VINTAGE LOW-VOLTAGE MOTOR CONTROL CENTERS – REPLACE OR

UPGRADE?
David B. Durocher Matthew R. Hussey
Senior Member, IEEE Member, IEEE
Eaton Corporation Eaton Corporation
26850 SW Kinsman Road 2900 Doc Bennett Road
Wilsonville, OR 97070 USA Fayetteville, NC 28306 USA
[email protected] [email protected]

Abstract - Low-voltage motor control centers are is simple; electrical power is presumed to be reliable and
universally applied in process industries. These electrical available, until it is not. Most production facilities in the upper
assemblies are perhaps one of the most dynamic in quartile for reliability and safety have rigorous and detailed
industry, ever changing as low-voltage motor loads are preventive maintenance procedures in place to assure “the
constantly added and modified in response to necessary lights don’t go out” unexpectedly. These include programs to
process revisions and upgrades. As existing low-voltage complete testing during scheduled rotational outages, such as
motor control centers (MCCs) approach 40 to 50 years age, dissolved gas analysis of transformer liquids and testing of trip
industry users are challenged with a decision to replace performance for power circuit breakers, as well as infrared
vintage MCCs approaching their end of life or consider scanning of electrical connections to check for hot spots and
upgrade of existing assemblies. This paper will discuss insulation breakdown.
upgrade versus replace alternatives, addressing UL 845 Although a robust preventive maintenance program of
North American industry standard requirements and how electrical control and distribution systems can be effective, the
this affects design, installation and maintenance of both plan to continue this cycle year-after-year without implementing
upgraded and new MCCs. Application issues including either a replacement or upgrade program for these valuable
considering the cost of replacing load cables versus re- assets will put yesterday’s productive plant on the future road
use of existing cables, high-resistant pulsing ground to obsolescence and eventual closure. It’s an obvious fact that
systems and opportunities for process improvements and legacy plant electrical systems, originally manufactured 40 and
network communications that leverage the latest 50 years ago, cannot keep pace with the rapid changes in
technology will be discussed. Finally, a case study technology. Analogously, it is certainly possible the television
comparing the alternative of replacing an existing MCC purchased for personal use at home back in 1975 could still be
versus a field upgrade based on changing out all exiting in service today, through careful and meticulous maintenance
starter and feeder circuit breaker units and an estimate of and replacement of worn or failed components. Of course,
the total installed cost for both MCC replacement and considering the extraordinary shift in technology with high-
upgrade for this application will be reviewed. definition LED network enabled televisions of today, it would be
senseless to consider the time and cost to extend the life-cycle
Index Terms – Motor Control Center, UL 845, Life cycle of the 44-year-old set. In this example, replacement is the only
extension, High resistance grounding, Motor management practical option.
relays.
II. APPLICABLE MANUFACTURING AND TEST STANDARDS
I. INTRODUCTION
In today’s modern engineered electrical systems, there are
Today’s global production in the process industries a host of assemblies that should be considered for either
continues to expand. Capacity additions are springing up in a replacement or life-cycle extension upgrades. It is important to
few key strategic areas, aimed at balancing increasing demand be familiar with the major components that serve as the building
and a fixed supply. The prospects of new capacity installations blocks of power distribution and control assemblies in industry.
that will successfully apply state-of-the-art technologies are In North American markets the Institute of Electrical and
exciting, offering the step-change potential to improve site Electronics Engineers/National Electrical Manufacturer’s
productivity, reliability and safety. That said, because many Association (IEEE/ANSI) and Underwriter’s Laboratories (UL)
existing plants in industry are not operating at design capacity, Standards prevail. Three-phase engineered low-voltage MCC’s
the fact remains that most global demand will continue to be are the focus of this paper, specifically 600 VAC low-voltage
served from existing facilities. Many existing plants were first motor control centers manufactured and tested to UL 845
commissioned 40 to 50 years ago and some existing systems “Standard for Motor Control Centers” [1]. Typically, these
might be approaching end of life today. Industrial plant assemblies include a steel supporting structure with individual
operators of existing sites will need to focus on considerations compartments that contain a protective device such as an air
regarding equipment replacement versus upgrades for magnetic molded-case circuit breaker and a contactor (vacuum
electrical power distribution and control systems. or air-magnetic). Each circuit breaker and contactor typically
Electrical power in most industrial manufacturing plants is includes a protective relay to assure either cables or connected
the most ubiquitous asset of the production process, while also motor loads are protected in the event of an overload or system
being arguably one of the most overlooked. The reason for this short-circuit condition. These assemblies also include main

PRESENTED AT THE 2019 IEEE IAS CEMENT INDUSTRY CONFERENCE, SAINT LOUIS MO: © IEEE 2019 - PERSONAL USE OF THIS MATERIAL IS PERMITTED
copper bus-bars used as current-carrying conductors, pulled and terminated, adding significant labor and materials
connecting the incoming power source to the multiple devices cost in replacing the original cables.
that serve and protect individual electrical loads. Although the
structure and bus components of both medium-voltage and IV. REVIEW OF STANDARDS PRIOR TO LV MOTOR CONTROL
low-voltage distribution and control assemblies are similar, CENTER REPLACEMENT
considerations involving their end of life replacement are
somewhat different. This paper will address replacement As mentioned previously, the manufacturing and test
versus upgrade considerations related only to low-voltage standard for LV MCC’s applied in North American markets is
motor control centers. UL 845. Although the authors are not suggesting that industry
One other industry standard relevant to this review is IEEE users study the details regarding this Standard, being familiar
Standard C37.20.7 “Guide for Testing Metal-Enclosed with UL 845 is useful in better understanding the scope and
Switchgear Rated Up to 38kV for Internal Arcing Faults”. Low- available ratings for this class of engineered electrical
voltage MCCs are optionally available as arc tested to this assembly. One recently developed Standard which is
Standard, which was recently updated in 2017. The arc testing recommended by the authors is IEEE1683-2014 [2]. The
requirements are individually defined in multiple Annex document, titled “IEEE Guide for Motor Control Centers rated
documents in the Standard, each applying to a unique type of up to and including 600 V AC or 1000 V DC with
assembly. For low-voltage motor control centers (LV MCCs), Recommendations Intended to Help Reduce Electrical
arc test procedures as outlined in Annex H of IEEE Std. Hazards” was recently created by a working group of engineers
C37.20.7-2017 are applicable. Other than this “add-on” arc from multiple manufacturing industries, consultants and
resistant test requiring a more robust assembly with heavier manufacturer’s. Note that this document is an IEEE Guide, not
gauge steel, bolts and latches, traditional steel enclosures for a Standard. Unlike UL 845, IEEE 1683 does not define specific
LV MCCs manufactured today are very similar to designs from construction and test requirements or specific features, rather
40 years ago. The main bus-bar for these assemblies also has the document addresses considerations around LV MCC
not appreciably changed. Typically, the bus system includes installation, considering the site power system and electrical
flat copper bar conductors for each of three electrical phases, safety criterion. The Guide also explains the benefits and
with multiple bars per phase being required to support higher limitations of certain LV MCC features, offering guidance
bus ampacity ratings. around common considerations for particular features. The
authors suggest review of the IEEE1683, as well as [3] and [4]
III. REPLACEMENT CONSIDERATIONS which offer valuable detail regarding choices and outcomes in
selecting a LV MCC based on recent industry applications.
Consistent site maintenance practices to assure both the LV
MCC steel structure and the bus system have not been V. LIFE-CYCLE EXTENSION CONSIDERATIONS
neglected are essential. If one or both has degraded or been
compromised over time, replacement of the assembly is A. Overdutied Assemblies
recommended. Examples of compromise for these parts of the
If the steel structure and bus have been well maintained over
assembly would be environmental contamination, rust, water
the years, upgrading existing low-voltage MCC assemblies can
ingress and breakdown of insulation between energized phase
often be a viable alternative. That said, the user will still need
conductors or a phase conductor and ground. If the structure
to assure the originally installed assembly is properly rated.
and/or bus system is at end-of-life and replacement is the
Over the course of the last several years, many existing
necessary and recommended option.
manufacturing facilities in industry have improved working
Before implementation of a replacement plan, careful project
conditions for employees by a renewed focus on electrical
planning is necessary to assure the project is successful.
workplace safety. Driven in part by improved standards for
Consideration of the required time to completely replace
safety, including NFPA70E-2018 “Standard for Electrical Safety
existing equipment will necessarily impact production. Access
in the Workplace”, an enhanced awareness and recognition of
to remove the existing assemblies and bring in the new
both electrical shock hazards and electrical arc flash hazards
equipment must be considered. One often overlooked issue
has emerged. This standard requires existing facilities to
involved is the cable terminations to existing loads. New
complete and, every five years update, an accurate model of
assembles are unlikely to match in location for existing line and
the plant electrical power distribution system. This includes
load cable terminations. This may require that the project scope
completion of a short-circuit, coordination and arc flash study,
include pulling all new cables, which improves overall reliability
with the end deliverable being warning labels affixed to each of
but adds cost in materials, labor and lost production. If existing
the “openable” electrical panels that identifies the shock
outgoing cables to the LV MCC motor loads are run in individual
hazard, arc flash hazard, working distance boundaries and
conduits, careful consideration regarding the conduit condition
appropriate personal protective equipment (PPE) required for
and the required number of cable bends should be reviewed. If
persons working on or near the panel while energized. One
motor cables are routed through open cable tray, removing
unintended consequence of these system studies has been a
existing cables and installing new may present added
realization of some overdutied electrical equipment in existing
challenges dependent on the cable routing. Even if existing
plants. LV MCCs have been one of the more prevalent
conductors can be reused, there is risk in disrupting existing
examples of existing overdutied electrical assemblies.
terminations that were first made perhaps 30 to 40 years ago.
Many of the vintage LV MCCs installed between the 1950’s
Oftentimes, especially for larger conductors, aged insulation
and 1980’s have lower bus bracing/short circuit current ratings.
systems can crack and become compromised during a
Vintage MCCs from this era typically include mechanical bus
replacement project. This would then require new cable to be
bracing rated from 35,000 to 50,000 symmetrical amperes.
Conversely, today’s designs typically have ratings up to
100,000 symmetrical amperes. System studies resulting from
current modeling of existing industrial facilities might for
instance, result in a system available fault current of 46,800
amperes at a vintage MCC installation of a product installed in
the 1960’s with a maximum 35,000 rating. Of course, when the
facility was originally built, there was not an error in selecting
the MCC’s to be installed. Instead, over the course of several
decades, facility loads, and system power sources change,
resulting in what once was adequately sized electrical
equipment to now be underrated, or overdutied.
In extending the life of existing LV MCCs in a facility, it’s
possible to increase the assembly bus bracing and interrupting
rating so the MCC can continue to provide safe and reliable
operation. Some field service engineering organizations that
are typically a service arm of a low-voltage MCC manufacturing
company offer the capability to modify existing bus bracing in
order to support higher short circuit ratings. For the user, it is
important to select a reputable firm with a solid track record of
experience to perform these services. Although it will likely be
difficult if not impossible to document that the modified
assembly will successfully pass original factory tests, in most Fig. 1 Components of a Low-Voltage Motor Control Center
cases a software model exists that validates a higher rating Starter Unit
based on engineering calculations. In some cases, when the
service organization is from the same supplier as the original original MCC manufacturer and it is critical that this component
supplied equipment, documentation of current or updated bus be ordered as original equipment. Following this is the motor
bracing designs versus the originally installed equipment will be starter, consisting of a magnetically operated contactor and a
supported by factory testing using bus support insulators as motor overload protective relay. Most vintage motor overload
supplied in the current design product. Should the field modified relays employ one of two antiquated means to protect the AC
assembly include upgraded short circuit ratings require third- motor based on overcurrent resulting in excess heat of a
party certification and UL label, a follow up field inspection resistive element in the phase current path. One of these is a
would be required to validate ratings against the manufacture’s bi-metal element; two dissimilar metals that deflect to engage
design testing. The authors recommend consultation with the a trip bar to open a contact to de-energize the contactor. The
original equipment manufacturer before proceeding with any other is a solder-pot element that includes a melting alloy which
field-based upgrades of any LV MCC assembly. again, upon melting actuates a mechanical movement which in
turn de-energizes the contactor. Both deploy three heater coils
B. Starter and Circuit Breaker Units in each of the three phase current paths which are sized based
After the structure and bus have been thoroughly inspected on motor full load amperes. On an over-current condition, the
and possibly modified to assure conformance and compatibility heater coil deflects the bi-metal or melts the solder alloy,
with the existing system, individual component ratings then resulting in a mechanical movement that in turn deenergizes
must also be investigated. Beyond the enclosure and bas bar the contactor. Other devices in the image include an internal
system, the other major component in any MCC assembly is control power transformer and pilot devices mounted on the
the multiple starter and feeder circuit breaker units that serve starter unit door. The center image shows the complete unit
various downstream loads. Smaller units are typically assembly which also includes unit control and power wiring,
withdrawable, connected at the structure vertical bus via power control terminals, a handle mechanism to open and close the
stab connections, while large units tend to be fixed-mounted. molded-case circuit breaker and painted steel “wrapper” used
Fig. 1 shows the component elements of a starter unit, this from as a means to bolt the unit components together into the
a vintage MCC assembly that is no longer available. However, common sub-assembly.
replacement units still can be supplied in support of this vintage C. High Resistant Grounding Upgrades
assembly. As shown in Fig. 1, individual components in the
starter unit from the upper left of this image include: A circuit Although high resistant grounding systems are typically not
breaker, in most cases a magnetic only molded case design, installed in LV MCCs, any industrial site considering upgrade
manufactured and tested to UL Standard 489 [5]. These of existing motor control centers should also consider system
devices are typically factory sealed with few replaceable parts. grounding. Most low-voltage installations in process industries
Although routine maintenance of molded case circuit breakers prior to the 1980’s were designed based on solidly grounded
is important, the topic is beyond the scope of this paper and the systems. For these systems, low-voltage motor control centers
authors recommend review of [6] and [7] regarding best were connected at the incoming section from a three-phase 3-
practices in maintaining these components. The next wire system that included three phase conductors from a wye-
component rotating clockwise from Fig. 1 is the three-phase connected transformer secondary winding. For traditional
stab assembly. The stabs consist of spring-loaded copper solidly grounded systems, the transformer neutral is connected
conductors that connect the starter unit incoming power to the to system ground. Because 600-volt class low-voltage metal
MCC vertical bus bars. Stab assemblies are unique to the enclosed switchgear typically distributes power to downstream
LV MCCs, the ground termination for solidly grounded systems dangers when his maintenance staff ignored the first fault in a
necessarily is made at the transformer secondary. Thus, three HRG system. As the story goes, he instructed the refinery
phase conductors from the switchgear feeder circuit breakers electrician to wire a yellow pilot light signaling a HRG alarm into
are connected at incoming lugs of the LV MCC and the control his office. He then summoned the entire electrical maintenance
center structure enclosure is then connected to ground at the staff for a meeting in his office where he explained that if the
facility ground grid. Assuming sufficient integrity of the system yellow light ever turns on, it needs to be off within the next 24
ground grid, a phase-to-ground fault at the MCC or at a hours or “heads will roll”. Another drawback to HRG systems is
downstream connected motor would result in a phase to neutral it can oftentimes be difficult and possibly dangerous in using
fault. Because the transformer neutral is at ground potential, a the window-type clamp-on ammeter to trace the downstream
downstream phase to ground fault would result in a line to fault. One cement plant operator suggested this can sometimes
neutral system fault at 277 volts for a 480-volt wye connected take days to trace. It also requires skilled and knowledgeable
transformer source. Loss of service continuity caused by labor with proper personal protective equipment (PPE) to work
protective circuit breakers tripping during a ground fault along around energized conductors.
with a growing awareness of arc flash hazards has rendered
most legacy solidly grounded systems obsolete.
The advantages of upgrading existing industrial facilities to
include high-resistance grounded (HRG) systems have been
well documented in technical papers including [8] and [9]. As
shown in the Fig. 2 schematic, HRG systems differ from solidly
grounded systems with the addition of a fixed resistance
connected between the transformer neutral and system
ground. This resistor is typically sized such that a downstream
phase to ground fault will result in no more than 5 amperes
flowing via the ground grid back to the transformer neutral.
Obvious advantages here are that the first unintentional line to
ground fault at the downstream LV MCC or motor results in no
trip condition and no arc flash event. Typically, current is
measured between neutral and ground or voltage across the
grounding resistor, and an alarm is annunciated, notifying
maintenance personnel of a downstream faulted feeder. At this
point, a pulsing contactor is opened and closed on
approximately 2 second intervals, switching additional
resistance in and out of the neutral to ground connection. While
the pulsing contactor is oscillating, and the system is still
running, maintenance operators use a hand-held clamp on
ammeter to locate the ground connected load. The special
window-type ammeter encircles all thee phase conductors and Fig. 2 Typical schematic for a low-voltage pulsing high-
will register pulsing current of the faulted load, versus resistance ground system
ungrounded three-phase loads that will of course sum to zero.
Measurements can be taken on the outside of conduits, New advancements in technology supporting HRG systems
busways or grounded raceways while plant systems remain including [10] and [11] look to have promise. The addition of
energized and operational. zero-sequence current transformers (ZSCT) at each power
Although converting existing solidly grounded systems to circuit breaker in low-voltage switchgear distributing power to
high-resistance grounded systems is not directly related to LV MCCs is one good addition. The ZSCTs can be wired to a
upgrading vintage low-voltage motor control centers, this is door-mounted ammeter on the switchgear panel, allowing
considered a value-added system addition. Stand-alone HRG maintenance persons to begin the pulsing contactor sequence,
systems including the necessary resistors, contactors, relays then quickly identify which downstream MCC has the faulted
and controllers are commercially available and these can be load. In some current version of HRG systems, ZSCT inputs
added as a system upgrade using floor mounted, wall mounted, can be directly wired back to an HRG relay which can then
or installation into existing low-voltage switchgear assemblies. annunciate on a dedicated display panel which MCC has the
Given the many operational advantages of HRG systems faulted load. Similarly, ZSCTs can be added to each individual
applied in industry today, there remain some drawbacks. One motor starter unit in the LV MCC and wired back to a HRG
deficiency of HRG systems is the importance of locating and relay. This allows nearly instantaneous identification of the
repairing the first grounded load before a second load is ground-faulted load. However, the cost of adding this
unintentionally grounded. Should this occur in a different phase functionality to potentially hundreds of individual starter units at
from the first load, a phase-to-phase fault will typically result in some point becomes a limiting factor.
an upstream protective device clearing the fault and taking the
operation out of service. So, discipline to initiate the pulsing VI. UPGRADE LV MCCS W ITH NEW STARTER AND FEEDER
circuit and use the clamp-on ammeter to locate and remedy the BREAKER UNITS
fault in a timely manner is paramount. The authors remember
one anecdotal story where the plant manager at a large-scale Assuming the enclosure and bus system of a vintage low-
refinery was made aware from a first-hand experience of the voltage MCC is in good condition, the most frequently installed
and viable method of life-cycle extension is by replacing the MCC units from a reputable supplier, assuring the UL 845 label
existing starter and feeder circuit breaker units with new ones. is clearly visible and certified test reports are included.
Fig. 3 shows an image of a vintage starter unit from a now Installation of replacement units that have not been properly
obsolete motor control center built in the 1960’s next to a new tested or are assembled with some used components can
replacement starter unit. Note that the replacement starter unit cause catastrophic failure during a fault, resulting in equipment
is a form-fit-function direct replacement for the vintage unit and damage, loss of production, injury or death of personnel.
that the old components have been replaced with new. In some
cases, the replacement starter units can include additional B. Replacing the Circuit Breaker versus a Complete Starter
components to enhance functionality of the vintage assembly; Unit
in this case, a unit mounted control power transformer and Returning to the topic of the MCC interrupting rating,
door-mounted Hand-Off-Auto selector switch and Motor Run oftentimes a vintage motor control center will need attention not
light addition. only to assure proper bracing of the main horizontal and vertical
copper bus, but also the components included in the starter unit
itself. As previously discussed, most vintage molded-case
circuit breakers typically have lower interrupting ratings and
upgrade of this component needs to also be considered. Like
the power stab assembly, it is important to consult with the
original equipment manufacturer or a qualified electrical
services organization, to investigate the viability of a MCC
upgrade using circuit breakers with higher interrupting ratings.
Not just the breaker rating but also the size and form factor
must be considered. The starter unit door-mounted handle
mechanism will typically be mounted on the circuit breaker, so
the location and movement of the circuit breaker handle must
be compatible with the door-mounted mechanism. In some
Fig. 3 Vintage design (left) versus current design (right) LV cases, new design molded-case circuit breakers with higher
MCC molded-case circuit breaker interrupting ratings can be installed in existing MCCs with
sufficient short circuit ratings to address issues regarding
A. UL 845 Versus a Counterfeit Copy
overdutied installations.
The UL845 Standard mentioned previously applies not just Fig. 4 shows a current design molded-case circuit breaker
to newly manufactured motor control centers, but also to versus one from nearly 50 years ago. Note that the new offering
replacement starter and feeder circuit breaker units. Just as includes features such as finger safe terminals and a push to
new units are tested in new control center assemblies, trip test button, available as standard with a 65,000-
replacement units must also be tested to meet UL 845 test symmetrical ampere interrupting rating. Although the form
requirements. Electrical testing defined in the Standard factor and breaker operating handle location for the vintage and
including heat-rise and short-circuit must be completed while new circuit breaker are identical, simply installing the new
the unit is installed in the MCC assembly. For upgrade of an breaker in place of the old is not recommended. The issue here
obsolete motor control center, new replacement units must be is that the withstand rating of the subassembly is based on the
tested in a vintage assembly originally produced by the combination of both the circuit breaker and the motor starter
equipment manufacturer. Manufacturers of UL 845 functioning together. The UL 845 test defines this combination
replacement units must test the combination of molded case rating. As previously mentioned, vintage magnetic starters
circuit breaker, contactor, overload relay and have traditionally used heater coils for motor overload
cabling/connectors within the unit assembly to verify and then protection, offering an impedance path to limit fault currents
label the unit interrupting rating. For a true UL 845 replacement during short-circuit conditions. This limitation gives the circuit
unit, the battery of testing performed is essentially the same as breaker magnetic trip element time to actuate and successfully
test requirements included for new MCC assemblies. Only after
all tests are successfully completed can a UL 845 label be
affixed to the unit, designating full compliance. Users should
take great caution in specifying and purchasing MCC units from
a reputable supplier, assuring the UL 845 label is clearly visible
and certified test reports are included. Users should always
ensure that replacement MCC units carry the short circuit
current rating for the assembly it will be installed in.
Over the years a growing trend has emerged where
unauthorized manufacturers have misrepresented replacement
starter units to be installed in vintage MCCs as being fully
factory tested to UL 845. Shops that specialize in assembling
control panels typically offer UL 508 or UL 508A labels affixed
to specialty control panels. Neither UL 508 nor UL 508A
considers bus systems within a control assembly, nor do these
address short-circuit and heat rise testing as defined by UL 845.
Users should take great caution in specifying and purchasing Fig. 4 Vintage design (left) versus current design (right)
LV MCC molded-case circuit breaker
clear the fault. New magnetic starters nearly universally apply current transformers allowing three-phase power conductors to
on-board current transformers with sophisticated electronics to connect between the switching contactor and three-phase
sense motor overload and a host of other abnormalities to motor terminals. Voltage terminations are also made at the
protect the motor and driven load. In the absence of the base module that support functionality beyond legacy motor
additional resistance from the vintage heater coils, the circuit protective relays including under-voltage, under-load and pump
breaker may not successfully clear a higher-level fault. As cavitation, along with metering of phase voltages, amperes and
defined in the UL 845 Standard, both the circuit breaker and the power in watts and vars. A base control module communicates
motor starter/protective relay are interdependent and must be new available data via a host of communication networks, the
tested together. most prominent in industry today being Ethernet/IP. An optional
user interface module is also used for local control and
C. Technology Advancements in Motor Protection monitoring as desired. One important added capability of the
Over the past several decades, advances in electronics have on-board microprocessor included in the base control module
accelerated the functionality of overcurrent circuit protective is in locating a grounded motor feeder in a high resistance
devices and compact adjustable frequency drives (AFDs) are pulsing ground system as discussed previously. Since the
now routinely installed in low-voltage motor control centers. measurement module of each relay includes three integral
Current design motor overload relays have evolved to function current sensors, special functionality of the new relay has been
as intelligent motor protective devices that continuously monitor added to recognize when the HRG pulser has been activated,
positive and negative sequence motor phase currents to and then report not only which motor feeder but also which
establish a precise thermal model of the machine’s windings. phase of the faulted feeder has a ground fault. This new
These deliver an order of magnitude of improved motor functionality greatly reduces added complexity in current
protection and functionality. Recent papers including [12] design HRG systems which require additional zero-sequence
discuss case history’s involving low-voltage motor control current transformers (ZSCT) wired back to a HRG relay at each
center installations where new motor management relays with individual LV MCC motor starter unit as discussed previously
enhanced functionality have been installed. The latest offerings [10,11].
include advanced protective features in a small, network Application of the latest designs of these motor
communications ready package. Referring to Fig. 5 as a typical management relays deliver a step-change in motor protection
current design device, a measurement module includes integral versus legacy controls installed in vintage equipment. More
importantly, the availability of real-time data measuring phase
currents and voltages for every driven load offers a new
platform of functionality that will be transformative for industry.
Without question, the added capability of network connectivity
can serve as an enabler to assure any existing industrial plant,
even a plant with 40 to 50 old legacy electrical systems, can be
positioned to compete with new plants utilizing the latest
technologies. Industry users can utilize network enabled
systems to deliver an abundance of available data and extract
useful information to improve system reliability, uptime,
efficiency and safety. Today’s fourth industrial revolution is
characterized by a transition from the manual, sequential value
chain in manufacturing to an information rich digital core
enabled by new developments in smart sensors, cloud
computing and the Industrial Internet of Things (IIoT). Several
existing industrial plants including some from the author’s
company have recently completed successful life-cycle
extension projects including upgrades low-voltage MCCs and
other electrical power distribution and control assemblies.
These have clearly leveraged the latest in network enabled
systems, offering a platform in support of the coming new era
of Digital Transformation. Table I offers suggested decision
criteria in reviewing the options to replace or upgrade existing
Fig. 5 Typical microprocessor-based motor management relay low-voltage MCCs as discussed in this section.

TABLE I
DECISION CRITERIA FOR REPLACE VERSUS UPGRADE
Alternative Initial Installation Cost to Reliability/ Required
Cost Cost Maintain Maintainability Downtime
Replace Existing Assembly High High Low Maximized Very High
Upgrade Existing Assembly Rating Moderate Low High Moderate High
Refurbish Existing LV MCC Starter Units Low Moderate Moderate Minimal High
New LV MCC Starter Units Moderate Low Low High Lowest
 VII. CASE HISTORY: REPLACEMENT VERSUS UPGRADE would require removal of existing MCC top-mounted conduits
One industrial lithium processing plant the U.S. State of North for both incoming and outgoing cables of the existing 8-
Carolina recently evaluated the alternative to replace an structure assembly as shown in the image of the line-up. In both
existing 45-year-old LV MCC versus upgrade with new UL845 the replacement and the upgrade alternatives considered, the
starter units. The existing plant, originally commissioned in the decision was made to upgrade legacy bi-metal motor overload
1970s considered replacing the vintage 8-structure assembly protective relays with a current microprocessor-based motor
shown in Fig. 6 with a replacement assembly using the latest management relay, capable of network communications via
designs available. Complete replacement of the assembly Ethernet/IP. Included in the upper section of Table II is an esti-

Fig. 6 Existing 45-year-old LV motor control center (left) and supplier proposed layout of replacement assembly (right)

TABLE II REPLACE VERSUS UPGRADE OF LV MCC

Labor Labor Material Outage
Hours $/Hour Cost Cost Totals
Purchase new 8 Structure Replacement LV MCC assembly $63,642 $63,642
Dismantle/Remove existing MCC assembly 48 $100 $4,800
Install new 8 Structure Replacement LV MCC assembly 48 $100 $4,800
Rewire existing in & out cables/conduits 18 $100 $1,800
Pull Ethernet comm cables and wire to mill fiber network 16 $100 $1,600
24-hour mill downtime at $22,000/hour $528,000 $528,000
Total LV MCC Replacement Cost $604,642

Purchase replacement MCC starter/breaker units

Full-Voltage Non-Reversing NEMA Size 1 (Qty 33) $95,618 $95,618
Full-Voltage Non-Reversing NEMA Size 3 (Qty 2) $8,320 $8,320
Dual 100A/100A Feeder Breaker (Qty 1) $2,417 $2,417
Single 100A Feeder Breaker (Qty 3) $5,748 $5,748
Purchase Ethernet switches (3) $1,800 $1,800
Remove existing MCC starter/breaker units 8 $100 $800
Install replacement MCC starter/breaker units, terminate cables 16 $100 $1,600
Install Ethernet switches (three) 8 $100 $800
Pull Ethernet comm cables and wire to mill fiber network 16 $100 $1,600
8-hour mill downtime at $22,000/hour $176,000 $176,000
Total LV MCC Upgrade Cost $294,702
mate of both the labor and material cost to remove and replace supported by 21st century technologies. The path forward in
the existing LV MCC assembly including the addition of new many cases will not require a wholesale change out of existing
updated network cables that would be connected at the newly systems, which is both cost prohibitive and simply impractical.
installed communicating MCC manufactured and tested to the Instead, a carefully planned program to upgrade existing
UL845 Standard including upgraded motor management systems is often a valid approach. Early alignment with key
relays. This is compared in lower section of Table II with an equipment suppliers and contractors to build a business case
estimate the labor and material cost to upgrade the existing to review the replace versus upgrade alternatives followed by
assembly, leaving the existing structure in place and installing installation of network enabled systems can position any
new UL845 replacement NEMA Size 1 and Size 3 starter units, existing manufacturing business to move forward toward their
and single/dual feeder circuit breaker units. Digitalization Transformation future.
Note that although the first cost to purchase a new 8
structure replacement LV MCC is lower than the UL845 IX. ACKNOWLEDGEMENTS
replacement starter and feeder breaker units, the total installed
cost of the upgrade is lower. The most significant cost impact The authors with to thank Mr. Brian McElligott of JH Kelly
in the replacement scenario is the extended required downtime. Construction and Mark Higginson of North Pacific Paper
In this case, plan for an estimated 24-hour outage to replace Company (NORPAC) in Longview Washington USA for
the vintage MCC would be reduced to 8 hours if the existing contributions in completing the labor and materials estimates
MCC remained in place and new starter units were installed. outlined in the replace versus upgrade total cost comparisons
Experience has proved there is not much opportunity to do outlined in Section VII. of this paper.
prep-work while the existing assembly is energized. After the
scheduled outage begins, more labor hours will be expended X. REFERENCES
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