Basics of Medium Voltage Motor Control Starter Power Components & Starter Types Larry Dalton Lead Operation Specialist Jude Hernandez - Application Engineer GE Industrial Solutions Slide # 1, Rev 3, 11/8/16
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Purpose and Learning Objectives Purpose of activity: This webinar will educate the participant in the various power components of a MV Class E2 motor controller and the different types of medium voltage motor starters. Learning objectives: At the end of this presentation you will be able to; 1. Understand and explain the differences between MV Class E2 Controllers (MCC) and MV MC Switchgear 2. Describe the basic power components of a MV Class E2 motor starter and their purposes. 3. Describe a few of the various types of MV Class E2 motor starters available. Notes: 1. This session is good for (1) PDH credit subject to receipt of a completed evaluation form. Refer to final slide. 2. This session is being delivered via the distance learning (live webinar) delivery method. 3. Content area: Health, Safety, & Welfare Including Core Technical. 4. Revision #3 dated: 11/8/16 Slide # 4, Rev 3, 11/8/16
MV MCC vs. MV MC Switchgear Standards: MV MCC vs. MV MC Swgr MV MCC; NEMA ICS-3 Part I and UL347 MV Swgr; IEEE/ANSI C37.20.2 (metal-clad), 37.04, 37.06, 37.09, 37.010, 37.11, 37.100, and NEMA SG- 4 (optional UL) When Arc Resistant enclosures are required, the specifications for both equipment types should also reference compliance to IEEE C37.20.7 and class of enclosure (with the most common enclosure Class being Type 2B) Construction: MV MCC vs. MV MC Swgr MV MCCs have a grounded metal overall enclosure vs. MV MC Switchgear has the same grounded metal overall enclosure, in addition to having the breaker, bus, and cable areas being compartmentalized and isolated from each other by grounded metal barriers, with no intentional openings MV MCCs have Bare Bus as standard (optional insulated bus available) vs. MV MC Switchgear which requires ALL bus and connections to be insulated MV MCCs can have a Stationary or Draw out switching device vs. MV MC Swgr where the breakers MUST be drawout MV MCC D.O. contactors normally do not require shutters over primary stabs when isolated by an isolation switch vs. MV MC Swgr which requires automatic shutters over the primary breaker stabs. MV MCCs are front access only, they do not require rear access (some possible exceptions) vs. MV MC Swgr which requires rear access MV MCC sections are typically smaller (approx. 2-Hi dims. 36 W x 30 DP x 90 H) vs. MV MC Swgr sections which are larger (approx. 2-HI dims. 36 W x 94 DP x 95 H) MV MCCs more cost effective vs. MV MC Swgr by a factor of approx. 2X Slide # 5, Rev 3, 11/8/16
MV Contactor vs. MV Breaker Functional Characteristics UL Class E2 Vacuum Contactor with Fuses Electrically held Mechanically latched - remains closed on loss of control voltage 1 Vacuum Circuit Breaker Mechanically latched - remains closed on loss of system voltage Continuous Current Rating 200, 400, 800A 2 1200, 2000, 3000, 3500, 4000A Switching Capability Electrical Endurance Mechanical Endurance Peak letthrough Current 3 Overcurrent Protection Maintenance Requirements From very low to approximately 10-15X continuous rating Contactor up to 1,000,000 operations From very low to full rated shortcircuit current (e.g. 63KA) Up to 100 full shortcircuit interruptions 2,000,000 +/- 5,000 to 10,000 Lower (current-limiting fuse clears fault in < 1/2 cycle) Coordinated with MV power fuses and an overload device Very Low Higher (Clears fault in 3 or 5 cycles after trip signal recieved) Requires protective relay(s) Medium - High 1 *Note: when using a Latched contactor, there is no anti-pump feature like a MV breaker, therefore a potential failure could occur if close/trip signals are given together. 2 Deratings may apply depending on enclosure, configuration, ambient temp, altitude, etc. 3 Peak let-through current is the highest current flowing in the circuit following inception of a fault (instantaneous value, not RMS) Slide # 6, Rev 3, 11/8/16
MV Motor Controller Components -1 Line Diagram- Volt Input Isolation Switch R (or E) Type Power Fuse PT CPT or M Vacuum Contactor Cntl Pwr Thermal Overload CT 3 or 11M O/L Relay GSCT 1 500HP RTDs Instrument Transformers (PTs, CPTs, CTs) Slide # 7, Rev 3, 11/8/16
MV Motor Controller Components -Isolation Switch- Volt Input Quick-Make, Quick-Break, Non-Load Break, Isolation Switch or R (or E) Type PT CPT M Cntl Pwr Safety device to isolate fuses/contactor from main bus Manually-operated Interlocks Prevent Operation when contactor closed (motor energized) Opening door when switch is closed (must be fully off) Accidental operation when HV door is open Thermal Overload CT 3 or 11M GSCT 1 RTDs 500HP Slide # 8, Rev 3, 11/8/16
MV Motor Controller Components -Isolation Switch- Open Closed Slide # 9, Rev 3, 11/8/16
MV Motor Controller Components -Fuses- Volt Input or R (or E) Type M PT CPT Type R fuses are used for motor applications and General Purpose type E fuses are used for transformer/feeder applications MV E2 motor controllers use current-limiting back-up fuses which provide the short-circuit protection for the motor and motor controller Fuses must be coordinated with the contactor and O/L relay for proper MV E2 motor controller applications Thermal Overload CT 3 or GSCT 1 Cntl Pwr 11M RTDs The MV fuses must permit repetitive switching of the load while taking into consideration the magnitude of inrush current and associated time without damage to the fuse Standard interrupting rating (S/C rating of equip) 50KAIC Bolt-on or Clip type fuses available 500HP Slide # 10, Rev 3, 11/8/16
MV Motor Controller Components -Fuses - Slide # 11, Rev 3, 11/8/16
MV Motor Controller Components -Contactor- Volt Input Vacuum contactor switching device Stationary or Draw-out construction available R (or E) Type PT Standard Electrically (magnetic) held, or Optional mechanically (latched) held available or M CPT Max Voltage: 2400V-7200V (higher voltage ratings may be available and/or MV breakers may be used for applications higher than 7200V) Thermal Overload CT 3 or Cntl Pwr 11M 200A, 400A, and 800A nominal ratings (deratings may apply for enclosure type, configuration, altitude, ambient temperature, etc.) BIL: 60KV GSCT 1 RTDs 500HP Slide # 12, Rev 3, 11/8/16
MV Motor Controller Components -Contactor- Slide # 13, Rev 3, 11/8/16
MV Motor Controller Components -Instrument Transformers- Volt Input CTs: Standard Window type or optional Bar type phase CTs are available. Optional window type GSCT available. R (or E) Type PTs Standard CTs used in MV MCCs are normally single ratio and have a relatively low Accuracy Class, e.g. C10 (window) or T50 (bar). Multi-ratio and higher CT accuracy classes are available, but may require additional sections or space, due to size to accommodate mounting. or M CPT CPTs: Standard stationary mounted in starter compartments are available from 500VA standard, up to 3KVA optional Thermal Overload CT 3 or Cntl Pwr 11M PTs: Optional stationary mounted in starter compartments are available in open-delta, or wye connected configurations, but may require additional space to accommodate mounting. GSCT 1 RTDs 500HP Slide # 14, Rev 3, 11/8/16
MV Motor Controller Components -O/L Relay- Volt Input R (or E) Type PT Many types/styles of O/L relays are available in MV E2 controllers for motor protection; from a basic 3 phase bimetallic block O/L Relay (Standard) to Digital Multifunction Motor Protection Relays (Optional) and all required CT inputs for operation. Primarily for O/L protection for the load and up to the switching/overload capability of the vacuum contactor Thermal Overload or CT 3 or GSCT 1 500HP M CPT Cntl Pwr 11M RTDs Must be coordinated with the contactor and fuse for proper MV E2 controller protection/applications Recommended/Suggested O/L relay protection functions for MV motors: 49 thermal overload 50/51 P/G Inst. and Time O/C 49RTD (S)/38 stator and/or bearing RTDs 51R mechanical jam 46 current unbalance 27/59 under/over voltage 37 undercurrent 87M motor differential (large MV induction/synch motors > 1500HP) 86 lockout Communication and I/O Others depending on type (ind/synch) and size of motor Slide # 15, Rev 3, 11/8/16
NEMA Type Enclosures NEMA Type 1 (vented) NEMA Type 1 Gasketed (non-vented) NEMA Type 12 (non-vented) NEMA Type 3R Outdoor (non-vented) Non-walk-in Walk-in Protected Aisle Slide # 16, Rev 3, 11/8/16
Basic Starter Types AC Induction Motors FVNR FVR 2S2W 2S1W RVNR (RVAT, RVPR, & MVSSSS) Transformer Feeders (Latched) Capacitor Banks Synchronous (Brush & Brushless) Other Types Available Slide # 17, Rev 3, 11/8/16
Starter Type -FVNR Sq. Cage Induction- Slide # 18, Rev 3, 11/8/16
Starter Type -FVNR Latched Contactor- Slide # 19, Rev 3, 11/8/16
Basic Starter Types -Reduced Voltage- *Motor current is proportional to starting voltage, and torque is proportional to the square of the starting voltage Slide # 20, Rev 3, 11/8/16
Starter Type -RVAT (Reduced Voltage Auto Transformer) Sq. Cage Induction- Slide # 21, Rev 3, 11/8/16
-RVAT (cont d)- Slide # 22, Rev 3, 11/8/16
-RVAT (cont d)- Slide # 23, Rev 3, 11/8/16
Starter Type -MVSSSS (Medium Voltage Solid State Soft Start) Sq. Cage Induction- Class E-2 Controller Fused isolation disconnect Isolation vac. contactor SCR stack w/ I 2 t overload Bypass vac. contactor Isolated cntl. compartment Controls MTR Slide # 24, Rev 3, 11/8/16
Benefits of Soft Starts? Eliminate torque shock damage Increases motor AND drive train reliability Keep starting kva to a minimum Maintain future flexibility Soft Start and Soft Stop pumps Reduce hyd. / mech. problems 4x Cost ratio vs. MV VFDs Slide # 25, Rev 3, 11/8/16
What Sets Soft Starts Apart High performance protection Motor Protection Relay quality Extreme flexibility Any kind of ramp profile Heavy duty ratings Rugged gate firing circuit Reliable, noise immune Slide # 26, Rev 3, 11/8/16
MVSS Ratings 500% for 30-60 seconds 600% for 30+ seconds Capable of Class 30 Mill Duty motors 200% for up to 2 minutes Allows for long accel times Tested at 40 C and 50 C Slide # 27, Rev 3, 11/8/16
Programmable I/O 120V inputs 2 wire or 3 wire control, external trip 1 Analog Tachometer Input 2ea 4-20ma analog outputs Programmable for RMS Current, % Motor Load, Bearing Temp, Stator Temp, or RPM 8 digital outputs Each can be assigned to alarms and/or trips Slide # 28, Rev 3, 11/8/16
Metering 10 current based metering functions 6 status screens Recorder for 60 events with time / date stamp 29 RTD option screens Voltage monitoring functions Including Line Voltage. Frequency, PF, kw, kw Demand, kvar, kvar Demand, kwh, kva, kva Demand. Slide # 29, Rev 3, 11/8/16
Communications RS485 Modbus RTU built-in Future options for DeviceNet, others RS232 Windows based programming / monitor program Slide # 30, Rev 3, 11/8/16
Starter Type -MVSSSS (Medium Voltage Solid State Soft Start) Sq. Cage Induction- Slide # 31, Rev 3, 11/8/16
-MVSSSS cont d- Slide # 32, Rev 3, 11/8/16
Arc Resistant Motor Controller Functionality Arc Resistant MV motor control has the same basic functionality as regular MV motor control. This optional construction feature offers additional protection against internal arc faults as defined in the ANSI Std. C37.20-7-2007 for Type 2B accessibility. The Arc Resistant motor control center is a more reliable and safer option to typical applications in oil and gas, pulp and paper, petrochemical, and in general where it is used as an additional solution for arc flash mitigation. Slide # 33, Rev 3, 11/8/16
Product Visual Identity Pressure Arc Relief Vent Welded LV compartment protects operator with door open Doors - reinforced latches & hinges to prevent gases from escaping Arc Duct redirects flash energy away from the operator Totally enclosed nonventilated welded enclosure for harsh environments Same proven internal components Heavy Duty reinforced side panels Slide # 34, Rev 3, 11/8/16
Summary MV Class E2 controllers/starters provide benefits such as high duty cycles, low maintenance requirements, front accessibility, and more compact designs vs. MV Metal-clad switchgear. Utilize the proper symbols on 1-Line diagrams to represent MV Class E2 starters/controllers, and if possible, separate specifications, or separate/distinct sections in combined specifications, to differentiate/describe the different MV equipment platforms (MCC or Switchgear) with respect to Standards, construction features, etc. To help manufacturer s quotation groups properly size a MV Motor Starter/Controller, complete information (nameplate or data sheets) of the motor/load should be provided in the RFQ documents (FLA, LRA, RPM, SF). If non-standard and/or additional components are required, e.g. bus diff CTs, High- Accuracy or Multi-ratio CTs, draw out PTs/CPTs, etc., additional space, mounting configurations, and/or sections may be required. Consultant manufacturer representative(s) prior to doing equipment/building layouts. When speed control is not required, Reduce Voltage starters can be a solution to limit the impact to the electrical and mechanical systems when starting and/or stopping large motors. However, care must be taken to ensure proper design coordination between the starter type and load requirements. Slide # 35, Rev 3, 11/8/16
Thank you for your time! This concludes the educational content of this activity. To request PDH credit for this webinar, please follow the directions in the thank you email you will receive after completion of this presentation. Please complete and return the course evaluation form to the following email address: ceu.credit@ge.com This webinar has been recorded and can be reviewed at the following website noted below. Please allow ~ 5 working days for processing before accessing the site. http://www.geindustrial.com/technical-tuesdays-webinar Slide # 36, Rev 3, 11/8/16