Motor Control Centres
Motor Control Centres are the nerve centre of industrial automation and electrical distribution systems ensuring seamless operation of machinery and equipment in industrial and commercial environments.
A Motor Control Centre (MCC) is an assembly of one or more enclosed sections each containing components such as circuit breakers, contactors, overload relays and other components that help manage the power distribution, switching and protection of the electric motors in your system.
Benefits of Motor Control Centres (MCCs):
– Efficient power management
MCCs can include energy monitoring and management features to reduce energy consumption and improve motor performance – all contributing to overall energy efficienty and cost savings for your plant.
– Reduced down time through improved monitoring & maintenance
The modular design of MCCS makes it easier to access individual motor starters and components, simplifying maintenance tasks and reducing downtime. MCCs can also be equipped with advanced monitoring and diagnostic features such as remote monitoring, fault detection and predictive maintenance capabilities which all help optimise motor performance and can identify issues before they lead to unplanned downtime.
– Safety and protection of the motors in your system
MCCs incorporate safety features such as circuit breakers, overload protections and interlocking mechanisms which all improve the safety of motor operations protecting both your people and your equipment from electrical hazards.
– Convenient and organised way of managing power distribution
MCCs provide a centralised location for managing multiple motors, saving valuable floor space and making it easier for operators to monitor and manage motor operations from a single point.
Maintenance
To keep your MCC in peak condition, regular maintenance is essential. This should include:
– Inspections:
Regular visual inspections should be done to check for signs of damage, overheating, losse connection or corrosion of MCC components including motor starters, circuit breakers, wiring, busbars an insulation.
– Testing & Calibration:
Protective devices such as overload relays and circuit breakers should be tested and calibrated to ensure they will operate when needed.
– Connections:
Electrical connections should be checked periodically to ensure they are secure and free of corrosion. Loose connections can lead to overheating and electrical faults.
– Cleaning:
It is essential that the MCC enclosure and components are kept clean and free of dust to ensure all equipment operates at peak performance.
– Cooling Systems:
If your MCC is equipped with a ventialtion or cooling system then the fans, filters and airlow pathways should be checked to ensure proper ventialtion and cooling of the MCC components.
Motor Control Centres offer a complete solution for motor control and power distribution, combining convenience, safety, and efficiency for your plant.
If you’d like to investigate a MCC solution for your plant or put in place a regular maintenance programme for an existing MCC, get in touch with the EAS team today on 07 834 0505.
December 2023 Newsletter Riddle
If Santa’s five elves take five minutes to make five dolls, how long would it take 100 elves to make 100 dolls?
Answer: 5 minutes
Halloween Riddles
Q: How do you fix a broken Jack-o-lantern?
A: With a pumpkin patch
Q: Why didn’t have the mummy have any friends?
A: He was too wrapped up in himself.
Q: What do you get if you cross a snowman with a witch?
A: A cold spell.
Circuit Breakers and the Importance of Testing
Circuit breakers are automatically operated electrical switches designed to protect an electrical circuit from damage caused by excess current from an overload or short circuit.
The basic function of a circuit breaker is to interrupt the current flow when a fault is detected. Unlike a fuse, which operates once and then must be replaced, a circuit breaker can be reset (either manually or automatically) to resume normal operation.
Circuit Breakers play a critical role in protecting expensive equipment in your plant. However, they can go long periods without activation, so it is essential that they are regularly maintained and tested. If they fail to activate when needed it could have catastrophic consequences for your staff and plant if an arc flash were to occur and would result in extensive damage to your plant’s electrical systems.
Primary & Secondary injection testing of your circuit breakers should be included as part of your Preventative Maintenance plan to ensure their reliability and safety.
Primary Injection Testing vs Secondary Injection Testing
Primary Injection Testing injects a multiple of the fault rated current of the breaker through the breaker to measure the trip time.
Secondary Injection Testing injects a ratio of the fault rated current directly into the trip unit and measures how long the breaker takes to trip.
The primary tests of the breaker are closer to a real-world scenario while secondary tests the timing and functioning of the trip unit.
Primary injection testing is usually the preferred test method as it tests the entire circuit including the current sensors, wiring and the current conduction path in the circuit breaker as part of the test. However, it is also more expensive, so is generally conducted at commissioning and on circuit breakers that are part of a critical process or engineered safety system. Other than trip testing other tests that can be conducted as part of your primary injection testing include:
– Power Transformers (Through Faults)
– Relay Testing
– Bus-work, Switchgear and HV Breakers
– Low voltage breakers
– Switchgear Testing
– Heat runs
– Stability tests
– Loose Connections
– Core Identification
If you need help incorporating primary and secondary injection testing as part of your preventative maintenance programme get in touch with the EAS team today on 07 834 0505 or [email protected].
Riddle – October 2023 Newsletter
Answer: Trouble
Riddle – September 2023 Newsletter
Answer: A hole
Improving efficiency and safety with Programmable Logic Controllers (PLCs)
Programmable Logic Controllers (PLCs) are used by businesses around the world to automate their manufacturing processes to ensure accuracy, consistency and improved efficiency and safety.
PLCs were originally developed in the late 1960s by the US automotive industry to replace relay logic systems. These systems were difficult to update or alter the automation process due to being hard-wired. Any changes to the automation process, using relay logic, meant rewiring and updating documentation. Even a single misplaced wire or failed relay could render the the whole system faulty, making troubleshooting a time-consuming process.
In comparison, PLCs use a tiny computer that takes inputs from data capture points and human input points such as switches and buttons. Based on its programming, the PLC then decides whether or not to change the output. PLC outputs can control a wide range of equipment including motors, solenoid valves, lights, switchgear, safety shut offs and many more.
Advantages of PLCs
- Control & Automation
PLCs allow the automation of complex tasks such as managing production lines, regulating temperature and pressure, coordinating machinery, and controlling robotic systems.
PLCs provide precise and reliable control over your processes by monitoring various sensors and input signals and making logical decisions based on predefined programming.
- Flexibility & Adaptability
PLCs are easy to programme or reprogramme to accommodate changes in production requirements or process parameters. They allow for the integration of new devices or components without requiring extensive rewiring or hardware changes.
- Reliability & Fault Tolerance
PLCs offer support features such as backup power supplies, self-diagnostic capabilities and error handling techniques that help identify faults and minimise your downtime.
- Safety & Protection:
PLCs play a crucial role in ensuring the safety of personnel, equipment and processes. They can implement safety protocols, monitor critical parameters and trigger emergency shutdowns or alarms in the event of hazardous conditions.
- Data collection and analysis:
PLCs can gather and process real-time data from various sensors and devices within the control system. The data collected via PLCS can also work with other data collection systems to improve data analysis, reporting and optimisation.
The EAS team have extensive experience working on projects utilising PLCs. If you’re looking for assistance with installing or upgrading your processes with PLCs, get in touch with the EAS team today on 07 834 0505.
Riddle Answer – August 2023
A puzzle piece