ELECTRIFICATION Low Voltage Switchgear Digital Upgrade

—ELECTRIFICATION – DISTRIBUTION SOLUTION DIVISION, 2020

Low Voltage Switchgear Digital UpgradeUpgrade INSUM 2 to MNS Digital

© Copyright 2020 ABB. All rights reserved. Rev.: ADocument ID.: 9AKK107991A4425

—INSUM 2 Overview

—INSUM 2 Overview

INSUM 2 Description

In service since early 1998. Application in all major industries.

Communication:

– Standard LON protocol internally

– Modbus RTU, Profibus DP and Ethernet for communication to control system

– Redundant communication is possible

Component:

– Motor controller MCU and/or circuit breaker PR

– Gateway and router

– User interface MMI for monitoring and parametering

– PC software tool INSUM OS

INSUM 2 Architecture

November 9, 2020

—

INSUM 2 Life Cycle

November 9, 2020 Slide 4

INSUM 2 Overview

ACTIVE CLASSIC

LIMITEDOBSOLETE

Last buy1 Year

1998 INSUM2Restricted Release

Min 5 years

5 years

2001 INSUM2General Release Feb. 2014

2018Viability Check

Every 2 Years

2007……2012Viability Check

Manufacturing endsClassic phase Announcement 1 Year

2013

In active phase the business viability check were performed every two years starting from the year 2007. The decision criteria to continue is the INSUM2 share in BU LPLS business for Intelligent Switchgear. This has ended in 2012.

The classic phase started 1 year after the announcement of end of active phase in 2013. When this happened, the classic phase is at least 5 years, after this a manufacturing viability check is done every two years starting 2018. INSUM 2 has been decided to enter the Limited phase in January 2019.

In this phase the manufacturing of units stopped. However for maximum support of our customer we will check the possibility to continue manufacturing. In either case the limited phase will be of minimum 3 years starting from 01.01.2019. Spare parts are available however not entire range is guaranteed.

Active Phase Classic Phase Limited Phase

Product obsolete announcement will be made prior to six month before complete discontinuation of INSUM2.

Obsolete Phase

Jan. 2019

Min 3 years

—Upgrade INSUM 2 to MNS DigitalReduce cost and maximize uptime through digitalization

November 9, 2020Slide 5

—Upgrade INSUM 2 to MNS Digital

Reduce upgrade cost: (estimated 30%) when compared to full switchgear replacement

Save cost on spare parts: higher spare part availability due to new and ‘active’ products

Safe and fast upgrade: (no motor/control cable replacement etc.) Replacement of full drawer/buckets possible to minimize times. Communication to Control System remains exact as with INSUM 2.

Extends the life of the switchgear: due to use of new and active components

Reduce total cost of ownership

Extend the life of switchgear to ensure customer’s plant performs with minimum investments.*

*Drawing shows logical connection only, devices are shown as examples.November 9, 2020

MNS DigitalINSUM 2

Motor Controller M10x-M

Circuit Breakeri.e. Emax2 or Ekip-Up

ABB AbilityCondition Monitoring -CMES

MNS Digital Gateway

Router and Gateway

PCS

Line 1

MCU

Line 2

MCU

Line 3 Line 4

MMI


Drawing shows logical connection only, devices are shown as examplesSlide 7

Digitalize the LV switchgear

Enhanced Reliability, availability and maintainability using integrated condition monitoring to enable predictive maintenance

Future proof (or Futuristic or Timeless) options throughout project life cycle seamlessly, as and when required (eliminating need for complete system upgrade

Cyber security requirements addressed and integrated

Industry 4.0 ready to connect with ABB Ability™

November 9, 2020

—MNS Digital Upgrade for INSUM System


—Upgrading INSUM 2 to MNS Digital

INSUM 2 MNS Digital with UMC100.3 or M10x-M

The upgrade solution retains the single point of interface to process control system (PCS) thus there is no change in the communication structure to PCS.

Migrating the INSUM 2 architecture to MNS Digital

Motor Controller UMC 100.3

Circuit Breakeri.e. Emax2 or Ekip-Up

Digital EdgeMNS Digital Gateway

PCS ABB Ability Condition Monitoring for Electrical System (CMES)

November 9, 2020

MMIBackplane with Router and Gateway

Line 1

MCU

Line 2

MCU

Line 3

MCU

Line 4

MCU

PCS

—

Upgrade of MCU Upgrade to MNS Digital with M10x-M

Upgrade to MNS Digital with UMC 100.3

Two options are available when upgrading the MCU which are the M10x-M and the UMC100.3

Both motor controllers support all protection, control and measurement functions available in MCU.

The main difference between the two options are:

1. Internal Switchgear Bus Communication M10x-M uses Modbus RTU while UMC100.3 uses Modbus TCP

2. UMC100.3 supports additional extension unit to add functionalities while M10x-M is only available in single units.

Slide 10

Upgrade INSUM 2 to MNS DigitalUpgrade of Motor Control Unit - MCU

MCU M10x-M

MCU UMC100.3

November 9, 2020


Slide 11

Upgrade of Air Circuit Breaker

Complete retrofit of SACE circuit breaker Emax is possible with Emax 2

Direct Replacement option is available to reduce downtime required in retrofitting.

Communication with Ekip COM module and Modbus TCP/RTU to MNS Digital Gateway

Alternatively, it is possible to add Ekip-UP unit to existing Emax circuit breaker to achieve communication with MNS Digital Gateway

Upgrade of Air Circuit Breaker

Emax Emax 2

Ekip-UP

November 9, 2020

—

Upgrade of Gateway to MNS Digital Gateway Upgrade to MNS Digital with M10x-M

Upgrade to MNS Digital with UMC 100.3

MNS Digital Gateway has the same signal mapping and communication protocol as Gateway

Up to 128 M10x-M/UMC100.3 per MNS Digital Gateway - similar to Gateway configuration

Internal communication renewed using Modbus RTU/TCP and optional redundancy

Optional MNS Digital Gateway to PCS communication enhanced to:

Modbus TCP

Slide 12

Upgrade INSUM 2 to MNS DigitalUpgrade of Communication Gateway Gateway

Router and Gateway MNS Digital Gateway

Router and Gateway MNS Digital Gateway

M10x – M

MNS Digital Gateway

M10x – M

MNS Digital GW

UMC 100.3 UMC 100.3

MTQ22 MTQ22

November 9, 2020


Slide 13

Upgrade of MMI to MView

Replace MMI or with MNS Digital MView web interface for enhanced user experience.

The following functions are provided (depending on user rights):

– Access to any MNS Digital Gateway and field device in the network

– Supervision of process values such as currents, voltages, device status

– Sending control commands to the intelligentfield devices (depending on user rights)

– Display of alarms and trips, reset trips

– Setting of some parameters such as time and date of the gateway

Upgrade of Human Machine Interface MMI

MMI

MNS Digital Web Interface

November 9, 2020


Slide 14

MNS Digital with M10x-M MNS Digital with UMC100.3

Redundancy in MNS Digital

November 9, 2020

M10x-M

MNS Digital GatewayPrimary

Modbus RTU

M10x-M M10x-M

MNS Digital GatewayBackup

Redundant Link

Digital Edge

ABB Ability Condition Monitoring for Electrical System (CMES)

Process Controller

Process Controller

Process Control System


MNS Digital GatewayPrimary

Redundant Link

Digital Edge


Process Controller


UMC 100.3

MTQ22 MTQ22

UMC 100.3

MTQ22

UMC 100.3

Modbus TCPEthernet Switch with MRP

MNS Digital GatewayBackup

Process Controller


—

INSUM 2 MNS Digital with M10x-M MNS Digital with UMC100.3

External Interface GatewayModbus RTU or Profibus DP or Ethernet for DCS Redundant configuration

MNS Digital Gateway with 1 port for Modbus RTU or with 1 port for Profibus DP as in INSUM 2Redundant configuration

MNS Digital Gateway with 1 port for Modbus RTU or with 1 port for Profibus DP as in INSUM 2Redundant configuration

Internal Communication

LON – Local Operating Network Modbus RTU to M10x Modbus TCP to UMC100Multiple Master

Motor/Feeder Control Unit

MCU – standard functionalityExternal CT and PTAddressing by softwareDigital input/outputAnalogue output

M10x-M replaces MCU and CT

Addressing by softwareDigital input/outputAnalogue output

UMC100.3 plus extension units as required to replace MCU and CTAddressing by softwareDifferent extension units available for more functionalities

Circuit Breaker SACE circuit breaker Emax (optional with PR112) Retrofit with Emax2 with Ekip COM Retrofit with Emax2 with Ekip COM

System Structure 128 MCU per one backplane 32 MCU per one router line, depends on type of gateway

Up to 128 M10x per MNS Digital Gateway, RS485 Modbus RTU

Up to 128 UMC100 per MNS Digital GatewayEthernet ring

Operator Interface MMI – user HMIHardware key

M10x-M front panel or use of MView with user access with password

MView – user HMIwith user access with passwordIndividual UMC100.3 front panel (optional),

PC Based Tool Windows© 95 based parametering Windows© base tool utilizing MNavigate and M10xparametering tool

Windows© base tool utilizing MNavigate and UMC parametering tool

Switchgear MNS 3 MNS Switchgear remains,modules can be upgraded to MNS 3

MNS Switchgear remains,modules can be upgraded to MNS 3

Upgrade INSUM 2 to MNS Digital

Slide 15

Select the solution that fits the requirement

November 9, 2020

—ABB Ability Condition Monitoring for Electrical SystemIntegrated Condition Monitoring for MNS Digital


—Condition monitoring

Slide 17

Data are always available locally, showing users what’s going on across their operations

November 9, 2020

Safety

– Monitoring of the system status can be done away from the switchgear.

– Possibility to add online temperature monitoring and arc fault detection to eliminate manual inspection

– Maintenance can be performed when needed to minimize the risk of unnecessary failures

Maximize plant availability and safety

Optimize

– Move to condition-based and predictive maintenance

– Faster fault analysis through guided troubleshooting

– Achieve continuous operation by avoiding unplanned outages

Analyze

– Access historical data easily

– Continuous data monitoring throughout the entire life of the device

—What to monitor in a switchgear?24/7 condition monitoring – field condition assessment

Thermal monitoring of motor

• To identify incorrect TOL protection settings

• Changing loads that affect installed motor

• Potential mechanical defects

Current monitoring

• Phase unbalance due to load issues

• Residual current because of winding ages

• Winding temperatures

Motor starting time supervision

• Supervision of motor starting time to detect change in process load, mechanical defects, aging, etc.

Monitoring of motors and connected assets

Nominal

Measured

Spee

dNovember 9, 2020

—What to monitor in a switchgear?24/7 condition monitoring – switchgear device assessment

Device operation to ensure availability

• Can detect if a motor has not been used for longer time and reminds fortesting of availability

Module insertion cycle supervision (mech. operations)

• Required for proper maintenance of module contacts (greasing of contacts)

Power contact temperature

• as a last measure to detect lack of maintenance

Module and breaker supervision

• Predict next required maintenance based on loads and operations

• Prediction of breaker life status

Maintenance and process related supervision of assets

Maintenancerequired

Time

Op

erat

ion

s

November 9, 2020

—ABB Ability™ CMES


Features and Functions

• Switchgear ‚black box‘ data collector; fully embedded solution

• No PLC, no programming required

• Web based full graphical user interface, secure access, password protected

• Online log for alarm, trip and status information

• Switchgear overview and single line diagramfor diagnosis purpose

• Condition and Energy consumption report to optimize the assets

• Thermal condition of switchgear

• Assessments maintenance date calculation

Dashboards Reports

Condition Monitoring for electrical systems

Condition report

—


Dashboard

ABB Ability™ CMES

Switchgear overview including:– Total number of devices monitored

up to 512– General temperature status– Mechanical components– Time related trend

SWGR health condition

Detailed list including per each event– Description– Possible cause– Severity– Suggested actions

Event list

Single line showing– Feeder name– Feeder status– Single devices status– Main electrical parameters

SWGR single line diagram

Single monitoring point:– Status details of each section in

switchgear– Position inside the switchgear– Module condition (traffic light)– Thermal condition (traffic light)

Panel view and Thermal monitoring

– Data collection and storage– Cloud connectivity to MRC

Data storage and cloud

– No additional software needed– Desktop and

Mobile view (tablet, phone)

Web browser user IF– Condition and Energy report

Report module

—ABB Ability™ Condition Monitoring for electrical systems


Monitor

– Collect the data from everydevice (with communication interface)

– Monitor and supervise the complete electrical system

– Prioritize information to getright action in time

Analyze

– Analyze collected data, connectdata with each other to

– Separate normal fromabnormal condition

– Enable fast fault finding

– Present only needed information

– Reduce time to identify maintenance needs

Report

Report creation tool for:

– Switchgear and connected load condition(one click information)

– Energy consumption and change report(quickly identify high

energy consumers)

Predict

Online 24/7 data analysisof devices such as motor starter,circuit breaker, switchgearmodules, etc. to predictmaintenance needs and time.

For example:

– Contact greasing

– Device maintenance

– Operation checks

ABB Ability™ CMES is the on-premise solution

Condition report



INSUM 2 MNS Digital

INSUM 2 is in limited stage of lifecycle.

Extend switchgear life and gain benefit through digitalization

An obsolete electronic equipment might increase the probability of failure

Increased cost of spare part and delivery time due to limited availability

UMC 100.3 /M10x-M

Circuit BreakerEmax2 or Ekip-Up

Digital Edge

MNS Digital Gateway


Upgrade to MNS Digital with minimum/no change at Control System

PCS

Lower cost of spare part through active product usage and enhanced maintenance strategy based on condition monitoring

Extends the life of switchgear while enhancing its reliability through digitalization.

MMIRouter and Gateway

Line 1

MCU

PCS

Line 2

MCU

Line 3

MCU

Line 4

MCU

ELECTRIFICATION Low Voltage Switchgear Digital Upgrade

Documents

Transcript of ELECTRIFICATION Low Voltage Switchgear Digital Upgrade