Smart Motor Management How data-driven visibility can help protect both processes and motors in key industrial applications This presentation illustrates how the Siemens TIA and TIP architecture and key components has increased a facility’s uptime. This was accomplished by Reducing or eliminating downtime and it’s associated costs due to early detection before a failure or extensive diagnostics after the failure occurs. Reducing downtime and the associated costs for planned maintenance programs were also reduced. The system accurately identifies worn or failing components through remote monitoring so that only components requiring replacement are replaced.

When the overload trips …. what happens to the process?? Smart Motor Management vs. Traditional Maintenance “Wait ‘til it trips” 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. When the overload trips …. what happens to the process?? This presentation is to showcase a facility wide control system for Vulcan Materials Company, designed and installed by Brozelco using primarily Siemens Automation and Controls products. The site is located in Columbia, TN. which is just outside of Nashville. The plant has now been in operation for approximately 1.5 years and has a staff of approximately xx employees. 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.

When the overload trips …. Smart Motor Management vs. Traditional Maintenance “Wait ‘til it trips” 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? What was happening when the motor tripped? The site had to strictly follow MSHA guidelines 50-60HP and above is on a soft start Everything is on SIMOCODE other than drives The system was required to control and monitor the following number and types of motor applications: 3 crushers 1 – primary HSI (Horizontal Shaft Impact Crusher) 2x300HP 1 – secondary HSI 1x400HP 1 – secondary VSI (Vertical Shaft Impact Crusher) 2x250HP 5 screens 1- 6x20 2 deck, 40HP (Scalping screen) used to produce riprap 2 – 6x20, 3 deck, 40 HP (Gradation Screens) 1 – 3x20, 3 deck, 2x30HP (Gradation & Wash Screen) 1 – high frequency screen, 2x10HP – used to make fine material Conveyors (15-100HP) Primary Plant Secondary Plant 3 Transport 16 Transport (15-100HP) 1 Traversing Stacking 10 Stacking What needs to be corrected to restore the process?

A tripped overload relay causes: Smart Motor Management vs. Traditional Maintenance “Wait ‘til it trips” A tripped overload relay causes: Unexpected shut downs Unidentified reason for the trip Potentially hazardous conditions Potential scrapped material Potential lost production The site had to strictly follow MSHA guidelines 50-60HP and above is on a soft start Everything is on SIMOCODE other than drives The system was required to control and monitor the following number and types of motor applications: 3 crushers 1 – primary HSI (Horizontal Shaft Impact Crusher) 2x300HP 1 – secondary HSI 1x400HP 1 – secondary VSI (Vertical Shaft Impact Crusher) 2x250HP 5 screens 1- 6x20 2 deck, 40HP (Scalping screen) used to produce riprap 2 – 6x20, 3 deck, 40 HP (Gradation Screens) 1 – 3x20, 3 deck, 2x30HP (Gradation & Wash Screen) 1 – high frequency screen, 2x10HP – used to make fine material Conveyors (15-100HP) Primary Plant Secondary Plant 3 Transport 16 Transport (15-100HP) 1 Traversing Stacking 10 Stacking 4

Time based maintenance does not “wait ‘til it trips”. It is: Smart Motor Management vs. Traditional Maintenance Time Based or Preventive Maintenance 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. The site had to strictly follow MSHA guidelines 50-60HP and above is on a soft start Everything is on SIMOCODE other than drives The system was required to control and monitor the following number and types of motor applications: 3 crushers 1 – primary HSI (Horizontal Shaft Impact Crusher) 2x300HP 1 – secondary HSI 1x400HP 1 – secondary VSI (Vertical Shaft Impact Crusher) 2x250HP 5 screens 1- 6x20 2 deck, 40HP (Scalping screen) used to produce riprap 2 – 6x20, 3 deck, 40 HP (Gradation Screens) 1 – 3x20, 3 deck, 2x30HP (Gradation & Wash Screen) 1 – high frequency screen, 2x10HP – used to make fine material Conveyors (15-100HP) Primary Plant Secondary Plant 3 Transport 16 Transport (15-100HP) 1 Traversing Stacking 10 Stacking 5

Smart Motor Management vs Smart Motor Management vs. Traditional Maintenance “Wait ‘til it trips” or Preventive Maintenance Traditional motor maintenance relies on traditional motor protection devices. 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. The site had to strictly follow MSHA guidelines 50-60HP and above is on a soft start Everything is on SIMOCODE other than drives The system was required to control and monitor the following number and types of motor applications: 3 crushers 1 – primary HSI (Horizontal Shaft Impact Crusher) 2x300HP 1 – secondary HSI 1x400HP 1 – secondary VSI (Vertical Shaft Impact Crusher) 2x250HP 5 screens 1- 6x20 2 deck, 40HP (Scalping screen) used to produce riprap 2 – 6x20, 3 deck, 40 HP (Gradation Screens) 1 – 3x20, 3 deck, 2x30HP (Gradation & Wash Screen) 1 – high frequency screen, 2x10HP – used to make fine material Conveyors (15-100HP) Primary Plant Secondary Plant 3 Transport 16 Transport (15-100HP) 1 Traversing Stacking 10 Stacking 6

Traditional motor maintenance Smart Motor Management vs. Traditional Maintenance “Wait ‘til it trips” or Preventive Maintenance Traditional motor maintenance Relies on traditional motor load protective devices. Offers little help in troubleshooting the cause of the trip. Does little to prevent unwanted shut downs caused by dynamic changes to the protected loads. The site had to strictly follow MSHA guidelines 50-60HP and above is on a soft start Everything is on SIMOCODE other than drives The system was required to control and monitor the following number and types of motor applications: 3 crushers 1 – primary HSI (Horizontal Shaft Impact Crusher) 2x300HP 1 – secondary HSI 1x400HP 1 – secondary VSI (Vertical Shaft Impact Crusher) 2x250HP 5 screens 1- 6x20 2 deck, 40HP (Scalping screen) used to produce riprap 2 – 6x20, 3 deck, 40 HP (Gradation Screens) 1 – 3x20, 3 deck, 2x30HP (Gradation & Wash Screen) 1 – high frequency screen, 2x10HP – used to make fine material Conveyors (15-100HP) Primary Plant Secondary Plant 3 Transport 16 Transport (15-100HP) 1 Traversing Stacking 10 Stacking 7

Smart Motor Management vs Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Condition based, or Predictive Maintenance is based on historical load information, such as: Operating hours Number of starts Number of trips Load data ($$$) The site had to strictly follow MSHA guidelines 50-60HP and above is on a soft start Everything is on SIMOCODE other than drives The system was required to control and monitor the following number and types of motor applications: 3 crushers 1 – primary HSI (Horizontal Shaft Impact Crusher) 2x300HP 1 – secondary HSI 1x400HP 1 – secondary VSI (Vertical Shaft Impact Crusher) 2x250HP 5 screens 1- 6x20 2 deck, 40HP (Scalping screen) used to produce riprap 2 – 6x20, 3 deck, 40 HP (Gradation Screens) 1 – 3x20, 3 deck, 2x30HP (Gradation & Wash Screen) 1 – high frequency screen, 2x10HP – used to make fine material Conveyors (15-100HP) Primary Plant Secondary Plant 3 Transport 16 Transport (15-100HP) 1 Traversing Stacking 10 Stacking 8

Smart Motor Management vs Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Condition based, or Predictive Maintenance requires gathering information. But how? The site had to strictly follow MSHA guidelines 50-60HP and above is on a soft start Everything is on SIMOCODE other than drives The system was required to control and monitor the following number and types of motor applications: 3 crushers 1 – primary HSI (Horizontal Shaft Impact Crusher) 2x300HP 1 – secondary HSI 1x400HP 1 – secondary VSI (Vertical Shaft Impact Crusher) 2x250HP 5 screens 1- 6x20 2 deck, 40HP (Scalping screen) used to produce riprap 2 – 6x20, 3 deck, 40 HP (Gradation Screens) 1 – 3x20, 3 deck, 2x30HP (Gradation & Wash Screen) 1 – high frequency screen, 2x10HP – used to make fine material Conveyors (15-100HP) Primary Plant Secondary Plant 3 Transport 16 Transport (15-100HP) 1 Traversing Stacking 10 Stacking Traditional devices only indicate the present condition of the connected load. 9

Smart Motor Management vs Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. 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. The site had to strictly follow MSHA guidelines 50-60HP and above is on a soft start Everything is on SIMOCODE other than drives The system was required to control and monitor the following number and types of motor applications: 3 crushers 1 – primary HSI (Horizontal Shaft Impact Crusher) 2x300HP 1 – secondary HSI 1x400HP 1 – secondary VSI (Vertical Shaft Impact Crusher) 2x250HP 5 screens 1- 6x20 2 deck, 40HP (Scalping screen) used to produce riprap 2 – 6x20, 3 deck, 40 HP (Gradation Screens) 1 – 3x20, 3 deck, 2x30HP (Gradation & Wash Screen) 1 – high frequency screen, 2x10HP – used to make fine material Conveyors (15-100HP) Primary Plant Secondary Plant 3 Transport 16 Transport (15-100HP) 1 Traversing Stacking 10 Stacking 10

Smart Motor Management vs Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. 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. The site had to strictly follow MSHA guidelines 50-60HP and above is on a soft start Everything is on SIMOCODE other than drives The system was required to control and monitor the following number and types of motor applications: 3 crushers 1 – primary HSI (Horizontal Shaft Impact Crusher) 2x300HP 1 – secondary HSI 1x400HP 1 – secondary VSI (Vertical Shaft Impact Crusher) 2x250HP 5 screens 1- 6x20 2 deck, 40HP (Scalping screen) used to produce riprap 2 – 6x20, 3 deck, 40 HP (Gradation Screens) 1 – 3x20, 3 deck, 2x30HP (Gradation & Wash Screen) 1 – high frequency screen, 2x10HP – used to make fine material Conveyors (15-100HP) Primary Plant Secondary Plant 3 Transport 16 Transport (15-100HP) 1 Traversing Stacking 10 Stacking 11

Enhanced capabilities allow the user to: Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. 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. select the response of the protective device. know why the device tripped. The site had to strictly follow MSHA guidelines 50-60HP and above is on a soft start Everything is on SIMOCODE other than drives The system was required to control and monitor the following number and types of motor applications: 3 crushers 1 – primary HSI (Horizontal Shaft Impact Crusher) 2x300HP 1 – secondary HSI 1x400HP 1 – secondary VSI (Vertical Shaft Impact Crusher) 2x250HP 5 screens 1- 6x20 2 deck, 40HP (Scalping screen) used to produce riprap 2 – 6x20, 3 deck, 40 HP (Gradation Screens) 1 – 3x20, 3 deck, 2x30HP (Gradation & Wash Screen) 1 – high frequency screen, 2x10HP – used to make fine material Conveyors (15-100HP) Primary Plant Secondary Plant 3 Transport 16 Transport (15-100HP) 1 Traversing Stacking 10 Stacking 12

SIMOCODE pro C SIMOCODE pro V Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. SIMOCODE pro C SIMOCODE pro V (Motor Overload) Current Voltage Power Power Factor Inputs Current I/O Expansion Digital Analog Temperature Ground Fault Local Logic PROFIBUS Outputs

SIMOCODE pro V in a typical tiastar™ unit Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. SIMOCODE pro V in a typical tiastar™ unit Here is a sample of some of the available data fields from SIMOCODE that directly improve system availablity. There are more fields then this. All of the set up parameters for SIMOCODE can also be monitored or changed as well 14

Smart Motor Management vs Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. SIMOCODE pro Standard Protective Functions Here is a sample of some of the available data fields from SIMOCODE that directly improve system availablity. There are more fields then this. All of the set up parameters for SIMOCODE can also be monitored or changed as well 15

Smart Motor Management vs Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. SIMOCODE pro Standard Protective Functions Here is a sample of some of the available data fields from SIMOCODE that directly improve system availablity. There are more fields then this. All of the set up parameters for SIMOCODE can also be monitored or changed as well 16

Smart Motor Management vs Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. SIMOCODE pro Optional Protective Functions – Voltage Based Here is a sample of some of the available data fields from SIMOCODE that directly improve system availablity. There are more fields then this. All of the set up parameters for SIMOCODE can also be monitored or changed as well 17

Smart Motor Management vs Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. SIMOCODE pro Optional Protective Functions – Analog Here is a sample of some of the available data fields from SIMOCODE that directly improve system availablity. There are more fields then this. All of the set up parameters for SIMOCODE can also be monitored or changed as well 18

Smart Motor Management vs Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. 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) Device Operating Hours Motor Voltage 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 Here is a sample of some of the available data fields from SIMOCODE that directly improve system availablity. There are more fields then this. All of the set up parameters for SIMOCODE can also be monitored or changed as well

Smart Motor Management vs Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. There are significant benefits from employing a Condition Based Predictive motor maintenance program: Smart motor management provides real time, dynamic motor and load data to facilitate Predictive motor and load maintenance. Smart motor management includes enhanced monitoring and protective functions. 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. Here is a sample of some of the available data fields from SIMOCODE that directly improve system availablity. There are more fields then this. All of the set up parameters for SIMOCODE can also be monitored or changed as well 20