Dr. Anton Poeltl, ABB PPHV, 5/19/2014 Condition Monitoring Approach Sensors, Methods, Data ABB Month DD, YYYY Slide 1
Introduction This presentation describes ABB breaker condition monitoring approach for a specific product line. Doble has asked not to use brand names. Although there are different approaches to breaker condition monitoring, this presentation details only one approach. The purpose of this presentation is to provide an understanding of what a breaker monitor does and what type of data it maintains
Monitoring Scope Diagnostic and monitoring system for SF6 single pressure power circuit breakers rated 38kV and above Interrupter Wear SF 6 Gas System SF 6 Mechanical System Electrical Controls & Auxiliaries M
Travel Sensor (Mech. Inside Cabinet) Rotary encoder mounted at end of auxiliary switch linkage
Phase Current Transformers Clamp-On CT s Integrated Burden Output Range: up to 5V output Typical Input Range(for 5V output): 140 A 357 A Does not interfere with protection or metering devices
Temperature Sensors For example Resistive temperature devices (RTD) Resistance change: 38.5 W/ 100 C Mounting locations: tank, mechanism, cabinet
Heater Current Transformers Measure Heater Current Determine on/off condition
Pressure Sensor For example 4-20 ma sensor 0 150 PSIG, 0.5 PSI accuracy
Other Connection Points Control Coils Motor Auxiliary Switches
Close (Open) Operation Analysis Contact Travel Make/Break Distance Total Travel Speed Calc. Zone Contact Velocity Reaction Time Mechanism Time Coil Time Close Coil Energization
C/O Operation Analysis Total Travel Speed Calc. Zone Contact Velocity Contact Travel Reaction Time Mechanism Time Close Coil Time Trip Coil Time Close Coil Energization Trip Coil Energization
Interrupter Wear Calculation Main Nozzle Arcing Contacts Aux. Nozzle Arc initiation Aux. nozzle exposed to arc Main nozzle exposed to arc Contact Travel Aux. Nozzle Wear I 2 Main Nozzle Wear Phase Current Contact Wear
Coil Continuity Breaker Monitor S 1 C 1 L coil 12 V Does not trip breaker Tolerates additional coil monitoring measures Works with variety of coils Shorted Coil 200 ms Open Coil 12 V Threshold Good Coil
Temperature Compensated Pressure dynamic quasi-stationary r 7 Pressure Liquefaction Curve r 6 r 5 p 2 p comp p 1 r 4 r 3 r 2 r 1 Liquid SF 6 Gaseous SF 6 T 1 20 C T 2 Temperature
Temperature Compensated Pressure Gas Trending Seconds Minutes Hours No Trend No Trend False Trend Days Clear Trend Months Slight Trend Time
Quantitative vs. Functional Monitoring Quantitative Monitoring Value Quantity Ok? Measure Calculate Compare Alarm Functional Monitoring / Exceptions Measure Value Identify State State Identify Exception Count Time Check Ok? Alarm Measure Value Identify State State
Quantities: Expected Range and Margins Problem Margin Calculated Value Problem Alarm Caution Alarm Exp. Max. Caution Margin Caution Alarm Exp. Min. Problem Alarm Time
Auto Definition and Auto-Adjust of Expected Range Auto definition: Exp. range is defined when quantity is defined Auto adjust: Exp. range is adjusted to include calculated value Calculated Value Auto-Definition Auto-Adjust Expected Range Defined Exp. Range Time
Quantitative vs. Functional Monitoring (Con t) Quantitative Monitoring Value Quantity Ok? Measure Calculate Compare Alarm Functional Monitoring / Exceptions Measure Value Identify State State Identify Exception Count Time Check Ok? Alarm Measure Value Identify State State
Exceptions: Expected Time and Margins Exc. Heater Current Time Temperature Thermostat Deadband Time Heater Off Func. States Low Temperature Time Heater Off at Low Temperatures Time Exp. Caution Problem Time Time Log Entry Margin Caution Alarm Margin Problem Alarm
Heater Monitoring Heater Off (not thermostat controlled) Heater Off at Cold Temperatures Heater On at Warm Temperatures Alarm if longer than 15 minutes (Caution) Alarm if longer than 2 hours (Problem)
Today s Count / Yesterday s Count Motor Starts Max. Count Day 1 Day 2 Day 3 Day 4: Problem Fixed Wrong Monitoring Approach: Time Alarm Alarm Alarm Normal Normal Normal Normal Correct Monitoring Approach: With Acknowledge: User Acknowledges Normal Alarm Normal Without Acknowledge: Normal Alarm Alarm Clears Normal
Motor Starts Motor Starts without Operation: Alarm if longer than 30 seconds (default) Alarm if more than 10 per day (default) Motor Starts with Operation: Alarm if longer than 90 seconds (default) No limit on starts per day
Other Monitoring Features Tank Temperature Mechanism Temperature Trip Count (Informative) Breaker Current (Informative)
Complete List of Monitoring Features Coil Continuity Total Travel Contact Velocity Reaction Time Coil Energization Time Contact Wear Auxiliary Nozzle Wear Main Nozzle Wear Trip Count RMS Current Tank/Gas Temperature Mech./Cab. Temperature Leak Rate (5 time spans) Heater off a low temperature Heater on at high temperature Heater off (heater w/o thermostat) Pump starts w/o operation Pump starts w/ operation
GUI Device Settings
GUI Conditions
GUI Log
GUI Operations
GUI Gas Trending
Communication Using RS232 CMU 2000 System Power Clock CMU 2000 System Power Clock CMU 2000 System Power Clock Communication RS-232 RS-485 Communication RS-232 RS-485 Communication RS-232 RS-485 Overall Condition Problem Caution Normal Overall Condition Problem Caution Normal Overall Condition Problem Caution Normal Detailed Condition SF6-Gas Mechanism Interrupter Charging System Control Coils Heaters A BB Detailed Condition SF6-Gas Mechanism Interrupter Charging System Control Coils Heaters A BB Detailed Condition SF6-Gas Mechanism Interrupter Charging System Control Coils Heaters A BB f.o. CMU 2000 System Power Clock CMU 2000 System Power Clock CMU 2000 System Power Clock Communication RS-232 RS-485 Communication RS-232 RS-485 Communication RS-232 RS-485 Overall Condition Problem Caution Normal Overall Condition Problem Caution Normal Overall Condition Problem Caution Normal Detailed Condition SF6-Gas Mechanism Interrupter Charging System Control Coils Heaters A BB Detailed Condition SF6-Gas Mechanism Interrupter Charging System Control Coils Heaters A BB Detailed Condition SF6-Gas Mechanism Interrupter Charging System Control Coils Heaters A BB fiber optic connection f.o. Company Network
Communication Using Ethernet f.o. link fiber optic connection Control House Ethernet Switch Company Network
Communication Using RF Modems Control House Company Network
Communication using Cellular Modems Cell Tower Provider Company Network
Communications Protocols Native Protocol Proprietary protocol Very efficient Documentation available to customers Modbus De-facto industry standard Supported by most SCADA systems Modbus memory map available to customers DNP3 (Distributed Network Protocol) Set of communications protocols used between components in process automation systems. Main use is in utilities such as electric and water companies. Plays a crucial role in SCADA system Used by SCADA Master Stations (aka Control Centers), Remote Terminal Units (RTUs), and Intelligent Electronic Devices (IEDs). Primarily used for communications between a master station and RTUs or IEDs.
DNP3 Data for Specific Product Makes each of its monitored conditions available via DNP3 protocol. This includes the calculated value, the set points, alarm status etc. Third party SCADA software can be configured to display monitoring data along with data from other IEDs Specific product is compliant with DNP3 level 2 but offers some level 3 functionality such as file transfer. Oscillographic data containing contact travel, phase current, and binary inputs is available via file transfer in COMTRADE format and can be viewed using a third part COMTRADE viewer
Modbus Data for Specific Product Larger set of data available Same as data structures as when using native protocol
Summary Types of Data Raw Data Operation Records Travel Curves Phase Current Waveforms Binary Traces (52a&b, close and trip coil energization) History for Gas Trending Pressure & temperature values Temperature compensated pressure values Intermediate Waveform Records Phase current snap-shots (2-period recording) Processed Data (Conditions) Calculated values (e.g. velocities, leak rates, interrupter wear etc.) Alarm state Various flags for status information and support functions Log Entries Alarms Sensor Changes User Intervention