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© 2008 Eaton Corporation. All rights reserved. 5 Ways to Protect your Motor and Increase your Uptime with Solid-State Overload Relays -hosted by Erie Bearings.

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Presentation on theme: "© 2008 Eaton Corporation. All rights reserved. 5 Ways to Protect your Motor and Increase your Uptime with Solid-State Overload Relays -hosted by Erie Bearings."— Presentation transcript:

1 © 2008 Eaton Corporation. All rights reserved. 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

2 2 2 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

3 3 3 Traditional Motor Protection Overview Traditional OLRs monitor 3- phase current to simulate motor winding temperatures OLR relay opens up contactor and prevents motor insulation breakdown Technology used – Thermal expansion properties of bi- metal cause trip Contactor Breaker/Fuses Overload Relay Motor XT Thermal 0.1 - 630A Freedom C306 Thermal 0.25 - 1500A IEC Style Starter NEMA Style Starter

4 4 4 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

5 5 5 Solid-State Technology Overview Benefits: 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 C440 Electronic 0.3 - 1500A Communicating Ground Fault C441 Motor Insight Energy Monitoring Motor and Pump Protection Advanced Diagnostics 1 - 540A

6 6 6 C440 Protects & Monitors Motors w/ Fewer Part #s 0.33 1.65 1 5 4 20 20 100 35 175 60 300 120 600 200 1000 300 1500 9 45 CT Ranges Q1 2011 5 part numbers (excluding CTs) for 0.33-1500 amps! 0-690 Vac

7 7 7 C441 Protects & Monitors Motors w/ Fewer Part #s 1 9 60 135 120 270 FLA Ranges w/CTs 240 540 Motor coverage from 1-540 amps with only 2 part numbers 0-660 Vac 5 90

8 8 8 210 Thermal Overload Relays 5 Eaton Electronic Overload Relays or Which has more capability ? Comparison to the Equivalent Bi-Metal Relays

9 9 9 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

10 10 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 decreases maintenance cost per repair and extended downtime Degree of/# of failures time minor Advanced warning and minor repair extends equipment life and reduces capital expenditure Monitoring = Scheduled Downtime & Energy Cost Avoidance $ $ Accurate Diagnostics decreases length of downtime and repeat faults

11 11 Protection FeatureBi-Metal OverloadEatons C440 and C441 1. Thermal Overload Not very accurate Relies on thermal characteristics of metals Different heater elements for Class 10 or 20 Accurate, Reliable – electronic design Microprocessor based trip time calculations utilize thermal memory tables Selectable trip classes (5 - 30) 2. Ground Fault Does not protect against ground fault Integral design – no external CT or module Selectable (ON/OFF) Solid State vs Bi-Metal OL: Thermal & GF Protection 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

12 12 Protection FeatureBi-Metal OverloadEatons C440 and C441 3. Phase Loss Does not protect against phase loss Programmable Phase Loss and Phase Imbalance Takes starter off-line in 1-20 seconds Selectable (ON/OFF) 4. Phase Unbalance (current) Does not protect against phase unbalance Eatons C306 bi-metal provides protection against phase unbalance, but may take up to 2 hrs. Solid State vs Thermal OL: Phase Protection 3. Phase Loss - Current (single-phasing) Definition: One of the three phase voltages is not present Source: 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

13 13 5. Jam Definition: 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. Source: 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. Protection Feature Bi-Metal OverloadEatons C441 5. Jam/Stall Does not provide Jam Protection Programmable Jam and Stall Protection from 100%-400% of FLA Same setting can be used down to 50% of FLA for current alarming 6. Overcurrent & current level alarming Does not provide Overcurrent Solid State vs Thermal OL: Jam/Stall/Overcurrent

14 14 7. Phase Rotation (phase-reversal) Definition: Improper wiring leading to phases being connected to the motor improperly causing the motor and load to spin the wrong direction Source: 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 wouldnt drive your car and then throw it in reverse at 60 mph would you? Protection Feature Bi-Metal OverloadEatons C441 7. Phase Reversal Does not protect against reversal of phase Programmable Phase Reversal Protection ABC, ACB or OFF Solid State vs Thermal OL: Phase Reversal

15 15 Under voltage Definition: When the line voltage to the motor is below the specified rating Source: 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. Protection Feature Bi-Metal OverloadEatons C441 8. Under Voltage 9. Over Voltage Does not protect against under or 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 Solid State vs Thermal OL: Line Quality Protection

16 16 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

17 17 Energy Monitoring Customers could realize an estimated $23B savings (U.S.) Sources: DOE 2002 Industrial Electric Motor Systems Market Opportunity Assessment, US Dept of Commerce 2002 Census, Team analysis $5B $3.6B $6.2B $2.3B $6.1B

18 18 In the U.S. motors use 71% of the electrical energy in a typical industrial facility Large population of motors in the 20-300 hp range consuming the majority of energy Very little monitoring done on low horsepower motors <1% Energy Savings Motor System Energy Use (GWh/YR) - 10,000.00 20,000.00 30,000.00 40,000.00 50,000.00 60,000.00 70,000.00 1-56-2021-5051-100101-200201-500501-10001000+ Compressor Pump Fan

19 19 Eatons 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 Power Factor Frequency* Motor Run Hours* Thermal Capacity C441 Motor Insight Monitors Power Avoid peak demand charges Shed non-vital loads Identify and rectify increased consumption Identify discrepancy between equal loads Identify Power Factor line Items

20 20 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 1 50 KW Motor 2 50 KW Motor 3 75 KW Motor Insight - Value Add: ENERGY SAVINGS Observed this abnormal operation in real-time Sent maintenance personnel immediately upon observation and removed the foreign object 25 KW *12 hours * 365 days *$0.10/kw-hr= $10,655 of wasted energy

21 21 Monitoring Beyond Energy C440/XTOE Current per phase & Average 3-Phase RMS Current Unbalance percent GF current Thermal Capacity Motor state status Last fault Frequency C441 Motor Insight Current Per Phase & Average 3-Phase RMS Current Unbalance Percent GF current Thermal Capacity Motor State Status Last 10faults Frequency Voltage Per Phase and Average RMS Voltage Unbalance Percent Power Power Factor Motor Run Hours Motor Starts Count

22 22 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 decreases maintenance cost per repair and extended downtime Degree of/# of failures time minor Advanced warning and minor repair extends equipment life and reduces capital expenditure Monitoring = Scheduled Downtime Energy Cost Avoidance $ $ Accurate Diagnostics decreases length of downtime and repeat faults

23 23 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

24 24 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.

25 25 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

26 26 Critical Pumps at Various Horsepower Source: Eaton Survey in Motor Diagnostics and Motor Health News

27 27 Power-based Overload Relays can See the Load beyond the Motor C441 MI looks at 3 phase current and 3 phase voltage & calculates power kW based OLR allows for monitoring of load performance kW based OLR allows for protection of harmful conditions to loads (pumps) Contactor Breaker/Fuses Overload Relay Motor Load

28 28 Load Protection Low Power Definition: Power provided to the motor falls below normal operating conditions Source: 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 Protection Feature Bi-Metal OverloadEatons C441 10. Low Power 11. High Power Does not protect against under or 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

29 29 Open valve = not dead-headed Good pump state, because the fluid in the centrifugal pump is constantly flowing keeping the pump cool In this state Motor Insight would read nominal power (KW) draw Outlet Valve C441 Pump Protection

30 30 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 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 Inlet Valve Outlet Valve How Motor Insight Protects a Low Suction Head/Starved Centrifugal Pump

31 31 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 C441 Motor Insight Protects a Dead-headed Pump

32 32 What did we learn? More than 5 ways to protect your motor and process Thermal, GF, Phase loss, Phase Imbalance, Jam, Stall, Current level alarms, Phase Reversal, Under Voltage, Over Voltage, etc. Advanced Motor Protection 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 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 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

33 33 XT SmartWire Communicating 0.3 - 65A 2010 Motor Protection Relay Value Map to Process Uptime, Energy Savings, & Diagnostics Performance Price Current product GAP, Electronic Overload with Ground Fault and Communications Overload Relays XT Thermal 0.1 - 630A XT XTPR Thermal 0.1 - 65A XT PKE Electronic 0.3 - 65A 2011 Motor Insight Energy Monitoring Motor and Pump Protection Advanced Diagnostics 1 - 540A 2010 Manual Motor Protectors C440 Electronic 0.3 - 1500A 2010 C440 Electronic 0.3 - 1500A Communicating Ground Fault 2010 Freedom C306 Thermal 0.25 - 1500A 2009

34 © 2008 Eaton Corporation. All rights reserved. 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!

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