Optimized design and maintenance for Low Voltage MCCs.

How to improve the performance of a Low Voltage Motor Control Centre.

Hans Meulenbroek Peter Freeman André Muileboom Jan Verstraten

Eaton Industries Shell Global Solutions Exxon Mobil Dow
Hengelo Rijswijk Rotterdam Terneuzen
The Netherlands The Netherlands The Netherlands The Netherlands

Abstract – In this paper the authors share their views on

which best practices in design, operation and
maintenance provide the optimum solution to maintaining
the performance of low voltage (LV) Motor Control
Centres (MCCs).

Aspects to be covered during design, operation and

maintenance window are:
A. Causes of MCC failures
B. Prevention of MCC failures
C. Maintenance strategies
D. Life expectation and Life extension
E. LV MCC specifications
F. Safety

Index Terms — LV Motor Control Centre.

Figure 1 : typical single line: MV switchboard 11kV / transformers / LV

I. INTRODUCTION swithchboard 415V / LV MCCs

Motor Control Centres are used for control of motors

and are in use for more than 50 years. For the
Petrochemical industries most customers require MCCs
with a design life beyond 25 years. In practice customers
are using MCCs until system parts become obsolete and
servicing is impossible.
During service life of an LV MCC, users are confronted
with initial erection, commissioning, modifications, failures,
maintenance, changes to operating windows and finally
obsolescence of the LV MCC.
Obsolescence is usually the trigger for replacement of
the old LV MCC and the specification of the new LV MCC.
LV Motors in the process industries are, in most cases,
three-phase induction motors. Each motor requires a
motor starter.
The motor starters are grouped in a LV MCC. The MCC
interfaces with the operators (signal lamps, meters),
interfaces with the process control equipment (for
automated process control) and offers a safe environment
to personnel and equipment in case of abnormal
conditions (faults).

Application of a proper maintenance and operation

program will result in a safe and cost effective use of the
LV MCC. In addition, a robust design is key enabler to
achieving a higher level of safety and reliability.

Figure 1 shows a typical HV/LV single line with MCCs

that are fed from a LV Switchboard. The LV MCC has an
incoming circuit breaker or switch disconnector, outgoing
feeders and motor starters.

The choice for the type of incomer may depend on the

size of the MCC and the requirements regarding Figure 2 : sub-station with LV MCCs
containment in case of incidents with internal arcing. The
policy should be chosen in favor of the lowest let through
energy with regard to safety of operating personnel.
 II. POSSIBLE CAUSES OF MCC FAILURES III. HOW TO PREVENT MCC FAILURES

Most MCC failures occur after poor maintenance or The basic principles to avoid failures are the same ones
improper modifications. Fewer failures are due to original as you would apply to your car:
design or aging of the LV MCC.
1. Do it right first time.
Some examples of short-circuit failures (including Good quality lasts longer
internal arcing) during maintenance or when performing
2. Do not repair what is not broken
modifications:
Often a failure occurs when you leave the
1. Frequent racking in/out of starters and circuit garage
breakers 3. Do not touch what is working well
2. Poor workmanship Only replace when ageing is involved,
3. Modifications, not per design e.g. tyres, oil (only about 14% of failures
4. Poor commissioning relates to ageing).
5. Poor maintenance.
6. Operating outside design envelope These principles are included in the equipment
7. inadequate control of engineering changes strategies for LV MCCs to achieve high reliability,
availability and safety figures.
Ad 1. FREQUENT RACKING IN/OUT
To eliminate failures it is necessary to consider all
Starters and circuit breakers are designed for a limited phases of the MCC selection, installation and operation:
number of racking operations. Racking out for every 1. Selection of vendors
isolation can exceed this limit after a number of years 2. LV MCC specification
service. 3. Installation and commissioning
4. Personnel and training
Ad 2. POOR WORKMANSHIP
5. Ambient conditions and operating window
Loose connections, open or incorrectly closed covers 6. Preventive maintenance plan
(typically with missing screws/bolts) or worse 7. Management of change
unintentionally left parts or tools while re-commissioning 8. Repair standards
the switchgear.
Ad 1. SELECTION OF VENDORS
Ad 3. MODIFICATIONS NOT PER DESIGN
Vendors should be evaluated for the ability to meet the
Increases in load and/or increases of short circuit current. customer’s requirements. The selected vendors should
Changes in protective relay co-ordination. have at least successful track record in similar projects.
Typically this should include at least three recent
Ad 4. POOR COMMISSIONING examples.

Incorrect setting of protective relays. Ad 2. LV MCC SPECIFICATION

Ad 5. POOR MAINTENANCE The LV MCC specification should include the following

information:
Maintenance intervals are too long. Incorrect selection of
replacement components.
Ad 6. INADEQUATE CONTROL OF ENGINEERING
CHANGES
Overloads or number of starts exceeding design
capability.
Maintenance tasks and design change procedures
should be adequate to avoid above mentioned failures.
• Short circuit rating
• Arc flash prevention and arc flash containment
requirements (IEC-TR-61641 criteria 1-7)
• Load flow conditions
• Diversity factors
• Type 2 coordination for contactors
• Ambient conditions
• Type of MCC following IEC61439 (or equivalent),
including separation of compartments
• Number of times starters must be able to be
withdrawn
• Foreseen preventive maintenance interval
• Protection scheme,
• Ability to do on-line maintenance on starters
• Redundancy requirements
• Site or company specific requirements as IP
requirements, personnel competencies, locking-
interlocking, grounding facilities, minimum
maintenance intervals for the various components,
etc.
• Required Factory and Site Acceptance Tests.
 Ad 3. INSTALLATION AND COMMISSIONING
Ensure that installation is in line with vendor
requirements.
The installation contractor should be familiar with make
and type of the LV MCC.
Ensure that all penetrations are closed. Especially
unused cable entries, as ingress of foreign object,
rodents, moisture etc. are known causes for MCC's
failures.
Ensure that all main protective relays are tested with
primary injection. Primary injection checks current
transformer orientation and all the wiring, which can be
missed if only secondary injection testing is carried out.
When the equipment is in use tests of protective relays
using secondary injection will be sufficient as no changes
in the LV MCC wiring or CT connections are expected.
Ensure that maintenance personnel are involved during
the installation works. Maximum benefit is gained if they
are present during commissioning, ideally assisting the
commissioning engineer so they are involved and get an
in depth understanding of the equipment.
For future reference and bench marking the test reports
should be available for maintenance personnel and site
engineering.
Figure 3 : MCC commissioning
Ad 4. PERSONNEL AND TRAINING
Maintenance personnel should be involved in an early
stage of the project. This will achieve a proper
understanding of the capabilities and limitations of the LV
MCC (see also Ad 3).
A maintenance plan should be available and
electricians should be trained in the operation and
maintenance of the LV MCC.
Ad 5. AMBIENT CONDITIONS AND OPERATING
WINDOW
Ambient conditions shall comply with equipment
specifications. Any change in ambient conditions should
be covered by management of change procedure.
The operating window sets:
1. The minimum and maximum load of a LV
MCC.
2. The diversity factor of the LV MCC and panels
3. Minimum and maximum ambient
temperatures, humidity conditions.
Again any changes in operating window should be
covered by management of change procedure.
IV. MAINTENANCE STRATEGIES
Ad 6. MAINTENANCE
Visual inspections are a key element in the
maintenance strategy. Often abnormalities can be
sensed by simply looking, smelling, or touching (after
proving dead). In addition there are quantitative
measurements such as comparison of load current of
starter against its nominal rating, examination of counters
showing the number of operations and hot spots (IR
scans) in cable compartments.
A more detailed inspection should be performed every
Turn Around (typical interval 4-6 years), where starters
require a visual inspection and stabs are greased. The
visual inspection should include looking for signs of
overheating, cracks, dust, condensation and similar
abnormalities. The starter isolator (if fitted) is a safety item
and should also be checked for correct operation.
As the incoming circuit breakers or switches are
generally only accessible during Turn Arounds, an
inspection of their mechanical parts is recommended.
Every 10-12 years a check on busbar and cable
connections should be performed, e.g. by checking
torques. Checking torques more frequently will overstress
the connections and will introduce potential failures. An
alternative is low ohmic impedance testing of the busbar
systems.
Thermo-graphics can be a valuable tool to address hot
spots in a LV MCC. Undoubtedly valid for cable
compartments, where easy access helps to make a
proper inspection. Opening of live starters or feeders
requires safety precautions.
The majority of components do not fail by aging.
Components fail by overload (overheating), poor
workmanship at installation and repairs. Maintenance will
not avoid failures when the equipment is operating
outside its operating envelope or if the failures are caused
by poor workmanship.
Some components, such as air circuit breakers, require
a regular greasing of mechanical parts. Current thinking is
that the best lubricant material is fluorosilicone. Tests are
ongoing to prove these greases can be effective for up to
15 years. Until the evidence is available, it is sensible to
adopt a cautious approach to re-greasing intervals,
especially for heavily loaded breakers.
As failures of protective relays are not apparent during
normal operation, these devices should be tested every 5-
10 years. Except where used to protect Exe motors,
conventional thermal overload relays of starters do not
require testing, as the probability and the consequence of
failure are normally low. However verification that the
overload settings are still correct for the motor full load
current should be carried out. It is not unknown for these
settings to be altered in service, especially if there are
problems starting a motor due to the thermal device
tripping.
Contactors should only need inspecting when the duty
requires frequent starting. In many instances it is more
cost effective in such applications to replace contactors
before failure rather than wait until an actual failure
occurs.
Capturing the history of maintenance, modifications and
repair can be essential in problem solving. The bench
mark should be the commissioning reports (FAT and
SAT).
Ad 7. MANAGEMENT OF CHANGE
A management of change procedure is essential for a
reliable and safe operation of the LV MCC.
Any replacement which is not "like for like" should be
subject to an engineering assessment. There are many
examples where even minor changes led to component
failure or a failure to operate as intended.
Any change in load should be reviewed as to whether
the change still fits within the operating window of the LV
MCC. If the knowledge to make this assessment is not
available at site, then the original manufacturer should be
consulted to confirm loading will still be acceptable
Note that changes can also be procedural changes or a
change to the preventive maintenance interval. Both
should fall under the management of change process.
Ad 8. REPAIR STANDARDS
Repairs or modifications should only be done by skilled
personnel, usually from the manufacturer.
Modifications should follow the site management of
change procedure.
Prior to a repair the cause of failure should be
addressed. The repair/modification should avoid a re-
occurrence of the failure. A root cause analysis of a failure
might highlight the need to make multiple modifications
not only on the directly affected LV MCC but also similar
switchgear elsewhere on the site.
FUTURE DEVELOPMENTS
The introduction of intelligent motor protection relays
offers the possibility of providing additional on-line
monitoring of the status of starters through trending
temperature rises and giving an alarm when these exceed
expected values. Although an absolute temperature value
may be used as an alarm, this assumes the starter is fully
loaded. To pick up deterioration in more lightly loaded
starters it would be necessary for an alarm to be raised
when temperature exceeds the normal steady state value,
which may well be below the maximum permitted
temperature in a lightly loaded cubicle. Any such system
should be capable of being set up to detect such changes
as well as if the temperature exceeds the maximum
permitted.
It is unrealistic to expect maintenance staff to be able to
closely monitor the performance of hundred’s of starters
across a plant. So it is important that, in addition to the
measurements themselves, there is software capable of
applying an intelligent filter to the output which only raises
alarms where they are real.
In fact it is the combination of the ability to measure
additional information about starter performance, together
with the ability to identify real problem areas, which will
make this technology really useful. In addition to heat or
voltage drops, other aspects such as number of times a
starter is withdrawn, numbers of starts / abnormal
numbers of starts per hour, number of contactor
operations or increasing levels of earth leakage current
before a trip value is reached, could be included in the
monitoring programme.
Even where alarm conditions have not been reached,
such a system could be useful in identifying those drives
which are under the greatest stress from loading or
numbers of operations, hence those which deserve closer
attention during Turn Around inspections.
Although it is outside the scope of this article, there are
other areas where intelligence can be made to work
harder by including monitoring of the motor as well as the
starter.
A system combining both switchgear and motor
monitoring with reliable indications would be a great step
forward in allowing targeted and condition based
maintenance rather than being mainly time based.
Currently such capabilities are only available from
limited number of vendors. Users should encourage their
preferred vendors to consider how they can apply
leverage from the presence of intelligence in the
compartment to aid early identification of developing faults
so there is a competitive market for this type of
technology.
V. LIFE EXPECTATION AND LIFE EXTENSION
An MCC reaches its end of life when spare parts are
not available and servicing is either impossible or
prohibitively expensive. Typically it is when the mean time
to repair becomes unacceptably long that action is forced
upon the user.
Provided that this condition is recognized, the low
failure rate normally experienced with LV MCC’s allows
sufficient time for alternatives for switches, circuit
breakers, contactors and protective devices to be
identified. However if attention is not paid to the
availability of spares, then it is possible to be caught out
and suffer extended outages or loss of service from a
compartment.
With proper maintenance the copper, cabinets and
insulation materials should remain in good condition and
do not suffer from age related defect mechanisms.
However this statement is subject to caveats regarding
heat and environment. Extended operation at or close to
the nominal rating of equipment will mean that the
equipment will run “hot” and insulation may well start to
degrade once the design lifetime is exceeded. Similarly a
simple mechanism such as rust due to extended
operation in a high humidity environment can fatally
weaken parts of the MCC structure forcing its
replacement.
As long as the function of the MCC does not change
significantly and the level of safety of the original design
is acceptable, the MCC can last at least for another
decade after the official obsolescence declaration.
Also upgrades can be considered, as more modern
components tend to be smaller and functionality
increased.
 Upgrade examples, installed at various petrochemical
sites are:
1. Arc flash detection and quenching. Detection
takes 2 milliseconds, following by a 35
milliseconds of tripping the incoming or
upstream circuit breaker. Quenching of an arc
with a quenching device takes 3 milliseconds.
2. Very Early Smoke Detection Apparatus to detect
hot spots and fire in an early stage. This can be
detection in the LV MCC (per panel) or room
detection.
3. Starter temperature monitoring
4. Replacement of fuses by circuit breakers when
an isolating device is not available
5. Microprocessor type relays replacing thermal
overload relays.
6. Insulation of cable connections
7. IR windows for hot spot detection
Figure 4 : LV MCC Arc flash quenching device
Also on the environmental side upgrades can be
considered, such as:
1. HVAC installation
2. Fire detection (VESDA)
3. Water leakage prevention
4. Insulating matting on floors
5. PPE in substations, as arc flash suits, face
shields, voltage rated gloves
6. Update documentation and drawings, as this is
often neglected. Include load flow, protective
relay coordination and arc flash energy
calculations.
7. Training of electricians and engineers
These types of replacements or upgrades extends the
life time of an MCC and increases the safety level to an
acceptable degree. In turn this avoids a costly
replacement of an MCC in the always too short Turn
Around period.
However caution needs to be adopted in assuming that
such works will achieve the same levels of safety as a
modern LV MCC. If the original design does not include
the level of segregation, insulation and separation called
for in a modern board, it is unlikely that it can be retro-
fitted with such features cost effectively.
Still, when above mentioned recommendations are
included, a higher safety, reliability and availability level
will be achieved.
VI. SAFETY
Overall safety level will be improved by reducing the
number of maintenance interventions. Maintenance
intervals for starters are 5-6 years. Maintenance intervals
for circuit breakers can be 10-20 years.
Applying modern PPE for arc flash protection and
protection against electric shock will further reduce risk.
Arc flash detection and quenching will reduce the
impact in case of an arc and reduce the arc flash energy
levels to low values. A reduction with 90% to 98% is
easily to achieve.
Early detection of evolving failures with VESDA
systems and thermo-graphics will avoid risk full situations
during maintenance activities.
Improving maintenance procedures and management
of change will be the final step in achieving a maximum
safety level.
VII. CONCLUSIONS
MCCs in the Petrochemical segment have to be safe
and reliable. They are an important part of the chain of
electrical supply from the supply source to the end
consumer.
The improvement of the performance of a MCC starts
when specifying the MCC.
Vendor selection is an important part of the pre-order
stage. End-customers and engineers have to invest time
and effort to satisfy themselves that the vendors asked to
quote will provide the right level of quality the application
calls for.
Only when the specifications are in line with the actual
use of the equipment and only when the vendor has
provided the end-customer with what he wants and
expects, can you start with a MCC that is fit for purpose
and that will perform well under the predicted
circumstances.
However it is the personnel that use, operate, maintain
and modify the MCC that can have an even greater
impact on its performance.
The users need to be trained, they need correct
working instructions and up-to-date as-built
documentation to be able to fulfill their role properly and to
minimise the chance of creating failures. Vendor’s
designs should build in “passive safety measures” that
help to prevent failures to occur.
An important part of the performance of a MCC is
determined by the maintenance strategies. It will always
be difficult to find the right balance between use for
production and availability for maintenance.
Good preparation for the maintenance works will help
to limit the time needed for performance improving
maintenance to a minimum.
 In the future we hope there will be improved status
information available from the boards themselves through
condition monitoring but there will always be a need to
combine this with traditional approaches and skills.
Vendors have to understand and plan in their
design/support that users will look for extended lifetimes
for LV MCC’s. This has significant implications for
retention of documentation and knowledge as well as the
need to provide upgrade paths for previous ranges of
equipment.
After a long life time (exceeding 1,5 – 2 times the
nominal design life time) the MCC will reach the End of
Lifetime condition. Now it all starts all over again with
specifying the right replacement material.
VIII. REFERENCES
PCIC PAPER BA-27 : Imcs versus conventional mcc -
are the benefits realised in practice?
IX. VITA
Authors:
Hans Meulenbroek, B.Sc
Graduated in 1985 from the HTS Hilversum, the
Netherlands with a bachelor degree (ing.) in Electrical
Engineering specialization Telecommunications. From
1987 he worked for Rossmark Watertreatment as a
process automation engineer and later he managed the
process automation department. In 1997 he joint Eaton
Electric in the role of application engineer/SCADA
specialist. After changing positions to Project Manager
and Export Customer Support Manager his current
position is Product Manager being responsible for the
marketing of LV MCC and Motor Management Systems.
Peter Freeman C.Eng MIEE
Graduated from Imperial College London with bachelor
degree (Hons) in electrical engineering in 1975. Joined
Courtaulds Ltd and worked at various Viscose Rayon
plants until 1981. Join Shell in 1981 and has worked at
variety of refinery and E&P locations in various
engineering design and maintenance roles. Currently
working for Shell Global Solutions Electrical Engineering
section based in The Hague, with specific responsibilities
in areas of Switchgear and Maintenance/Commissioning.
Ing. André Muileboom
Graduated in 1977 from HTS Rotterdam, The
Netherlands with a bachelor degree (ing.) in Electrical
Power Engineering.
He joined DSBV, an architect and engineering office, as
electrical/instrument engineer. In 1979 working for De
Hoop-Groenpol as marine electrical engineer, specialized
in large LV switchgear and MCC's and ship electrical
power systems.
In 1985 he joined ExxonMobil Chemicals, where he
covered various positions as site electrical/instrument
engineer, project engineer and reliability engineer. Since
2005 he is working for Core Engineering, the ExxonMobil
Chemical global engineering department.
Jan Verstraten, B.Sc
Graduated from HTS Hilversum. Currently a Sr. electrical
specialist, he has worked for Dow Benelux BV in
Terneuzen since 1990, in various departments:
Maintenance central E&I, Maintenance Technology
Department and Powerplant. Since 2004 he has held the
post of Installation Responsible Person for Dow in the
Netherlands, Electrical SME for Dow in Benelux, UK &
Scandinavia and Electrical Safety and Reliability auditor.
Member of: NEC 623.