administration
reported that 80% of the total
energy consumed in the U.S.
industrial sector is used
predominately by the process
White Paper
industries. Sixty-four percent of
the energy consumed in a
process plant today is used to
operate motors.1 In the future
there will be limited energy
resources to sustain process
manufacturing factories. Your
operation will depend on how
well your company can
manage its energy
consumption.
(continued on page 2)
process
Energy consumption is the second largest operating Motor Operations
expense in a plant (after raw materials), and thus The integration of motor management data directly into
optimizing the energy consumption of motors is a logical the DCS allows the device to communicate its operational
starting point for improvement. By integrating smart condition and status. This can be used for real-time
motor controls to monitor energy consumption, the monitoring of motors that can potentially detect motor
factory can remove wasteful energy expenditure, prevent problems before they occur. The maintenance performed
unplanned downtime, and improve overall operational on the motors is no longer reactive. Predictive and
efficiency. Additionally, with the recent amendment to the preventative measures can now be performed to prevent
U.S. Government's Energy Policy Act (EPAct) in 2005, tax motor failure and damage, allowing plant operators to
incentives are being offered for implementation of certain extend the life of their motors. Because motors consume
energy-savings measures. approximately 64% of the energy in the plant, monitoring
the operating condition is an essential aspect of any
The tight integration of motors, drives, and Smart MCCs energy conservation and maintenance program.
into a process automation system not only cuts energy
consumption, it also enables the end users to reduce their It is estimated that up to 40% of manufacturing revenue is
Total Cost of Ownership in an environmentally responsible applied to maintenance, and up to 60% of scheduled
way that demonstrates results in reduction of installation, maintenance checks on valves and motors proves
commissioning, operation and maintenance costs. unnecessary.2 Monitoring motor operations significantly
helps the plant operator develop an effective predictive
Let's take a closer look. and preventative maintenance program that is focused on
maximizing operational efficiency.
Introduction
Distributed control systems (DCSs) were designed to Motor Efficiency
provide regulatory control for the process control industry. Over the past two decades, significant improvements have
They were based on proprietary components such as been made to increase motor efficiencies above the
operating systems, networks, hardware, and configuration industry averages. Electric motors consume 10 to 25
tools. The standard DCS was mainly designed for times their purchase price in electricity each year, so even
communication within system boundaries and was known a 1% increase in motor efficiency can mean thousands of
for analog control and redundancy. Programmable Logic dollars worth of savings in the operation of the motor.
Controllers (PLCs), on the other hand, were designed for Premium efficiency motors cost a little more because of
high-speed control of discrete devices like motors, pumps, the superior material that goes into them, but the higher
and drives. cost typically can be recovered in 12 months or less.
Significant reductions in energy consumption can be
In the traditional process plant, PLCs were used to control realized by this technique.
the electrical infrastructure such as motors, drives and
MCCs, while regulatory control was left to the DCS. Since Variable frequency drives (VFDs) are becoming a popular
it was not economical to hardwire all of the operating approach to optimizing energy consumption to control
data from individual motor buckets into the PLC, nor to flow instead of using the traditional combination of a
pass this data to the plant's DCS, only minimal amounts of fixed-speed motor plus regulatory control valve. By
motor performance information was available to the regulating the speed of a drive in order to directly control
system operator to optimize energy usage. The power flow rate, a 50% energy reduction can be achieved in fluid
consumption information was available locally to the flow control applications.
plant electrician, but there was no mechanism to convey
the real-time power consumption of the plant to the Motor Control Center (MCC)
process operations or Manufacturing Execution Systems Motor control systems have a prominent role in industrial
(MES). Therefore, it was virtually impossible to determine processes. These systems are often housed in an MCC
the energy consumption for each individual process or which contains a comprehensive array of control and
unit. This prevented the plant from scheduling partial monitoring devices. Advances in technology and
shutdowns to improve energy efficiency or to take decreased cost of electronic devices have led to a boom in
advantage of the incentives that electric utilities offer to the inclusion of various controls and monitoring devices
reduce energy consumption during times of peak into the MCC. These devices, like relays, variable speed
demand. drives, and soft starters, are capable of providing a wealth
of data back to the control system regarding the condition
Today, a new class of DCS has emerged that is not only of the motor. This information can be presented in the
capable of providing the optimum control for regulatory DCS in a clear and easy-to-read format that can be used to
applications, but is also able to integrate and control high- increase productivity, minimize downtime and energy
speed discrete devices like MCCs, drives, soft starters, consumption, and improve personnel safety. Figure 1 on
breakers, and power metering devices. Process control page 3 shows the network view of a typical smart motor
systems capable of supporting this integrated approach control center.
enable dynamic monitoring of motor performance and
usher in a new era in energy management and
operational excellence.
2
Additionally, integrating power monitoring devices
into an MCC, which is connected to a DCS, gives
plant electrical engineers a central location where
all the information related to production data and
to the power system are recorded for analysis and
improvement.
Power monitors can record power consumption and
power quality data at the same time. There are
many causes of power quality problems, such as
voltage sags/swells, harmonics, fast impulses, sub-
cycle impulses, and neutral to ground high
frequency noise.
Factors that Affect Motor Performance
The five most important factors that affect the
motor performance in any process control system
Figure 1 Fieldbuses such as PROFIBUS and Actuator Sensor Interface (AS-i) are
are:
the communication backbone for the Smart Motor Control Center
1. Power quality
2. Motor operation
Conventional Motor Bucket 3. Motor condition
Each combination motor control unit is called a motor 4. Load and power consideration
bucket. Each motor bucket comes in different dimensions 5. Operating efficiency
depending on the size of the motor and is the part of the
MCC where the power to the individual motor is
controlled.
A motor designed to deliver higher horsepower would
require a larger size bucket, which means it would need a
larger contactor and breaker. This is where the similarity
between the conventional bucket and intelligent bucket
ends.
In a conventional bucket, an electrical overload switch and
a combination of relays would control the power to the
motor via a contactor. The relays are usually controlled by
the outputs from the PLC, and the feedback is provided via
auxiliary contacts to the digital inputs on the PLC.
Making MCCs "Smart"
An intelligent motor management system, such as
SIMOCODE from Siemens, can be added to the motor
bucket to make it "smart" (see Figure 2). The SIMOCODE
motor protection relay controls and protects the motor
and acts as an overload switch. The relay has a built-in
current and potential transformer to help the SIMOCODE Figure 2 Typical motor bucket with Intelligent Motor Management System
measure line current and voltage. It is capable of sending
all information on the motor's operating condition directly
to a DCS via a digital fieldbus, such as PROFIBUS. The
advantage of using fieldbus versus hardwiring of the
signals is that it enables all the data about the motor
operation to be transferred into the DCS in a cost-effective
manner. For example a single cable (fieldbus) can be used
to transfer data that would have required 6-12 separate
wire pairs per conventional MCC.
3
Power Quality Excess voltage applied to the motor causes it to waste
Monitoring the quality of the incoming power is very energy and operate inefficiently. Data logged in the DCS
important for maximizing the lifespan of the motor and can help operators identify these situations.
for ensuring that it continues to operate efficiently. Some
examples include: Motor Operation
A DCS that can monitor, log, and notify operations
Monitoring the voltage fluctuations to limit the personnel, when conditions require attention, can be
degradation in motor winding used to improve the overall efficiency and performance of
Ensuring that voltage in the power system is within the motor. In order to do predictive maintenance on the
proper range as to not create iron saturation that can motor, it is necessary to be able to measure all of the line
cause excessive heat to build up, resulting in the currents in the motor. Since the heat in each motor
degradation of the winding insulation winding is a function of the amount of current that flows
Lowering voltage, causing excessive current draw through it, the motor's potential weakest point is
that may result in damage to the winding and contained in the phase with the largest current (see
decrease in the motor efficiency or increased I2R Figure 3).
losses
Motors typically draw 6 to 10 times their rated current
Inconsistencies in the voltage can be caused by harmonics when they are started. This high current can cause the
introduced by variable frequency drives that are being windings to heat up, leading to degradation. Therefore, it
used within the plant or in nearby facilities. A small is necessary to limit the number of motor starts. An
amount of voltage distortion causes a large current effective predictive maintenance strategy will ensure that
distortion, which in turn will lead to excessive motor the number of hot starts is limited to protect the motor
currents and the potential for damage to the windings. winding (see Figure 4).
Figure 3 DCS faceplate showing the three line currents and
last trip current
Figure 4 DCS faceplate showing the number of permissible
starts and cooling down period
4
Motor Condition Analyzing trends in the DCS aids in the identification of
Tracking, trending, and alarming of motor operating these types of problems. In Figure 6, the large amplitude
conditions in a DCS is a valuable tool for predictive spikes indicate when the motor was started. The area on
maintenance (see Figure 5). A motor that draws the motor trend marked by the red lines indicates a
excessively large current during startup indicates condition when the energy consumption of the motor
load-related problems. This results in inefficient energy increased by 25%. This increase in the energy
usage and can cause unnecessary burden on the power consumption indicates a change in the motor's operating
system every time it starts. conditions, which could result from an increased load,
unusual process conditions, or a problem with the motor.
Figure 5 DCS faceplate showing the details of the single motor bucket parameters
Figure 6 Motor load current consumption trend displayed and archived in the DCS
5
Load and Power Consideration Motor efficiency is a measure of the effectiveness with
Load, percentage of load, horsepower demand, kilowatt which a motor converts electrical energy to mechanical
usage, and power factor are also important factors energy. This ratio of the output power or work done
relating to a motor's long-term performance. Significant versus the input power is not constant for all load
load fluctuations might indicate a potential process- conditions. Motors are optimized to be run most
related problem. Many motors continue to operate within efficiently at a specific load condition; operating the
nameplate ratings while being forced to carry load motor above or below that point causes it to run less
demands above their capacity. These excessive load efficiently. Figure 7 shows the effect of the motor load on
demands cause the windings to run above a safe level. the efficiency of the motor. The area on the trend marked
Motors required to operate above nameplate horsepower between the red lines indicates the area of maximum
ratings also suffer from greater torque demands, which operational efficiency for the motor.
can inflict undo stress on the motor's rotor.
Figure 8 shows a DCS faceplate displaying the power
factor, actual power consumed, terminal voltage, and
winding temperature. By monitoring these key operating
parameters the motor's condition can be analyzed and
alarms can be triggered when they exceed safe levels.
Figure 7 A typical graph of an AC motor efficiency verses the motor load
Power Factor Actual Power Consumption
Three Phase Voltage
Winding
Temperature
Figure 8 DCS faceplate showing the Three Phase voltages, Power Factor, Actual Power and Winding Temperature
6
Motor Operating Efficiency Benefits of Integrating Motor Control Data in DCS
In an effort to reduce a plant's Total Cost of Ownership,
each facility should frequently and carefully monitor Improve Productivity
power usage and operating efficiency of the motors. Engineers can access the parameters of the individual
Motors are often oversized or undersized due to incorrect MCC bucket directly from an engineering station in a
initial design or from post-commissioning modifications to central location. They can modify operating parameters,
the process design. Oversized motors have higher initial analyze performance, and reset faults from the control
costs and are typically more costly to repair and operate. room. SIMATIC® PCS 7 Asset Management software from
Undersized motors perform poorly and suffer from higher Siemens allows parameterization and diagnostics
energy losses, which can lead to premature failure. information to be published on the DCS HMI screens,
Improperly sized motors are less efficient and, therefore, providing easier access to the maintenance personnel
are more costly to operate. (as shown in Figure 9).
The dynamic motor data logged in the DCS can be very Minimize Downtime
helpful in troubleshooting, repair, and replacement of the Implementation of an effective predictive maintenance
motor. Integration of the Smart MCC in a DCS allows the program is critical to avoiding unscheduled downtime. It
dynamic data of the motor to be logged and trended for is estimated that over $20B is lost annually due to
the early detection and prevention of costly repairs. It also unplanned downtime, with 38% caused by preventable
provides valuable data which can be used to pinpoint and equipment failure.3 Any unusual condition, like phase
correct problems with the sizing of a motor and its unbalance or loss and excessive current draw, are
dynamic response to changing process conditions. reported in the DCS. This allows the operator and/or
maintenance personnel to take corrective action. Even in
a trip situation, the cause and location of the trip can be
easily identified and necessary maintenance can be
quickly performed.
Smart MCC Function Block
Smart MCC Faceplate
Tagname Alarm Message Process Alarm Alarm
Operating
Priority Engineering Station
includes tag Area State Station (ES)
description and (OS)
Alarm Meaning
Smart MCC Commissioning and
Troubleshooting Tool
Message Type Additional Info
(Alarm, Warning or Exists (Corrective
System Event) Action)
Figure 9 Central access to all devices (including motors, drives, and Smart MCCs) improves process visibility and helps you to
create an effective, preventive, and predictive maintenance program for all of your plant assets
7
Decrease Installation Cost designs that are focused on improving energy
Using a digital fieldbus like PROFIBUS, motor buckets can consumption. Process optimization techniques together
be connected to the DCS using a single or redundant cable with real-time energy consumption information all play a
that is daisy-chained between motor buckets. This allows part in enabling manufacturing processes to be operated
tremendous reduction in the cost of field wiring, at maximum profitability and with greater energy
terminations, and PLC hardware. Based on actual project efficiency.
implementation data, reductions in engineering,
installation, and maintenance costs by 30% or more are Optimizing energy consumption and improving
not uncommon. operational efficiency are continuous processes that are
important during all stages of a plant's lifecycle:
Improve Equipment Reliability and Efficiency
Fault tolerant communication architectures can be Design and Engineering
designed to ensure a high degree of availability of the Installation and Commissioning
communication between the DCS and MCC. Different Operation and Maintenance
physical mediums, such as copper or fiber, can be used to Process Modernization/Optimization
connect the digital fieldbus. For example, a fault-tolerant,
redundant, fiber-optic PROFIBUS ring can be used between During the initial design and engineering phase, an
the DCS and MCCs that are positioned in remote locations. investment in the technologies that enable the
optimization to be performed at the later stages can be
Improve Personnel Safety very helpful. Installation of premium efficiency motors
Every time a motor bucket is disconnected from the and integrated power monitoring and switching systems
control system for repairs or maintenance, the change in lays the foundation on which further optimization can be
status of the motor bucket is logged in the DCS. The realized. Pre-engineered libraries of software function
operator initiating the request can write comments in the blocks allow easy integration of power control devices in
operator request area or alarm comment field to inform the DCS.
other operators and maintenance personnel. There is
always a central place for operators to look for this The most significant gains in energy efficiency are seen
information, thereby reducing confusion and improving during the operation and maintenance phase. Situations
safety. like inefficient operation of the motors can be identified
by analyzing the data that is recorded in the DCS. This
Energy Management also provides a powerful tool for the operations
Smart MCCs enable the power consumption of different management team to understand which operators are
parts of the plants to be collected within the DCS. This good at producing a particular product with the minimum
information can be displayed for the operator to monitor energy input. Those best practices can be transferred to
the KWh consumption of the manufacturing process other operators.
alongside other key process parameters. The information
can be further passed into a historian or an MES for Sections of the process control system that do not
reporting purposes. perform well can be improved using the tools available in
the DCS. The data available from the DCS can be analyzed
This information can be used to implement different in detail to identify potential process improvements. Using
energy management strategies, allowing plants to create a the real, quantitative data, energy efficiency projects can
strategy which helps to optimize energy usage and be undertaken resulting in the efficient use of capital
production output simultaneously. resources with high return on investment (ROI).
Energy Optimization in Process Industries Conclusion
Understanding where energy is used in the manufacturing Saving energy in manufacturing has two significant
process is a key first step in the development of strategies paybacks: a reduction in green house gases emission and
to minimize energy consumption. Distributed control the lowering of the energy cost for the plant operators.
systems that are capable of integrating process and power Technology, such as the use of Smart MCCs exists today to
system information can be a valuable resource to the make process control systems more efficient. By adopting
conservation of energy in process manufacturing. Energy these smarter technologies, manufacturers can not only
management systems do not replace human involvement save energy and reduce their impact on the environment,
in the decision-making process, but should be looked at as but also become more competitive economically.
a real-time tool to keep energy consumption in check.
References
Through understanding of the energy consumption for (1) U.S. Department of Energy Website, “Improve Motor
each individual process or unit, experts can create better System Efficiency with Motor Master,”
[Link]
by Moin Shaikh, DCS Marketing Consultant October 2005
[Link]@[Link] (2,3) “Collaborative Process Automation Drives Return on
Siemens Energy & Automation, Inc., October, 2006 Assets,” Dave Woll, ARC, June 2002.
Siemens Energy & Automation, Inc. [Link]
3333 Old Milton Parkway
Alpharetta, GA 30005 ©2006 Siemens Energy & Automation, Inc. All Rights Reserved.
Siemens is a registered trademark of Siemens AG. Product names mentioned may be trademarks or registered
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