WO2005083858A1

WO2005083858A1 - Modular control centre

Info

Publication number: WO2005083858A1
Application number: PCT/GB2005/000625
Authority: WO
Inventors: Thomas Hayden
Original assignee: Thomas Hayden
Priority date: 2004-02-23
Filing date: 2005-02-18
Publication date: 2005-09-09
Also published as: GB0403868D0

Abstract

An apparatus and method for providing control equipment is disclosed including at least one equipment container comprising a body portion for containing selected control equipment and including a power connector. Also an electrical conductor for supplying power to at least one of the containers via a power connector of at least one container is included.

Description

MODULAR CONTROL CENTRE

The present invention relates to control centres.

In particular, but not exclusively, the present invention relates to a method and apparatus for providing a form 4 modular power control centre and/or a modular form 4 motor control centre.

Low voltage form 4 motor or power distribution systems will typically consist of a form 4 motor or a power control centre with each motor/power circuit and its associated control located in their own individual compartment. All compartments are fixed or withdrawable (one piece welded structures or modular framewor with full-length covers) adjacent to each other in tiers. Or withdrawable" inner compartments. Each compartment is fed with power either direct from / or via cables direct from the busbars. The busbars, some quite large and each capable of carrying a hundred amps or more with a high fault rating quite frequently supply small motor control compartments and control circuits that only require a few amps. This produces an inefficient manufactured assembly. The busbars are often supplied from a large singular main isolator or circuit protection device i.e. fuse or circuit breaker.

The form 4 motor control centre can be large and costly to manufacture with any spare compartments contained within the original manufactured supply. It can be costly to transport and ^λoff-load' requiring specialist lifting equipment. Once installed it is both difficult and/or expensive to modify the size of a compartment or material contained within a compartment . Design and lead times can be many months before the arrival on site from placement of an order as full manufacturing information is often required prior to starting any work, on any Part of the form 4 motor control centre . On site handling and access for the low voltage motor or power distribution centre is also an issue as these can be both heavy, bulky and unstable in handling prior to being fixed in place at a final desired location.

The industry has been developed to enhance the philosophy of form 4 motor control centres with the busbar systems- and in some cases irrespective of the end users system requirements. The industry has also developed products and educated the end users into the need to purchase and install these form 4 motor control centres irrespective of the total fault or load requirements . It is an aim of embodiments of the present invention to at least partly mitigate the above-mentioned problems.

It is another aim of embodiments of the present invention to enable a control centre to be located in a smaller control room or with restricted access or assembled around structures than would not be permitted with prior art systems .

It is another aim of embodiments of the present invention to provide a system in which a control centre can be constructed using lightweight modular structures to ease handling.

It is another aim of embodiments of the present invention to provide a system in which a control centre can be constructed using individual autonomous containers attached to each other. It is another aim of embodiments of the present invention to provide a system in which containers can be enclosed within a manufacturer standard product structure .

According to a first aspect of the present invention there is provided apparatus for providing control equipment comprising: at least one equipment container each comprising a body portion for containing selected control equipment and including a power connector; and an electrical conductor for supplying power to at least one of said containers via a power connector of at least one container.

According to a second aspect of the present invention there is provided a method for providing a modular control centre, comprising the steps of: locating control equipment in at least two equipment containers; releasably securing said at least two equipment containers at a desired location; and supplying power to said at least one container from a isolator or circuit protection device via a power connector.

By locating electrical control components such as small PLC's relays, timers, circuit protection devices, isolators, contactors and overloads in separate containers which can then be independently secured to a wall or floor/standing support structure a lightweight and convenient modular control centre can be provided. These individual containers may optionally contain other components other than those required for motor starting i.e. excludes propriety motor starter enclosures that only contain the components to run and protect a motor i.e. contactor overload assemblies with pushbuttons .

These individual containers may optionally be assembled on or off site as a project develops and used as either a temporary or permanent installation.

Advantageously, the container may optionally be made out of metal, metal and plastic, or plastic compound such as GRP. If required, the container can include a viewing window, which can extend for only a part or the full length of the front of the local control panel . Clear or tinted glass or plastic compound may be used.

Embodiments of the present invention will now be described hereinafter, by way of example only, with reference to the accompanying drawings in which:

Figure 1 illustrates a container; Figure 2 illustrates a container;

Figure 3 illustrates an open container;

Figure 4 illustrates a single floor standing support;

Figure 5 illustrates a floor standing support; Figure 6 illustrates equipment containers releasably secured (front fixing and rear fixing) to a floor- standing support structure; Figure 7 illustrates equipment containers of various shapes and sizes secured to a support structure;

Figure 8 illustrates containers enclosed within a manufacturers standard product structure; and

Figure 9 illustrates typical power distribution to the containers .

In the drawings like reference numerals refer to like parts.

Figure 1 illustrates a container for holding equipment of a form 4 control centre such as small PLC's relays, timers, isolators, circuit protection devices, contactors and overloads. The container 10 is formed as a substantially rectangular shaped box body portion 11 having a door 12 that pivots about a hinge, hinged on any side (top, bottom or sides) 15 and may be secured across the front of the container via a locking bar 14 or fastenings. It will be understood that embodiments of the present invention may be provided without such a door locking mechanism or hinge/s. Also, the container can include a wide variety of components necessary for the proper functioning of the device with which the container is associated.

A viewing window 13 is provided in the door 12 to enable a user to view various parts of the equipment located in the container. The door may optionally also not contain a window. A securing lock 14 enables the door to be secured in a closed position. Alternatively the door could be a snap fit rather than a hinged door and without a securing lock. The door includes a sealing mechanism such as a gasket (not shown) which prevents ingress of foreign material and so prevents the accumulation of debris on equipment within the body of the container.

Figure 2 illustrates an alternative container 20 in which the box like body portion is more cuboid. It will be understood that embodiments of the present invention are not restricted to these two shapes of container.

Cable access points or connectors 21 are formed in a side or back of the container to enable cables carrying power and/or signals to/from equipment located in the container. A main power Cable access point / connector

22 is located to the rear or side of the container so that when the container is fixed to a support power may be supplied to equipment within the container. Each container may be formed from metal and/or liquid plastic or plastic compound such as GRP .

Figure 3 illustrates a container with the cover 12 open. Equipment 30 such as small PLC's relays, timers, isolators, circuit protection devices, contactors and overloads are arranged within the container. In this way each container can contain a control circuit or motor/power circuit and its associated control. These containers may be individually designed and assembled on/off site and brought to a desired location where they can be fixed to a support or enclosed within a structure .

The viewing window may also include a user interface, which enables adjustment of the electrical components located within a container. Figure 4 illustrates a floor/standing support frame 40 which includes twin uprights 41 and cross bars 42. The support frame has a base 43 and a bracing piece 44 and provides a rigid structure to which the containers illustrated in figures 1 to 3 may be releasably secured. It will be understood that rather than securing the containers to such a floor-standing structure the containers may be bolted directly to another type of framework a wall mounted support to a wall itself or enclosed within a structure.

Figure 5 illustrates three floor-standing support structures in a side by side arrangement. It is understood that any number of floor standing structures or any number of manufacturers standard product structures can be used to form an motor control centre in /on which the containers are fitted. The first framework 50a is formed by uprights 51a and cross pieces 52a and has a support base 53a. Adjacent to this is a second support 50b formed from uprights 51b cross pieces 52b and a base 53b. A third floor-standing support structure 50c is formed from uprights 51c, cross pieces 52c and a base 53c. The three supports are rigidly secured to the floor. Cable tray 54 is attached between the floor- standing supports to facilitate the wiring to the containers. Cable tray 54 also enables the three supports to be secured together. Glandplate 55 is attached to facilitate the glanding of electrical cables. It is understood that the glandplate is not always required to be fitted and that the cable tray may be replaced by trunking or other cable carrying device or not at all. Figure 6 illustrates a number of equipment containers secured to a floor-standing support either by the base fixing or by front/side fixings. By securing containers separately to the support a modular control centre for motor or power control equipment can be provided. Each container holds the control circuit motor or power circuit and its associated control . The containers are secured together either on or within a frame or other support structure or enclosed within a structure or wall without the need for fault rated busbars. The fault ratings for the electrical supplies are reduced via upstream protection, circuit breakers or fuses. The prospective fault current that can pass through a protection device before the protection device will operate, is dependant upon its tripping characteristics (maximum let through energy) . The loop impedance of the electrical conductors will assist in restricting the value of the fault current. The containers may be prepared off site or at the site and because they may be releasably secured to the support they may be changed after an initial installation. Power may be provided to the containers from a remote power distribution board. The power distribution board can be existing and may also be used for other services. Thus when only a small number of containers are required a busbar system would be uneconomic . The containers may be fitted with various options to suit the site conditions. Electrical components other than an isolating switch or contactor and overload may also be fitted within the compartment. The support comprising a frame that is typically floor standing, may be a metal framework formed from a welded construction or bolted together. The framework may be either constructed in one or more sections dependent upon the installation requirements and number of containers to be supported.

The support may be provided with means for mounting a cable ladder, tray, ducting, trunking gland plates or other cable carrying devices and may have an earthing system fitted.

The containers may be fitted or enclosed within any manufacturers standard product structure .

Figure 7 illustrates the side by side support structure of figure 5 partially full of containers forming a modular form 4 motor control centre . When further containers are required they may be secured to the central region 70 which is unused.

By forming the containers as separate structures they can be removed after installation without the need to remove any adjacent containers after isolation of the electrical supply. This means that equipment in those other containers may be run whilst selected containers are removed and/or replaced. The individual containers are wired and tested as required, the supply wiring to the individual containers is typically from a distribution board containing circuit protection devices. The circuit protection devices are required to limit the perspective fault current to the current to the current carrying capabilities of the cables and equipment located within the container. Embodiments of the present invention provide a modular form 4 motor control centre that comprises of individually made containers. Each of these containers holds the motor circuit and its associated control or control circuit . The containers are secured at a desired location, either on a frame or structure wall or enclosed within any manufacturers standard product structure . The containers do not need integral fault rated busbars. The fault ratings for the electrical supplies are reduced via upstream protection, circuit breakers, and/or fuses. The containers although individually designed can be individually assembled/installed on site and changed after installation. By providing a modular control centre embodiments of the present invention provide the benefit that a smaller control room is required to hold only necessary equipment. This helps reduce transport costs. By having individual containers, which may be secured independently, a lightweight system is provided which eases handling and health and safety issues.

Since the containers may include standard components, which may be purchased "off the shelf" or after only a small amount of preparation short, manufacture times are possible for the provision of a full control centre. Since the containers are replaceable costs savings may be made when a fault occurs or when new functionality is required.

Each container may be isolated independently so that the main form 4 motor control centre is still "alive" when a small part of the equipment fails. This reduces site interruption and improves maintenance flexibility.

Much of the functionality in a control centre includes common components from site to site. This means that the containers may be reusable at other sites and do not need to be destroyed or wasted when their normal life expires at a particular location. Because of the modular design embodiments of the present invention can be installed and commissioned by a qualified trades man rather than specialist personnel. This reduces installation costs. Embodiments of the present invention provide the advantage that a visual indication of components within a container may be provided together with the option to reset or adjust those components during operation. This means that items may be monitored and reset by plant operators under instruction from qualified personnel.

Embodiments of the present invention provide a control centre with reduced internal wiring and component requirements. No additional internal cables are required between the' control and site mounted equipment power to mini PIC, internal motor cables and hardwired interlocks will still be required. This reduces manufacturing and engineering costs. Also design, drawings, wiring, testing and material costs are reduced.

Since no single busbar system is in place standard power cable tests only are required. This reduces commissioning and testing costs . By using standard components and a layout container wiring no longer needs to be site specific.

Embodiments of the present invention have been described hereinabove by way of example only. It will be understood that modifications may be made to the described examples without departing from the scope of the present invention. It will be understood that the text used in the described examples, to describe the compartments and containers are only general descriptive terms. As within the industry many different descriptions are used for each item of equipment. e.g. compartment = cubicle. Tier = rack, bay, section. Motor control centre = main power board, (Descriptive of location - Pump Panel, Pump Control) Main Panel, control distribution, main panel, etc, etc.

Claims

CLAIMS :

1. Apparatus for providing control equipment comprising: at least one equipment container each comprising a body portion for containing selected control equipment and including a power connector; and an electrical conductor for supplying power to at least one of said containers via a power connector of at least one container.

2. Apparatus as claimed in claim 1 wherein each equipment container comprises securing means for releasably securing the container to a support or enclosed within a structure.

3. Apparatus as claimed in claim 1 or claim 2 wherein each container includes sealing means for preventing accumulation of dust or debris within the body portion.

4. The apparatus as claimed in claim 3 wherein said sealing means comprises a gasket or seal gasket.

5. Apparatus as claimed in any preceding claim wherein each container includes electrical cable entries or connectors located in the bottom and/or top and/or side and/or back portion of said body portions.

6. The apparatus as claimed in any preceding claim wherein each container may include a cover including a viewing window for enabling a user to view at least a part of the control equipment located in said container.

7. The apparatus as claimed in claim 6 wherein said cover, if fitted is hinged and/or loose with respect to said container.

8. The apparatus as claimed in any preceding claim further comprising a floor-standing support including securing means for securing one or more of said containers to said frame or enclosed within a structure.

9. Apparatus as claimed in any one of claims 1 to 8 wherein said control equipment comprises control or motor control equipment .

10. The apparatus as claimed in any one of claims 1 to 8 wherein said control equipment comprises power control equipment .

11. A method for providing a modular control centre, comprising the steps of: locating control equipment in at least two equipment containers; releasably securing said at least two equipment containers at a desired location; and supplying power to said at least one container from a isolator or circuit protection device via a power connector. Of said container.

12. The method as claimed in claim 11 wherein said step of locating control equipment occurs at a location remote from said desired location.

13. The method as claimed in claim 11 or claim 12 comprising the steps of: securing each container to a floor-standing support or enclosed within a structure.

14. The method as claimed in any one of claims 11 to 13 further comprising the steps of: subsequent to a first period of operation, releasing at least one container and replacing said released container with a further container holding further respective control equipment; and releasably securing said further container at said desired location prior to a second period of operation.

15. The method as claimed in claim 14 further comprising the steps of : replacing said container whilst power is maintained to remaining containers of said control centre .

16. The method as claimed in any one of claims 11 to 15 further comprising the steps of: providing a support, to which said containers are securable, in a plurality of sections or plurality of enclosed structures.

17. The method as claimed in claim 16 further comprising the steps of : providing an earthing system for said support .

18. The method as claimed in any one of claims 11 to 17 further comprising the steps of: in the container, providing a viewing window to permit a user to view at least a portion of the control equipment in each container.

19. A method substantially as hereinbefore described with reference to the accompanying drawings .

20. Apparatus constructed and arrange substantially as hereinbefore described with reference to the accompanying drawings .