1 levine lectronics and lectric, inc. motor protection for this millennium presented by john s....

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Levine Lectronics and Lectric, Inc.

Motor Protection for this Millennium

Presented by

John S. Levine, P.E.


[email protected]

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Facts:

Computers and the Internet are here to stay!

With microprocessors it is just as easy to give you everything verses several relays to do a job!

Corporations are downsizing personnel! We are in a constant state of change!

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Conclusions:

The equipment has to be able to help the few remaining personnel solve the problems even if that person is 1000 miles away !

Products need to be designed as families to reduce the cost.

Products are much more complex than 10 years ago!

We can not avoid the change!

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Motor Failure Rates and Cost Motor failure rate is

conservatively estimated as 3-5% per year.

In Mining, Pulp and Paper industry motor failure rate is up to 12%.

Motor failure cost contributors:

• Repair or Replacement.• Removal and

Installation.• Loss of Production.

AVERAGE

FAILURE CONTRIBUTOR % FAILED COMPONENT % %

Persistent Overload 4.20% Stator Ground Insulation 23.00

Normal Deterioration 26.40% Turn Insulation 4.00

Bracing 3.00

Core 1.00

Cage 5.00

Electrical Related Total 30.60% Electrical Related Total 36.00%

High Vibration 15.50% Sleeve Bearings 16.00

Poor Lubrication 15.20% Antifriction Bearings 8.00

Trust Bearings 5.00

Rotor Shaft 2.00

Rotor Core 1.00

Mechanical Related Total

30.70%Mechanical Related

Total32.00%

High Ambient Temp. 3 Bearing Seals 6.00

Abnormal Moisture 5.8 Oil Leakege 3.00

Abnormal Voltage 1.5 Frame 1.00

Abnormal Frequency 0.6 Wedges 1.00

Abrasive Chemicals 4.2

Poor Ventilation Cooling 3.9

Other Reasons 19.7 Other Components 21.00

Environmental Related & Other Reasons: Total

38.70%Maintanence Related &

Other Parts: Total32.00%

Mechanical Related Failures

31%

Environmental, Maintanence & Other Reasons Related Failures

36%

EPRI STUDYIEEE STUDY

Electrical Related Failures

33%

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469 and 369Motor Management Relay

Protection and management of medium voltage motors and driven equipment

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Product Highlights Inputs / Outputs Motor Protection Power Metering Diagnostics Communications /

469PC/369PC Simulation

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Comprehensive motor protection

Protection of motors with high inertia loads

Induction and Synchronous motors

Two speed motors Differential protection

(469), Input to 369 Reduced voltage start RTU functions Remote start/stop

Product Highlights

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3 phase CTs 1 amp 5 amp

3 differential CTs (469)

1 ground CT Zero sequence Residual

3 phase VTs Open Delta Wye

Typical wiring

Core balance differential CTs 1 amp 5 amp

CT and VT Inputs

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Differential in a Motor (469)Differential in a Motor (469)

A B

C

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Residual ground wiring

Alternate differential wiring

Summation of two CTs provides a larger zone of protection• Observe polarity

CT Inputs

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Using Power Factor Correction Capacitors

CT’S

Contactor

Cap

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12 RTDs, field programmable type

Independent trip and alarm settings

Trip voting Feedback to thermal

model Programmable RTD

name Open sensor

detection

RTD wiringRTD Inputs

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9 digital inputs (469), 6 digital inputs (369)

pre-defined (Access, test-469, emergency, remote reset, starter status-469)

4 assignable (speed switch, load shed, pressure, vibration, tachometer, counter, general & programmable)

Digital Inputs

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4 analog inputs (469) self powered or loop powered 100 mA @ 24 Vdc Assignable name Min., max., & units Block from start Trip Alarm delay

Loop powered analog inputs

Analog Inputs (469)

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6 output relays (469), 4 output relays (369), Form C,

4 programmable analog outputs(469), option on 369 4-20 or 0-1 mA (as ordered-469)

programmable on 369 29 programmable parameters

2 RS485 ports(469), 3 RS485 ports(369), 1 front panel RS232 port 22 front panel status indicators (469), 10 on 369

Output Relays

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Thermal Block starts Short circuit / backup Mechanical jam Phase reversal Unbalance Undercurrent Ground fault / backup Differential Acceleration Stator/Bearing/Other Ambient RTD

Single line diagramMotor Protection

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Thermal Model - Thermal Capacity UsedWe will use the following model to aid in a better understanding of motor thermal modeling concepts. The motor’s thermal capacity, that is to say, the amount of heat energy the motor can hold, will be represented by the glass vessel. The lava like fluid filling the vessel will represent thermal energy or heat energy that has been absorbed by the motor.

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Thermal Model - Thermal Capacity Used The sources of thermal energy that will fill the vessel or heating the motor are:

• Ambient temperature

• Motor losses due to current unbalances and I squared T

• Motor heating due to a start

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Thermal Model - Thermal Capacity Used Motor cooling will be represented by:

• The vapour evaporating from the surface of the liquid when the motor is running or stopped will represent the motors ability to dissipate heat.

• The fan is representative of the additional cooling effect of the motor’s cooling system which is commonly a fan mounted on the motor shaft.

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15 standard overload curves 1 custom curve (FlexCurve) 1 Voltage dependent curve (469) Under/Over voltage Reverse power Underpower Under/Over frequency kvar, PF (Synch. motor) Amps, kW, kvar, kVA demand

alarms Trip coil supervision (469) Breaker failure Incomplete sequence Service Factor Protection

Standard Overload CurvesMotor Protection

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20 sec20 sec15 sec15 sec

6 X FLC

Cold Motor Curve

Hot Motor Curve

Hot / Cold Ratio = 15 sec/20 sec or .75

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Relay overload curve

Thermal Model - Thermal Limit Curves

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• Hot/Cold motor compensation• RTD Thermal Bias

• Min. temperature (40 C) / No biasing

• Max. temperature ( Insulation rating) /Thermal capacity =100%

• Mid point temperature and thermal capacity

• Negative Sequence Current Bias• Accounts for excess rotor heating

due to unbalanced voltages (skin effect - Induced current rotating in opposite direction at 2x line freq..)

• Not accounted for by curves provided by motor manufacturer

RTD and Unbalance BiasingThermal Bias

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Custom curve for running in overload

Minimum starting voltage Minimum stall point Min. accel. intersection point

with custom curve Maximum starting voltage Maximum stall point Max. accel. intersection with

custom curve SR469 dynamically shifts

curve for all voltages

Voltage dependent O/L curveVoltage Dependent O/LCurve

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Motor Acceleration Curve at 80% Voltage

Motor Acceleration Curve at 100% Voltage

3 parts of the Curve1) Locked Rotor2) Acceleration3) Running

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Phase amps Differential amps % load Ground amps % unbalance Voltage +/-kW (HP), +/-kvar, kVA Wh, + varh, - varh PF Frequency Demand (A, kW, kvar,

kVA and peak demand)

Metering and Monitoring

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• RTD temperatures• Speed RPM (tach.

input)• 4 analog inputs• Learned parameters

• Acceleration• Starting current• Starting capacity• Max. RTDs• Min./Max. analog

inputs

Metering and Monitoring

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• Statistical data on:• Number of trips• Type of trips• Number of motor starts• Number of running hours• Last 255 events recorded

(time and date stamped)

• Cause of last trip • Pre-trip data • All active alarms

Maintenance & Diagnostics

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Communications

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Communications

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Memory Map Example

Group Address Description

Current 0300 Phase A Current

0301 Phase B Current

0302 Phase C Current

030D Phase A Differential

030E Phase B Differential

030F Phase C Differential

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• Windows based• Access all:

• Actual Values• Setpoints• Status• Event records

• Oscillography• Graphical trending• Setpoint programming• Setpoint files• Download updated

firmware to Flash memory

Free PC Software and Firmware

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1. Motor Nameplate

2. Motor Temperature Data

3. System Configuration

4. Current Sensing

5. Voltage Sensing

6. Motor Starting Supervision

Motor Setting Auto-Configuration

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369 Motor Settings Auto-Configurator Report

Motor Settings Auto-Config Report

• Clearly Organized

• Individual Setting Identified

• Report identifies warnings and provides suggestions

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Single-click access to Motor Health Report

Reads event history, learned motor parameters, motor start data logger from 369

Applies basic analysis to key motor parameters – Red/Orange/Green results

Prepares summary report as PDF file with all key information presented

Built into EnerVista™ 369 Setup and included in EnerVista™ Launchpad

Motor Health Report

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Motor Health Report – Motor Stop/Trip History

Histogram representation of motor stops and trips

Classified by stop and trip causes

Simplifies troubleshooting and analysis

Quickly identifies motor and system issues

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Security Audit Trail – Complete Traceability

Patented Security Settings Report

Only motor protection relay on the market to include this feature

History of last 100 changes

When, # of changes made, method, who, etc.

NERC CIP Compliant

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Thank youThank you

1 levine lectronics and lectric, inc. motor protection for this millennium presented by john s....

Documents

n loop powered n

n products

sequence n residual

n induction

n self

n computers

n corporations

n trip n alarm n delay