1.4 Executive Summary:
a) Cement and captive power plants are large plant with complex process to
operate and control. As the individual starter are used for control of individual
motor function only like workshops, de-watering pump station, single belt
conveyors, standalone crushers etc. Hence, it is not recommended to use
single starter for process control functions at all.
b) The conventional motor control centre is widely used for large and complex
process control applications. The common uses of the system are in the
cement, power, refineries and petrochemical but now the same is being replaced
by intelligent MCC’s
c) The intelligent motor control centre are the advanced version of conventional
motor control centre and being used for large and complex process like
cement, power, steel, refineries etc. There are hundreds of drives to operate
in sequential mode at a given time. A small delay in fault tracing will lead to
higher rectification costs. Hence, intelligent motor control centre following
benefits to the plant:
- By reducing fault occurrence frequency of system and Improving system
reliability - By improving fault traceability and decreasing rectification time,
- By engaging less man power for operation and maintenance,
- By lowering motor burning rates due to accurate setting and reliable operation,
S. N. Description Standard MCC Intelligent MCC
1 Total cost of the motor control centre in a
cement project in Rs lacs (Integrated Unit)548 6842 Total cost of DCS system in complete
cement plant in lacs832 756A) SUB TOTAL-A in lacs 1380 1440
1 Cost of cables, cable trays (from MCC
panel to I/O panel) , cable glands and other
Hardware’s in lacs40 10B) SUB TOTAL-B 40 10
TOTAL(A+B) 1420 1450
TOTAL IMPACT ON CAPITAL COST DUE TO
INTELLIGENT MCC (Rs. Lacs)301 Total installation and commissioning time for
MCC’s and plant DCS system75 days 45 days2 Per day loss due to delay in plant
commissioning @ 50% capacity in Rs lacs12 123 Loss due to delay in plant commissioning as
above in Rs lacs360 0