UR Upgrade Program

Outline

1. Introduction
2. Why Upgrading?
3. Who Is Affected?
4. How to Upgrade?
5. Benefits of the New Upgraded UR

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UR Upgrade Program
9/9/2015
1. Introduction
UR Protection and Control Devices
. . . Proven State of the Art Family of P&C Systems
• Common hardware
• Plug and play modules
• Reduced stock of spare parts
• Reduced maintenance cost
• Swappable modules

 Modular design that delivers unparalleled flexibility and fights obsolescence

2. Why Upgrading?
 Lifespan of Digital Protection Relays…
• Determining lifespan factors of any digital relays are based on environmental
conditions, application of the relay and individual component age.
• Old relays may:
• Lower the reliability and process uptime • Lower the electrical equipment lifespan
• Increase in service/maintenance costs • Not comply with new requirements (i.e.
smart grids)
• Lower personnel safety
• Have problem with replacing components
unavailability due to obsolesce
• Typical lifespan Bathtub curve
• Infant Mortality
• Weak Solder joint; cracked ceramic caps or silicon die;
Design margin issues

• Steady State
• Single event burnout; Silver/NiCr corrosion; Opto-
isolator/LED degradation; Airborn particles

• Wearout
• Electrolytic caps; solder joint fatigue; connector
corrosion; Package delamination

 Proactive action is crucial → Solution: Retrofit

UR Power Supply Life Expectancy
Continuous Design Improvements
1H Power Supply – 1998 -> 2004
• Design life 10 years @40DegC, confirmed by field return data
• At 10 year point, the device failure rate is expected to increase at a rate of 1% per year
• Life of Electrolytic capacitors affected by heat and electrical stress
• Analog subsystem susceptible to failure of C27/C28 (8V Rail) (GER-4477)
• Failure of 27/C28 (8V Rail) may result in incorrect metering and false trip

RH Power Supply – 2004 -> 2014 (Jun)

• Utilized newer Capacitor technology to increase design life of 15 years @40DegC
• At 15 year point, the device failure rate is expected to increase at a rate of 1% per year
• Added 200mS ride through capability
• KEMET Capacitor batch issue described in GER4012B (2005/2006)

SH Power Supply – 2014 (Jun)

• Eliminated C27/C28 & others, leaving only 1 long life reservoir capacitor for ride through
• Utilized new technology to give design life of 40 years at @45DegC
• 28% more output power, without increase in heat dissipation
• Micro controller on board to manage output rail sequencing
• Voltage rail monitoring to ensure analog & digital subsystems operate correctly
 Solutions – Retrofit by Replacing
• Cost of new relay, accessories and spare parts
• Re-engineering costs(new drawings, settings,
trainings, tests, etc.)
• Panels modification costs(new cut-out, door,
blank/drop-in plates, wiring, relocation, etc.)
• Service, maintenance and outage costs
Months Months Days Days 1-2 Days
Validate complete IED Create new Remove existing IED Install new IED Commission new IED
Engineering
standards
-New complete -Disconnect all wiring -Install IED -Test all IED functions
hardware
-Remove IED Reconnect all wiring -Test all I/O from and
-New complete -Create new drawings to other devices and
Firmware Create new panel cut- -Test all wiring (point –
-Create new settings out to-point) equipment
files with re- -Test all wiring
configured I/O
-Perform system tests
-Create testing
procedures
-Retrain all staff on
new IED & S/W
Solutions – Retrofit by Upgrading
Using UR Replacement kits
• No need to replace the relay
• Not offered by all vendors
• No panel modification needed
• Compatible with the existing protection and control system
• Limited service, maintenance and outage costs
• Enhanced functionalities and new generation relay features
• Relays more than almost 10-year old are concerned.

 Modular design provides seamless upgrades resulting in

average savings of 50% on retrofit project.
 UR Upgrade Program
Fast Replacement – Eliminates Rewiring & Reconfiguration
 Unique Modular draw out mechanism (no panel cut-out required)
 Easy upgrade & retrofit without disturbing existing wiring
 Draw out aged relay modules and install new modules - plug & use (no reconfiguring of I/O
wiring to fit new terminal boards)
 Minimize training & labor hours required for commissioning – reduce service costs (no
wiring test and terminal inspection required, No tools required (replace all modules))
• UR Setup software compatibility (easy transfer of existing protection setting schemes)
• File conversion, file version selector, and file comparison tools for quick setpoint file
modifications
Weeks Weeks <1 Hour Hours Hours
Validate Only changes Update existing No need to remove Replace UR modules Maintenance test UR
-Only new CPU and Engineering existing UR -Remove old modules -Check all analog
DSP Standards -Disconnect only values
-Install new modules
-New firmware -Update drawings communication wiring -Test enabled
features -Reconnect
-Convert settings files -UR chassis remains communications functions
-Update testing -No new panel cut-out wiring -Test all UR I/O only
procedures
-Train staff only on
changes

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UR Upgrade Program
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 UR Upgrade Program
Easy transition to enhanced next generation functions
Upgrade for a better reliability and security
• Proactive approach to compensate for electronic component aging
• New technological advancements on UR protective relaying systems
• Commitment on enhanced product performance improvement

Simplified process for ease of upgrade transition

• Arrange for advance replacements to meet scheduled outages
• Hardware upgrade kits available with an Upgrade Guide for seamless upgrades

Economical solution to revamp existing installed base products

• Proactive upgrade would minimize maintenance labor costs and maximize process
uptime
• Offers special discounted rates on upgrade

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3. Who Is Affected?
 Upgrade Recommendation
Upgrade recommended for UR Devices 10 years and older
The recommended replacement for UR relays (versions 3.5 or below):
• CPU versions T, U, V DSP versions L, M, N, R, S
• Firmware versions: 7.xx and above
If existing standards dictate other versions, they can be offered.
CPU and DSP modules have to be changed, i.e. version 3 DSP’s are not compatible with later versions.
UR Relays with Firmware 3.5 and below CPU Cross Reference
UR 3 CPU Recommended UR 7 CPU
A T, U or V. If 2 serial ports required, UR 9E
C T or U
D T or U

UR Relays with Firmware 3.5 DSP Cross Reference

UR 3 DSP Recommended UR 7 DSP
8A 8L
8B 8M
8C 8N 13
UR Upgrade Program
8D 8R 9/9/2015
4. How to Upgrade?
Upgrade Process
Simple selection, Fast replacement, Easy set-up, Economical
Determine if
• UR model and serial numbers
upgrade is • Existing firmware version
required.

• CPU-type required
Obtain the
• Specific firmware required
replacement • Additional software options
kits. • Contact local GE sales office

Settings • By latest EnerVista UR setup software

conversions.

Modules • Follow UR3 upgrade guide

replacement (GET-8550)

“Do it yourself guide:

Upgrade guide!” Pre-in-service
• Visual verification
•In-service
checks and maintenance tests
testing •Out-of-service
maintenance tests
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UR Upgrade Program
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5. Benefits of the New Upgraded UR
Single Platform, Scalable Solution

“Incrementally Scalable” Single Platform Solution

UR Feature Enhancements-I
Proactive approach towards enhanced quality, reliability and functionality
Protection
• Multiple new applications
• Breaker and a half capabilities for D60 and L90
• Breaker failure support for B30 and G60
• Incipient cable fault detection for F35 and F60
• New Trip Bus for all UR models
• Watt-metric ground for D60, F60 and L90
• Voltage-dependent overload and Broken Rotor Bar for M60
• 100% stator and rotor using the GPM and Split-phase protection (G60)
• Teleprotection Inputs/Outputs for:
• B30, C30, C60, D60, F35, F60, G60, M60, T35 and T60

Control
• Enhanced breaker control:
• block open/close;
• double-point status per phase with alarming
• Autorecloser extended to 4 shots, selectable activation modes and breaker initiated
• Additional control functions (Capacitor, PID regulator, AVR)
UR Feature Enhancements-II
From Firmware V3.50 to V7.xx

Monitoring
• New elements for Power system components (CTs) monitoring
• Breaker arching for B30, C60, D60, F35, G60, L90, M60, T35 and T60
• PMU functionality on D60, L90, G60, G60, F60, T60
• Internal hardware monitors on DSP and voltage rails

Communication
• Enhanced IEC 61850, IEC62439 PRP and IEEE 1588 PTP, IEC 103
• Hard-fiber (61850 Process Bus)
• Enhancements to PMU and other protocols

Reliability
• Enhanced environmental monitoring and capabilities
• New DSP failure mode with enhanced diagnostic DSP
• Enhanced design, validation and manufacturing processes
UR Feature Enhancements-III
Bringing more to power system installations…
Software
• Selected settings auto-configuration
• One click records retrieval
• Settings templates and more

Security
• Role-based access control
• Audit & recovery
• CyberSentry level 1 with Radius and Syslog support
• Meet well known NERC CIP standard
• Additional features: access control, intrusion detection & prevention, audit

Platform Enhancement
• Enhanced CPU and DSP
• Upgraded I/O & inter relay modules
• New power supply
• Multiple languages
UR Hardware Enhancements
More Powerful CPU and Power Supply…
CPU
• Speed: much faster (400MHz vs. 64MHz)
• Memory: 8 times more for events and oscillography and much faster
(from SDRAM to DDR2)
• Three independent Ethernet ports (MAC and IP addresses)
• Maintains backward compatibility with existing hardware
• Three types of CPU Modules

Power Supply
• Higher input voltage range (88 to 400VDC vs. 88 to 300VDC)
• Overall output power increased (45W vs. 35W)
• Voltage Rail monitoring on all rails vs. none
• Isolation voltage level (2300VAC vs. 2000VAC)
• limited use of electrolytic capacitors for ride-through 1 vs. 27 in LV & 10 in HV)
• Microcontroller based power supply control vs. none
• Over temperature protection vs. none
Summary
• Best solution for relay retrofit without replacing it
• Not offered by other vendors
• Lower service, maintenance and outage time
• Enhanced reliability, Improved Performance
• Easy transition to enhanced next generation relay systems
• Ease of upgrade / replacement
• Compatibility with smart grid emerging needs.
• Use of well known UR strengths
• Under 10 year warranty coverage

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UR Upgrade Program
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