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“5 Ways to Protect your Motor and Increase your Uptime with Solid-State Overload Relays” -hosted by Erie Bearings Adam Krug – Product Manager Industrial Controls Division, Eaton Corporation © 2008 Eaton Corporation. All rights reserved. Training Goals • Understanding of basic motor protection then and now • “5 Ways to Protect Your Motor” • Leveraging additional capabilities from electronic relays beyond simple thermal protection to protect motors • “Protecting your Utility bill” • Getting onboard the energy monitoring trend with today's relays • “Protecting your load/pump” • Seeing beyond the motor to the actual load with no additional hardware 2 2 Traditional Motor Protection Overview • Traditional OLR’s monitor 3phase current to simulate motor winding temperatures Breaker/Fuses IEC Style Starter NEMA Style Starter Contactor Freedom C306 Overload • Thermal • 0.25 - 1500A Relay XT • Thermal •0.1 - 630A • OLR relay opens up contactor and prevents motor insulation breakdown • Technology used – Thermal expansion properties of bimetal cause trip Motor 3 3 Bi-Metal Technology Overview • User selects “Heater Packs” by motor nameplate FLA (Full Load Amps) • User selects singular overload trip class (either 20,10 by purchasing specific heater pack Drawbacks • Very limited adjustability of FLA range 1.6:1 – Why? • • Thermal properties of metal Inconsistencies in trip times – Why? • • 10-15% variation in trip times Manufacturing of metal compositions 4 4 Solid-State Technology Overview Benefits: C440 • Electronic • 0.3 - 1500A • Communicating • Ground Fault C441 Motor Insight • Energy Monitoring • Motor and Pump Protection • Advanced Diagnostics • 1 - 540A • No “Heater Packs” • Settable Trip Class (5,10,20,30) • Very wide adjustability of FLA range – Why? • Flexibility of electronic design • Large reduction of part numbers • More motor protection onboard • More consistent protection • Energy cost avoidance • Pump and Load Protection 5 5 C440 Protects & Monitors Motors w/ Fewer Part #’s 0.33 1.65 1 5 4 20 9 • 5 part numbers (excluding CTs) for 0.33-1500 amps! 45 20 100 35 175 • 0-690 Vac 60 300 CT Ranges 120 600 200 1000 300 1500 6 6 C441 Protects & Monitors Motors w/ Fewer Part #’s 1 9 5 90 • Motor coverage from 1-540 amps with only 2 part numbers FLA Ranges w/CTs 60 • 0-660 Vac 135 120 270 240 540 7 7 Comparison to the Equivalent Bi-Metal Relays Which has more capability? 210 Thermal Overload Relays or 5 Eaton Electronic Overload Relays 8 8 Training Goals • Understanding of basic motor protection then and now • “5 Ways to Protect Your Motor” • Leveraging additional capabilities from electronic relays beyond simple thermal protection to protect motors • “Protecting your Utility bill” • Getting onboard the energy monitoring trend with today's relays • “Protecting your load/pump” • Seeing beyond the motor to the actual load with no additional hardware 9 9 C440 and C441 Overload Relay Value • Advanced warning/protection and location of a pending motor/load failure • Improves process uptime and throughput • Reduces costs per repair • Reduces capital expenditures through extension of life • Optimizes labor- “Finding the needle in the haystack” (which motors get serviced during shutdown) Sensorless, non-intrusive, starter-based technology (you need one anyway!) • Cost-effective (versus sensors, wiring, man-hours for install and data interpretation) • Greater motor coverage • No firewall to penetrate, since there is no data interpretation needed catastrophic Protection Degree of/# of failures • Accurate Diagnostics decreases length of downtime and repeat faults $ decreases maintenance cost per repair and extended downtime $ minor Monitoring = Scheduled Downtime & Energy Cost Avoidance time Advanced warning and minor repair extends equipment life and reduces capital expenditure 10 10 Solid State vs Bi-Metal OL: Thermal & GF Protection Protection Feature Bi-Metal Overload Eaton’s C440 and C441 1. Thermal Overload • Not very accurate • Accurate, Reliable – electronic design • Relies on thermal characteristics of metals • Microprocessor based trip time calculations utilize thermal memory tables • Different heater elements for Class 10 or 20 2. Ground Fault • Does not protect against ground fault • Selectable trip classes (5 - 30) • Integral design – no external CT or module • Selectable (ON/OFF) 2. Ground Fault • Definition: • • A line to ground leakage path from the motor to the ground Result: • An undetected Ground Fault can burn through multiple insulation windings ultimately leading to motor failure 11 11 Solid State vs Thermal OL: Phase Protection Protection Feature Bi-Metal Overload Eaton’s C440 and C441 3. Phase Loss • Does not protect against phase loss • Programmable Phase Loss and Phase Imbalance 4. Phase Unbalance (current) • Does not protect against phase unbalance • Takes starter off-line in 1-20 seconds • Eaton’s C306 bi-metal provides protection against phase unbalance, but may take up to 2 hrs. • Selectable (ON/OFF) 3. Phase Loss - Current (single-phasing) • Definition: • • Source: • • One of the three phase voltages is not present Loose wire, improper wiring, grounded phase, open fuse, etc. Result: • • Single-phasing can lead to unwanted motor vibrations causing mechanical wear Reducing the life of your motor from the extra heat on the other two phases 12 12 Solid State vs Thermal OL: Jam/Stall/Overcurrent Protection Feature Bi-Metal Overload Eaton’s C441 5. Jam/Stall • Does not provide Jam Protection 6. Overcurrent & current level alarming • Does not provide Overcurrent • Programmable Jam and Stall Protection from 100%-400% of FLA •Same setting can be used down to 50% of FLA for current alarming 5. Jam • Definition: • • Source: • • Jam is a current draw on the motor above normal operating conditions, often referred to as locked rotor current. During initial start-up this is referred to as Stall. Mechanical stall, interference, jam, or seizure of the motor or motor load Result: • • To drive the additional load the motor draws an abnormal amount of current, which can lead to insulation breakdown and motor failure Mechanical failure of devices that are jammed caused by the extra torque of the motor. 13 13 Solid State vs Thermal OL: Phase Reversal Protection Feature Bi-Metal Overload Eaton’s C441 7. Phase Reversal • Does not protect against reversal of phase • Programmable Phase Reversal Protection •ABC, ACB or OFF 7. Phase Rotation (phase-reversal) • Definition: • • Source: • • • Improper wiring leading to phases being connected to the motor improperly causing the motor and load to spin the wrong direction A mis-wired motor Inadvertent phase-reversal by the utility Result: • • • Phase-reversal can cause unwanted directional rotation of a motor Possible mechanical failure and/or injury to an operator You wouldn’t drive your car and then throw it in reverse at 60 mph would you? 14 14 Solid State vs Thermal OL: Line Quality Protection Protection Feature Bi-Metal Overload Eaton’s C441 8. Under Voltage • Does not protect against under or over voltage 9. Over Voltage • Does not protect against voltage at all • Fully programmable over and under voltage protection • Alarm and Trip modes • Auto resets when voltage is good Under voltage • Definition: • • Source: • • When the line voltage to the motor is below the specified rating Poor line quality Result: • • • • motor stall spinning the motor too slowly which effects throughput excessive current draw. This increases the heating of the motor windings and can shorten insulation life. A trip limit set to 90% of rated voltage is recommended by NEMA. 15 15 Training Goals • Understanding of basic motor protection then and now • “5 Ways to Protect Your Motor” • Leveraging additional capabilities from electronic relays beyond simple thermal protection to protect motors • “Protecting your Utility bill” • Getting onboard the energy monitoring trend with today's relays • “Protecting your load/pump” • Seeing beyond the motor to the actual load with no additional hardware 16 16 Energy Monitoring • Customers could realize an estimated $23B savings (U.S.) Revenue Impact ($$) Annual U.S. Savings Potential from Continuous M onitoring for Energy Efficiency and Reliability $7,000,000,000 $6,000,000,000 Energy Cost Savings ($$) Maintenance Cost Savings ($$) $6.2B $6.1B $5B $5,000,000,000 $3.6B $4,000,000,000 $3,000,000,000 $2.3B $2,000,000,000 $1,000,000,000 $Pump Compressor HVAC (Fans and Refrigeration) Conveyor Other (material processing, ….) Sources: DOE 2002 Industrial Electric Motor Systems Market Opportunity Assessment, US Dept of Commerce 2002 Census, Team analysis 17 17 Energy Savings • In the U.S. motors use 71% of the electrical energy in a typical industrial facility Motor System Energy Use (GWh/YR) 70,000.00 60,000.00 • Large population of motors in the 20-300 hp range consuming the majority of energy 50,000.00 Compressor 40,000.00 Pump 30,000.00 Fan 20,000.00 10,000.00 1-5 6-20 21-50 51-100 101-200 201-500 501-1000 1000+ • Very little monitoring done on low horsepower motors <1% 18 18 C441 Motor Insight Monitors Power Eaton’s C441 Monitors (data/warning) • Current Per Phase and Average RMS • Current Unbalance Percent* • Ground Fault Current* • Voltage Per Phase and Average RMS • Voltage Unbalance Percent* • Power •Avoid peak demand charges • Power Factor •Shed non-vital loads • Frequency* • Motor Run Hours* •Identify and rectify increased consumption • Thermal Capacity •Identify discrepancy between equal loads •Identify Power Factor line Items 19 19 Motor Insight Success – Energy Savings May 2009 Control Engineering, Sheboygan WWTP Scenario: • Three 480V 75 hp, 96 amp tripping-current motors at Indiana Ave lift station • Customer was previously only monitoring flow to detect problems • Flow was the same for all three pumps, however with Motor Insight they observed pump 3 drawing abnormal power due to a foreign object on the impeller Motor Insight - Value Add: ENERGY SAVINGS • • Observed this abnormal operation in real-time Sent maintenance personnel immediately upon observation and removed the foreign object Motor 1 Motor 2 Motor 3 50 KW 50 KW 75 KW 25 KW *12 hours * 365 days *$0.10/kw-hr= $10,655 of wasted energy 20 20 Monitoring Beyond Energy C440/XTOE C441 Motor Insight • Current per phase & • Current Per Phase & • Average 3-Phase RMS • Average 3-Phase RMS • Current Unbalance percent • Current Unbalance Percent • GF current • GF current • Thermal Capacity • Thermal Capacity • Motor state status • Motor State Status • Last fault • Last 10faults • Frequency • Frequency • Voltage Per Phase and Average RMS • Voltage Unbalance Percent • Power • Power Factor • Motor Run Hours 21 • Motor Starts Count 21 C440 and C441 Overload Relay Value • Advanced warning/protection and location of a pending motor/load failure • Improves process uptime and throughput • Reduces costs per repair • Reduces capital expenditures through extension of life • Optimizes labor- “Finding the needle in the haystack” (which motors get serviced during shutdown) Sensorless, non-intrusive, starter-based technology (you need one anyway!) • Cost-effective (versus sensors, wiring, man-hours for install and data interpretation) • Greater motor coverage • No firewall to penetrate, since there is no data interpretation needed catastrophic Protection Degree of/# of failures • Accurate Diagnostics decreases length of downtime and repeat faults $ decreases maintenance cost per repair and extended downtime $ minor Monitoring = Scheduled Downtime Energy Cost Avoidance time Advanced warning and minor repair extends equipment life and reduces capital expenditure 22 22 Monitoring Data for Action • Modbus, DevicNet, Profibus easily ties OLRs into Plant Management Systems • Schedule Maintenance when changes are detected before downtime occurs • Line Quality, Pump behavior, Thermal Capacity, Consumption • Find the needle in the haystack and change routine spot checks into targeted maintenance • 23 23 Monitoring Benefit – Doing More with Less Cleveland Based Steel Manufacturer Scenario • 3 Hot Well Pumps (480VAC 150HP), two of them are needed to run all of time and the other is hot spare. • 3 Cold Well Pumps (480VAC 300HP), two of them are needed to run all of time and the other is hot spare. • 2 Panel Pumps (480VAC 300HP), one of them is needed to run all of time and the other is hot spare. • 2 Lance Pumps (480VAC 150HP), one of them is needed to run all of time and the other is hot spare. • “We put Motor insight on each pump. We have designed a screen that shows each motor data live. We can check the pump operation from any PC in plant. I can also use eworkplace from home and check the status of each pump from my couch. We trend all data collected, and have a goal of using this to detect/predict motor failure. With all this data, we can also automatically switch over to the spare before or immediately after a failure. With the hot and cold well pumps, we have to have the same number of pumps running at the same time or there is an immediate flood in the basement.” 24 24 Training Goals • Understanding of basic motor protection then and now • “5 Ways to Protect Your Motor” • Leveraging additional capabilities from electronic relays beyond simple thermal protection to protect motors • “Protecting your Utility bill” • Getting onboard the energy monitoring trend with today's relays • “Protecting your load/pump” • Seeing beyond the motor to the actual load with no additional hardware 25 25 Critical Pumps at Various Horsepower Source: Eaton Survey in Motor Diagnostics and Motor Health News 26 26 Power-based Overload Relays can “See” the Load beyond the Motor Breaker/Fuses • C441 MI looks at 3 phase current and 3 phase voltage & calculates power • kW based OLR allows for monitoring of load performance Contactor • kW based OLR allows for protection of harmful conditions to loads (pumps) Overload Relay Motor Load 27 27 Load Protection Protection Feature Bi-Metal Overload Eaton’s C441 10. Low Power • Does not protect against under or over voltage • Fully programmable over and under voltage protection • Does not protect against voltage at all • Alarm and Trip modes 11. High Power • Auto resets when voltage is good Low Power • Definition: • • Source: • • Power provided to the motor falls below normal operating conditions A portion of the user's load disappears, changed in viscosity, hydraulic fluid leakage, reduction in feed-rate, broken belt, a dry-pump (low suction head), or a dead-headed centrifugal pump. Result: • Mechanical failure can or has occurred • Running a pump dry or running a pump in a dead-headed condition can cause excessive heating, damaging expensive seals and breaking down desired fluid properties 28 28 C441 Pump Protection • Open valve = not dead-headed • Good pump state, because the fluid in the centrifugal pump is constantly flowing keeping the pump cool • Outlet Valve In this state Motor Insight would read nominal power (KW) draw 29 29 How Motor Insight Protects a Low Suction Head/Starved Centrifugal Pump A low suction head situation creates a low power draw on the motor. Motor Insight detects the low power draw and trips the motor to protect the pump • Closed inlet valve = Low suction head or dry pump. • This can be caused by a closed valve as shown here, or a unnatural clog from foreign material Outlet Valve Inlet Valve 30 30 C441 Motor Insight Protects a Dead-headed Pump • Closed blocked valve/dead-headed = bad pump state Outlet Valve A dead-head situation creates a low power draw on the motor. Motor Insight detects the low power draw and trips the motor to protect the pump saving your seals, downtime and maintenance costs 31 31 What did we learn? • More than “5 ways” to protect your motor and process • • Advanced Motor Protection • • • • • Avoid unnecessary energy costs Shed non-vital loads Identify and rectify increased consumption overtime Identify discrepancy between equal loads Identify Power Factor Line Items Other Benefits of Monitoring • • Improves process uptime and throughput Reduces costs per repair Reduces capital expenditures through extension of life Optimizes labor- “Finding the needle in the haystack” (which motors get serviced during shutdown) “Protecting your Utility bill” • • • • • • Thermal, GF, Phase loss, Phase Imbalance, Jam, Stall, Current level alarms, Phase Reversal, Under Voltage, Over Voltage, etc. Early detection of failures “Protecting your load/pump” • • • • • • Pump failures from deadhead and dry conditions Submersible pump/motor failure from poor line conditions Detect improper feed-rates Detect improper viscosities Find broken shafts/belts Leakage of hydraulic lines 32 32 Motor Protection Relay Value Map to Process Uptime, Energy Savings, & Diagnostics Performance 2010 2009 Motor Insight • Energy Monitoring • Motor and Pump Protection • Advanced Diagnostics • 1 - 540A 2010 C440 2010 Current product GAP, Electronic Overload C440 with Ground Fault • Electronic and • 0.3 - Communications 1500A • Electronic • 0.3 - 1500A • Communicating • Ground Fault 2010 XT SmartWire •Communicating • 0.3 - 65A 2011 XT • Thermal •0.1 - 630A Freedom C306 XT PKE • Thermal • 0.25 - 1500A •Electronic • 0.3 - 65A XT XTPR •Thermal • 0.1 - 65A Price 33 33 “5 Ways to Protect your Motor and Increase your Uptime with Solid-State Overload Relays” hosted by Erie Bearings Adam Krug – Product Manager Industrial Controls Division, Eaton Corporation Thanks for Participating in the Webinar! © 2008 Eaton Corporation. All rights reserved. 35 35