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CHAPTER 7
DESIGN AND IMPLEMENTATION OF
EMBEDDED MOTOR PROTECTION SCHEME
7.1
INTRODUCTION
The three phase squirrel cage induction motors are widely used in
industries due to their reliability, low cost and robustness and hence treated as
work horses of industry. But the possibility of faults is unavoidable. Two
kinds of faults occur on induction motors: mechanical or electrical ones.
Measurement of signals such as currents, voltages, speed, vibrations and
temperature can supply relevant information about faults. This thesis deals
with the diagnosis of electrical faults by mean of current and voltage
measurements only. Motors are critical components for electrical utilities and
process industries. A motor failure can result in the shut down of a generating
unit or production line or require that redundant plant be utilized to
circumvent the problem. Whatever be the consequences of failure, such
events are undesirable since they constitute a decrease in overall system
reliability and additional demands on manpower, finance and time in order to
rectify the problems.
On line detection of the electrical failure mode in its earliest stage is
crucial to promote safe and economical use of ac machines in industrial
applications. Fault location would not only increase the speed of the repairs,
but would also permit more optimal scheduling of the repair outage.
216
ii)
iii)
217
iv)
v)
vi)
In the
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7.3
7.3.1
General Requirements
Motor protection should be simple and economical. Cost of
ii)
iii)
iv)
v)
vi)
7.3.2
summarized below:
i)
ii)
iii)
219
iv)
v)
vi)
x)
xi)
7.3.3
protection chart for induction motors used in industries. Table 7.1 shows that
separate devices are used for protecting individual faults. Instead of it, if a
common, single protecting device is used to protect all the above faults then it
will be very economical protection for low voltage motors. Considering the
above, a low cost, integrated, digital protection scheme is developed and
implemented in this thesis.
220
Alternate forms of
protection from which
Remarks
choice is made
Overloads
Differential protection
Under voltage
Unbalanced
voltage
single
preventer
Stalling
Thermal Relays
Instantaneous Trips
Switching
surges
RC surge suppressor
221
7.3.4
Electromechanical relays
Early 20th century to
present day
1960s to 1980s
Digital relays
222
(i.e current, voltage, status indication etc) in many different ways. Registered
data in the relay can be sent through a communication network to the
operation / engineering head quarters for continuous monitoring or fault
analysis. The relays together with CTs and VTs can therefore be utilized by
other departments (maintenance, planning, etc.,) in addition to the main task
of motor protection.
The merits and demerits of microcontroller relays compared to
electro mechanical relays are given below:
Merits of Microcontroller based Relays
i)
ii)
iii)
iv)
v)
vi)
vii)
223
7.4
i)
ii)
iii)
iv)
ii)
iii)
iv)
v)
7.5
is shown in Figure 7.2. PIC16F877 block stands for PIC16F877 chip, which is
developed by Microchip Co. US. Since it adopts RISC (Reduced Instruction
224
225
ii)
iii)
iv)
Over voltage(OV)
226
v)
vi)
vii)
7.6
ix)
x)
Stall (ST)
agreement with the reported results using test set up. Based on the results of
this study, the condition monitoring of induction machines is proposed.
Table 7.2 shows the value obtained from electrical fault analysis of induction
motor and their permissible value, which is used for hardware implementation
of protection system.
Table 7.2 Observations from fault analysis
Faults
Unbalanced Supply
Voltage
Current Unbalance
1% to 5%
1% to 5%
Up to 45%
Over current
Frequency
Up to 60 Hz
Motor will run up to 75 %
of its rated Load.
Motor will run in reverse
direction
Upto 30%
Upto 20%
Upto 2A
Up to 40%
1.5 Times rated
current
------
Single Phasing
Phase Reversing
Under Voltage
Over Voltage
Ground Fault
Tolerable Value
Permissible Value
Not Permitted
Not Permitted
Upto 20%
Upto 10%
Upto 1 A
227
7.7
ii)
The starting current does not change with the type of load on
the motor, but the time duration changes according to the
inertia of the driven load.
iii)
iv)
v)
vi)
The motor with 1.15 service factor has a higher full load
current than the same motor with 1.00 service factor, even
though the starting current is the same.
x)
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7.8
HARDWARE DESCRIPTION
The Microcontroller based motor protection system combines
values) to the system is given through the keypad. LED Seven Segment
display unit is used as an output device to display the output data, warning
229
message and fault condition. The system works with any motor design with
high degree of accuracy. The method is very sensitive, fast and detects faults
while running and before start. The prototype model is developed and tested
on a three phase induction motor with rated current of 5A and the test results
are satisfying the design criteria.
The maximum allowable under voltage unbalance and over voltage
unbalance is 5%. When the limits are exceeded, controller generates trip
signal, which in turn switch off the induction motor and display warning
message as unbalanced voltage fault and hence induction motor is protected
from heavy unbalancing condition. Similarly other faults are monitored and
induction motor is protected from those faults. The overall circuit diagram of
the protection scheme is shown in Figure 7.4.
The device has two modes of operation setting mode and monitoring
mode. If the device is on setting mode, the user is able to adjust the parameter
according to his application; else the device will be on monitoring mode were
the three phase motor currents and voltages are monitored by current
transformers (CT) and voltage transformers (PT). CT outputs (distorted sine
wave signal proportional to the load current) and PT outputs (voltages) are fed
the low pass filter module. LPF filters the 13th harmonics and above. RMS
module converts the waveforms to DC proportional to its RMS value. The
digitized signals are used to check all the protection schemes taking into
consideration of the users adjusted values.
230
231
7.8.1
Power Supply
Circuit diagram of a typical power supply used in this system is
shown in Figure 7.5. The transformer steps down the ac voltage to the level of
the desired dc output. A diode rectifier then provides a full-wave rectified
voltage that is initially filtered by a simple capacitor filter to produce a dc
voltage. This resulting dc voltage is given to the IC voltage regulator circuit
which provides a dc voltage with less ripple and constant dc value.
phase supply line. The turn ratio used for current transformer used here is
1000:1 A. The potential transformer is used to monitor the input three phase
supply voltage. The turns ratio of potential transformer used in this system is
400: 5V. This transformer will give the output in the range of 5V to the
voltage sensing circuits.
232
7.8.3
output from the current transformer is measured by this current sensing unit.
The output range of current sensing unit is from 0 V to 5V. The three phase
supply voltage is monitored by potential transformer, whose output is sensed
and measured by voltage sensing circuit as shown in Figure 7.7.
233
7.8.4
the phase reversing fault which occurs in supply side. Figure 7.8 shows the
zero crossing detector using LM 358 IC. The input from current transformer
is applied to RC ladder filter circuit. Then filtered output is given to IC LM
358, which is low power dual operational amplifier. The phase reversing fault
is identified when any two of three phases RYB is reversed, then zero
crossing detector will measure this effect and pass information to micro
controller which in turn generate trip signal to relay unit.
following specifications.
i)
Power rating
2.2 KW
ii)
Line Voltage
400 V
iii)
Rated current
4.6A
iv)
Frequency
50Hz
v)
Number of Poles
vi)
Rated Speed
1440 rpm
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7.8.6
vii) Connection
Delta
16F877. This micro controller having inbuilt flash memory and ADC. The
micro controller has the following core and peripheral features:
i)
Programmable code-protection
Low-power,
technology
high-speed
CMOS
FLASH/EEPROM
235
Low-power consumption
ii)
Peripheral Features
7.8.7
Brown-out detection
Relay Unit
A relay is a switch operated by electromagnetic principle. When the
controlling current flows through the coil, the soft iron core is magnetized and
attracts the L-shaped soft iron armature. This rocks on its pivot and opens,
closes or changes over the electrical contacts in the circuit being controlled.
In this protection system, DC 12 V, 10 A relay is used.
The proposed system uses normally opened type relay. When the
controller output from the microcontroller is high the relay is energized.
When the controller output from the micro controller is low the relay is
reenergized. Therefore, according to the controller output the valve will open
or close and thus level is maintained.
236
7.9
237
7.10
SOFTWARE ALGORITHM
The algorithm used for developing embedded programming is
given below:
i)
ii)
iii)
iv)
Monitor and read supply voltages (Va, Vb, Vc) and line
currents (Ia, Ib, Ic) through potential transformer (PT) and
current transformer (CT).
v)
vi)
x)
xi)
If the mean value of VSa, VSb and VSc is less than 0.8 times
of rated voltage (set value), than trip the motor after a
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xvi) If amplitude of Ia, Ib, Ic 1.5 times of set value for time T,
then trip the motor after specified time delay and display error
message as over current (OC).Otherwise,
xvii) If the phasor sum of Ia, Ib, Ic > 1A, then trip the motor after a
specified time delay and display error message as Ground
Fault (GF). Otherwise,
xviii) Goto step iv.
239
7.11
system
during
signals
from
the
motor
protection
system
during
single
phasing
condition
240
signals
from
motor
protection
system
motor
during
under
voltage
condition
system
condition
protection
protection
system
protection
during
condition
phase
system
reversing
241
signals
protection
during
locked
condition
Figure 7.17
from
system
rotor
normal
operating
condition
Output signals from the zero crossing detectors (IDR, IDY) during
phase reversal
242
243
7.12
CONCLUSION
The developed microcontroller (MC) based relay features and
specifications are given below in Tables 7.3 and 7.4. The developed model is
commissioned at M/s. Harshini Textiles, Anamalai, Coimbatore, India for the
main motor drive in LR-6 Ring Frame machine and working satisfactorily.
Table 7.3 Microcontroller based relay features
Protected Item
Time Characteristic
Within 5 Sec.
Within 3 Sec.
Ground Fault
Within 1 Sec.
Unbalance (UB)
Within 8 Sec.
Immediately.
Instantaneous Current
Within 5 Sec.
Over Voltage
Within 5 Sec.
Phase reversal
Within 1 Sec.
Stall
Within 3 Sec.
Time Characteristic
0.5-5A, Wide Range
(6-3000 A) With external CT
1-25 sec (Definite time) / OFF
0.5 / 1.30 sec & 0.5/1-10 sec
(2 step Definite Time)
0.5/1-30 Sec (Definite Time)
On / Off
0.02 3 A (Definite time type) /OFF
5-50% OFF (Disable)
(2-5) * (Ioc)
50-100% OFF of Ioc