) / DIRECT-ON-LINE OR ee ee STAR-DELTA\?? rory fox tence? Guidetines are given for design and operation engineers Naveed Jabbar, AMIEEEP ‘hat wl essen making the ptinum: choice. Background There are number of facts and fallacies (old wives’ tales) that need to be addressed © There are KESC/WAPDA/Electric Inspector rales on the method employed for starting of particular size of motor. FALSE! © Itis the mechanical and electrical considerations of the driven machine and the power supply system that govern the choice of particular starting method. TRUE! © Owing to its simplicity, robusiness, and ease of operation, the squirrel cage induction motor is used in 90% of all applications. TRUE! Types of Starting ‘The various methods used for starting three-phase squirrel-cage induction motors are: 8) Direct-on-line (or full-voltage) b) Auto-transformer ) Part-winding : @) Star-delta ©) Primary-resistance 4) Electronic soft-starer Of the above, “ditecton-line” and “star-delta” ate the most commonly used and we shall be investigating the applications of only these two in this paper, Factors Determining Starting Method Various mechanical and electrical fuctors need to be looked at while selecting the starting method. a) tions Let us look at a number of torque-speed curves of drives, FFig-1 shows the characteristics of three-phase squirrel-cage induction motor between zero speed and synchronous speed (motor-iorique = My, My, My, My = Mj). Also shown is the characteristic of the driven machine (load forque = My). The difference between the two torques is the accelerating torque (My). PagetM,, = Starting Tore g ie Ac Lie: ie toe My = Breakdown Torque: . N, = Syneonows Speed 3 = Breakaway torque ae Ms = Pulluptraue The starting torque (M,) must exceed the breakaway torque (M,) of the driven machine by a sufficiently large amount, and the motor torque (M,.) during the run-up to working speed must always be higher than the load-torque (Mi). On the other hand, the acceleration torque (My) should remain within limits since otherwise the mechanical tansmission clements and the driven machine may sustain damage. The mechanical design of the machine and the choice of motor, including its rotor torque class, will determine the amount of starting and accelerating torque available under full-voltage and reduced-voltage starting methods. Low Torque Rotor, Medium Torque Motor High Torque motor Fig-3a Fig-3b Fig-3c = = Load torque during starting Fig-3a to 3e show how different rotor torque classes and starting methods are applied for different types of load torques. For the purposes of this paper, it will be assumed that mechanical considerations do not preclude the use of either “star- delta” or “ditect-on-tine” starting, and the choice is to be made on electrical considerations only. Its thus imperative that the “stiffness” of electrical system be analysed and the voltage-dip on starting be approximated so that a decision can be ‘made on the starting method to be employed, as explained below. Electrical Considerations Motors when started on full-voltage, i.e. “direct-onsline”, depending upon rating and rotor class draw a starting current about 6 times their normal full-load current, The power supply system needs to adequately sized to supply this starting ‘current without adversely affecting the motor being started (since the torque varies squarely with respect fo voltage, a higher dip may not allow the motor to develop the required torque to drive the machine connected to it), or other Joads/equipment connected to same power supply, as follows:dropping out of contactor/relays holding-coils, ee., (35%) extinction of discharge lamps (15%) speed variation or stopping of motors Hicker, ic, fluctuation of luminosity of lamps causing physiological discomfort if the Frequency of starting is more than the perceptibiity threshold >» failures and computation errors for computers or measuring instrument equipped with electronic devices (>10%) commutation failure in thyristor bridges operating in inverter mode. Otherwise, a reduced-vollage starting method will have to be employed. vyyy Calculation of Voltage Dip. ‘Two different cases will be examined, 4) Utility supply through transformer ‘The short-cireuit level at the point of common coupling, ie., where the motor is connected to the power system ean bbe used to calculate the voltaze dip that occurs dur to the high starting current of the motor. D>, KESC/WAPDA ‘The electrical system shown in Fig-4 shows three buses where the short-cireuit levels have been calculated as poe a 25kA, ISkA and SkA. lecn25h ‘The voltage dip caused by the motor-starting can be simply calculated by Inxk Vadip(%) = x 100 eo=Ska, Where In = Motor full toad current . k = Multiplying factor for starting for DOL, = 2 for SD) 5.5 Ihe = Short-cireuit current Figs 4 The chart below (Table-/) shows the results of the calculation for the three motors. In order to cater to practical reduction in the short-circuit current available (owing to the impedance of the utility source, various contact resistances, ete) a factor of safety of 2 will be used, thus doubling the voltage dip calculated. Motor FulbLoad [ Sore ‘Actual Voliage Dip Using FOS=2 | No. | Rating | current [bot | 80 L_ aia | 1ska | cae [085% I [IA ian 2a [ska [ 252% [om | Page-3One can see from the above, that a 55kW (75hp) motor started DOL at the main LV panel of a 1000kVA transformer would occasion a voltage-dip of only 4.70%, which is far below the voltage-depression figures that would affect other electrical equipment. Even a 1 LkW (1Shp) motor started DOL further downstream causes only a 5.04% dip. In cases where the layout of the entire system is not available for calculation purposes, itis possible to estimate the short circuit level at any point in an electrical system by measuring the voltage variation from no-load to full-load. Seine I BEE «100 Where I, = Short-cireuit level r Full-load current y= Voliage-dip from no-load to fall-load Vo = No-load voltage ‘Thus ata point in electrical system, where the no-load voltage Vp 40SV, and the voltage drops to 400V when a current of T= 120A is flowing, the short-circuit level is approximately: le = 12x05 ~ 5 At such a location, a 22kW (30hp) motor started DOL would cause a voltage dip not exceeding 5%. 72 kA KESC/WAPDA, i art OS 000 Compared with transformer supplies, which are fairly we16% (D> x=6% “stifT” (x = 5% - 7%), diesel generating sets had relatively high internal impedance (x ~ 15% - 22%). ‘Thus the instantaneous voltage dip at the genset terminals is very hhigh inspite of the automatic voltage regulator whose typical function itis to restore the output voltage to within 3% of nominal value within 0.3 ms, Fig-5 shows the same system as Fig-4, but being fed from a TSOKVA (x=16%) diesel genset. The corresponding bus short-circuit levels have reduced 10 6.5KA, 5.5kA and 3kA. ssi Figs The chart below (Tubfe-2) illustrates the higher instantaneous voltage dips, Full-Load f Au Vos Dip] _Using FOS=2 | No | Rating | Curent Dot. 3) bo | sD MI | SSkW | 98K | 588A) 196A | 25K om | 30% | Teoex | 600% wa | aauw [ia] 20a |e iska | aerw | tam | age | 208% wa [aie [aia [asa [aaa] ska [azo [aon | aon | eeeIn this example, the DOL starting of SSkW (75hp) motor would cause a dip not exceeding 18%, which may not be acceptable to discharge lighting and unprotected electronic loads operating on the same system. In this case, “star-delta" starting may be adopted for this motor ouly. The other two motors, with dips of less than 9%, would experience no problems with “direct-on- line” starting, Itis prudent to obtain actual data on gensets proposed to be used (sce Annexure-1), or alternatively, to specify the acceptable impedance of genset altemators. In critical cases, oversized alternators may provide the economically optimum solution. Advantages of Full-Voltage Starting ‘Why would one prefer “direct-on-line” to “star-delta” starting? The main reason is cost. A perusal of Zuble-3 indicates that “star-delta” starting including switchgear and cabling, becomes typically 30% costlier than “direct-on-line” for motors rated 22kW and above. Wwe 7 , oo Rating 3) @ SSW | _Rs.17,000_| Rs 12,000 [Rs 1000 | 9% TERW_ | Rs. 12,000_|"Rs. 15,000 | Rs.3,000 [25% DKW | Rs. 16, 000_| Rs. 21,000 | Rs. 5,000_| 31% SEW | _Rs.23,000_| Rs 31,000 | Rs. 8000 | 34% TSEW | _Rs.45,000 | Rs. 63,000 | Rs. 18,000 | 40% Table-3 Additionally “direct-on-line” starting has the advantage of being simple, and consequently more reliable, as there is a ‘minimum of components and complex circuitry. Finally i paper outlines the principles involved complex computer programmes are available for a dynamic similation of motor- starting conditions. In the absence of this tool, it would be advantageous for electrical engineers, designers and! operation/ ‘maintenance personnel to carefully:examine each motor-starting case on its own merits, co-ordinate with the mechanical drive engineers, analyse the charavteristics of the electrical system at the point where the motor is to be installed, and engineer the optimum solution Annexure-1 References “Practical Aspects of Industrial Control Technology”, Telemecanique, France. “Three-phase Low-Voltage Motors: Explanatory Notes & Application Data, Siemens, Germany “Motor Application & Maintenance Handbook’, by Robert W. Smeaton, USA “Electric Motor Manual” by Robert J. Lawrie, USA. “Motor Starting on Diesel Generators”, by MG. Payne, IEE Electronics & Power Journal, June 1977 6. “Electromagnetic Compatibility, Part-2, Section-1, CEI-1990”, IEC Technical Report No, 1000-2-1 “Caterpillar Generator set Sizing Guide", Caterpillat, USA IL 3 4 < (Naveed Jabbar isa Project Engineer with Fahim, Nanji & deSouza, a multiisciplinary consulting firm in building services. This paper was presented at 17" IEBEP Multi-topic Symposium at Karachi on 3" April 1999.) 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