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Levine Lectronics and Lectric, Inc.
Motor Protection for this Millennium
Presented by
John S. Levine, P.E.
Levine Lectronics and Lectric, Inc.
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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
469 and 369Motor Management Relay
Protection and management of medium voltage motors and driven equipment
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Levine Lectronics and Lectric, Inc.
Product Highlights Inputs / Outputs Motor Protection Power Metering Diagnostics Communications /
469PC/369PC Simulation
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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
Differential in a Motor (469)Differential in a Motor (469)
A B
C
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Levine Lectronics and Lectric, Inc.
Residual ground wiring
Alternate differential wiring
Summation of two CTs provides a larger zone of protection• Observe polarity
CT Inputs
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Levine Lectronics and Lectric, Inc.
Using Power Factor Correction Capacitors
CT’S
Contactor
Cap
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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
Relay overload curve
Thermal Model - Thermal Limit Curves
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Levine Lectronics and Lectric, Inc.
• 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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
• 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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Levine Lectronics and Lectric, Inc.
• 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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Levine Lectronics and Lectric, Inc.
Communications
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Levine Lectronics and Lectric, Inc.
Communications
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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
• 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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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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Levine Lectronics and Lectric, Inc.
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Levine Lectronics and Lectric, Inc.
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Levine Lectronics and Lectric, Inc.
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Levine Lectronics and Lectric, Inc.
Thank youThank you