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| Deutsche BP AG - Chemical Productions Marl; Marl (Germany) | | A clever investment | Simocode pro at BP
A modern motor management system is distinguished by the fact that it contains a number of service functions in addition to extensive protection, control and monitoring functions. BP Marl is therefore converting all its pump drives in the Cumol production to Simocode pro. In connection with a new process control system this increases the plant transparency and availability considerably.
The Deutsche BP AG-Chemicals Production Marl produces large amounts of styrene, ethyl-benzole and Cumol on the Marl industrial estate in the Northern Ruhr region. In the course of modernization of the plants the pump controls have been equipped with intelligent low voltage switchgear thus replacing the old contactor controls with a future-safe concept. Instead of modernizing the previous contactor motor control and linking the signal technology to the new process control system (PCS) by additional wiring of control contactors, the people at Mark chose a more modern solution: "The new motor management system Simocode pro does not cost more than a contactor control but supplies a lot more data and offers extensive service functions", Dirk Pletowski, Engineering Assistant for Electrical Engineering gives reasons for the decision.The plants for the Cumol production are running virtually all the year round 24 hours a day. For conversion of the process technology, 80 pump drives are being equipped with the new motor management system Simocode pro during operation in the first step. BP in Marl sees a great advantage in the possibility of initially operating the motor management system as a standalone solution - i.e. without PLS support and processing the acquired data in the control stand on site. When the new process control system is then running in full operation, the devices can be connected to the total solution via Profibus DP without any great delays. "We are already doing the bus addressing for this in the installation of the Simocode pro", Pletowski explains. This works very simply with an address plug. To assign a Profibus address this just has to be plugged briefly to the system interface. With the immediate addressing the team saves time later because only the lines already provided have to be plugged into the Profibus connections on the devices.From the protection and control unit to motor managementAt BP in Marl the company engineers use Simocode pro C in 79 of the 80 pump drives. "C" stands for Compact and represents the basic equipment of the new motor management system. This includes a current intake module, a basic unit and an optional operating unit. The modules are electrically connected by a cable and can be mechanically mounted optionally as a unit or separately."The resultant flexibility is a great advantage for us", Pletowski stresses. "Because the current intake module and the basic device may now be up to two meters apart. In this way a high equipment density can be achieved in the two control rooms for the Cumol production, therefore saving space in the right places."Simocode pro C for direct and reverser starter is considered the currently most cost-effective, communicable motor management system in its class. It is ideally suited for simple changeover from contactor controls to communication-capable motor branches. This brings many advantages. In addition to protection of the motor and linking to Profibus DP the measurement of electrical currents is particularly relevant in practice. These allow you to immediately read whether a pump drive is running in the normal range or unusual changes result in the process. In this way the operating team can respond before damage or failure occurs and can very easily implement a condition-oriented maintenance concept.An essential feature of Simocode pro is the autarchic design of all protection and control functions. Even when the bus system or the process control technology fails both the functionability and protection of the motor branch are retained. This even allows a certain behavior to be parameterized for the event of a breakdown.High flexibility due to modularityFor a drive, the BP people chose the Simocode pro V model (V = variable) because up to two additional digital modules can be connected to the appropriate basic device, "to be able to tap certain sensor signals", Pletowski explains, because process-technical plants especially contain many different sensors.Therefore the pro V variant can be extended by an extra, external grounding module and an own temperature module in addition to the two possible digital modules. Three analog sensor measuring circuits in two or three-wire technology can be evaluated. It makes no difference whether these are sensors of the PTC, NTC, Pt100, Pt1000 or KTY type. By integrating the motor temperature monitor in a process control system, the plant availability can be positively influenced preventatively.An analog module can also be added to Simocode pro V. With this filling level values or volumetric flows which need to be measured very often in process technology can be very easily integrated in the motor management. The appropriate values are also available in the process control system via the Profibus connection. An extensive motor management is possible with Simocode pro. In addition the systems contains many pre-defined motor control functions such as reverser or direct start and star-delta switching with and without direction of rotation reversal already as standard.With the individually adapted equipment Simocode pro provides a phase sequence detection, the CosPhi, current, temperature, power and voltage monitoring. Other protection and control functions can be adapted by freely parameterizable logic components such as truth tables, counters or flank evaluation. And of course mixed operation of Simocode pro C and Simocode pro V is also possible without additional effort. Dirk Pletowski is convinced by the new motor management system "With the Simocode pro devices we have everything we need today and for the future."
Advance 3 / 2005 | |
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