Lawe-lawe Terminal Shipping Pump Motor Starter Upgrade

Lawe-lawe Terminal Kalimantan Operation Chevron Indonesia Company 2012

TABLE OF CONTENTS

TABLE OF CONTENTS............................................................................................................ i FIGURES............................................................................................................................... ii CHAPTER I............................................................................................................................ 1 1.1. 1.2. 1.3. Chevron Indonesia Company .............................................................................. 1 Lawe Lawe Terminal......................................................................................... 2 Existing Condition of Shipping Pump Motor ....................................................... 9 Shipping Pump Motor at Lawe-Lawe Terminal .......................................... 9 Starting Method of Shipping Pump Motor at Lawe - Lawe Terminal ...... 10 Load Torque Characteristic of Shipping Pump .......................................... 13

1.3.1. 1.3.2. 1.3.3.

CHAPTER II ........................................................................................................................ 15 2.1. 2.2. 2.3. High Motor Starting Current ............................................................................. 15 High Transformer Losses ................................................................................... 15 Obsolete Starting Method ................................................................................ 16

CHAPTER III ....................................................................................................................... 17 3.1. Motor Starting Methods ................................................................................... 17 Direct-On-Line (DOL) ................................................................................. 17 Star Delta ................................................................................................ 21 Autotransformer Starter ........................................................................... 31 Start via Reactans or Resistors .................................................................. 34 Shunt Capacitance..................................................................................... 39 Frequency Converter ................................................................................ 40 Softstarter ................................................................................................. 48

3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.2. 3.3. 3.2.

Starting Methods Comparison .......................................................................... 55 Selected Starting Method Simulation ............................................................... 57 Comparison : Waste Water Pump Softstarter .................................................. 66

CONCLUSIONS AND SOLUTIONS ....................................................................................... 78 REFERENCES ...................................................................................................................... 79

FIGURES

Figure 1.1. CICo Operation Area.......................................................................................... 1 Figure 1.2. Lawe Lawe Terminal ....................................................................................... 3 Figure 1.3. Lawe Lawe Terminal Process Flow Diagram .................................................. 4 Figure 1.4. One Line Diagram 4160 V Switchgear at Power House .................................... 8 Figure 1.5. Shipping Pump ................................................................................................ 10 Figure 1.6. MCC Shipping Pump at Power House : (a) Phase Breaker and Fuse; (b) Winding of Autotransformer; (c) Protecting Devices; (d) Tapping Breaker ...................... 11 Figure 1.7. Wiring Circuit of Autotransformer Starter ...................................................... 12 Figure 2. 1 Autotransformer starter for shipping pump A and B at Lawe Lawe Terminal .......................................................................................................................................... 16 Figure 3. 2. Direct Online Starting Ilustration ................................................................... 17 Figure 3. 3. Wiring Circuit Manual Operated Direct Online Starting ................................ 18 Figure 3. 4. Wiring Circuit Electromagnetic Operated Direct Online Starting .................. 19 Figure 3. 5. Direct Online Device ....................................................................................... 20 Figure 3. 6. Torque / Speed Curve Characteristic at Direct Online Start ........................... 20 Figure 3. 7. Current Curve Characteristic at Direct Online Start ....................................... 21 Figure 3. 8. Star-Delta Starting Ilustration ........................................................................ 22 Figure 3. 9. Balanced Three Phase Power Circuit (a) Wye-Connected (b) Delta-Connected .......................................................................................................................................... 22 Figure 3. 10. Delta-Wye Impedance Conversions ............................................................. 23 Figure 3. 11. Motor Winding Termination Using Star-Delta Starter ................................. 25 Figure 3. 12. Phase Sequence Connection ......................................................................... 26 Figure 3. 13. Wiring Circuit of Combined Star-Delta Starter ............................................. 27 Figure 3. 14. Wiring Circuit of Partially Wound Star-Delta Starter ................................... 28 Figure 3. 16. Wiring Circuit of Uninterrupted Star-Delta Starter ...................................... 29 Figure 3. 15. Speed Characteristic Curve of Uninterrupted Star-Delta Starting at Open Transition .......................................................................................................................... 29 Figure 3. 18. Torque/Speed Curve at Star-Delta Start ...................................................... 30 Figure 3. 17. Current Curve of Star-Delta Start ................................................................. 30 Figure 3. 19. Autotransformer Starting Ilustration ........................................................... 31 Figure 3. 20. Wiring Circuit of Autotransformer Starter ................................................... 32 Figure 3. 21. Torque/Speed Curve for an Autotransformer Starter .................................. 33 ii

Figure 3. 22. Starting via Reactans or Resistor Ilustration ................................................ 34 Figure 3. 23. Wiring Circuit of Primary Reactor Starting .................................................. 35 Figure 3. 24. Torque/Speed Curve of Primary Reactor Starting ..................................... 36 Figure 3. 25. Wiring Circuit of Primary Resistance Starting .............................................. 37 Figure 3. 26. Torque/Speed Curve of Primary Resistance Starting ................................... 38 Figure 3. 27. Shunt Capacitance Starting Ilustration ........................................................ 39 Figure 3. 28. Frequency Converter (VSD) Block Diagram .................................................. 41 Figure 3. 29. Rectifier Circuit with 6 Diodes..................................................................... 41 Figure 3. 31. Full-Wave Rectification Signals .................................................................. 42 Figure 3. 30. Three Phase Signals ...................................................................................... 42 Figure 3. 32. Intermediate Circuit ..................................................................................... 43 Figure 3. 33. Three Phase Inverter Circuit ......................................................................... 43 Figure 3. 34. Pulse Width Modulation Signal .................................................................... 44 Figure 3. 35. Carrier and Reference Signal of PWM .......................................................... 45 Figure 3. 36. Voltage/Frequency Curve of Control Circuit ................................................. 46 Figure 3. 37. Torque/Speed Curve for an VFD set to 10%(6 Hz) Increments ..................... 47 Figure 3. 38. Softstarter Single Line Diagram ................................................................... 48 Figure 3. 39. Voltage Signal Output .................................................................................. 48 Figure 3. 40. Torque/Speed Curve when Using a Softstarter ............................................ 49 Figure 3. 41. Current Curve when Using a Softstarter ...................................................... 49 Figure 3. 42. Start Ramp and Stop Ramp Diagram of Softstarter..................................... 50 Figure 3. 43. Action of Current Limiter on the Output Voltage ......................................... 51 Figure 3. 44. Current Limit Function in Softstarter use ..................................................... 52 Figure 3. 45. Motor Parameter for Simulation.................................................................. 58 Figure 3. 46. DOL Simulation Schematic Diagram ............................................................ 58 Figure 3. 47. Graphics of Motor Speed in DOL Starting .................................................... 59 Figure 3. 48. Graphic of Motor Current in DOL Starting ................................................... 60 Figure 3. 49. Autotransformer Simulation Schematic Diagram ........................................ 61 Figure 3. 50. Graphic of Motor Speed in Autotransformer Starting ................................. 62 Figure 3. 51. Graphic of Motor Current in Autotransformer Starting ............................... 62 Figure 3. 52. Softstarter Simulation Schematic Diagram .................................................. 63 Figure 3. 53. Graphic of Motor Speed in Softstarter ......................................................... 65 Figure 3. 54. Graphic of Motor Current in Softstarter....................................................... 66 Figure 3. 55. Payne Engineering Softstarter 18EM3-4-150HP3 ........................................ 68 Figure 3. 56. Wiring Circuit of Payne Engineering Sofstarter............................................ 69 Figure 3. 57. Power Circuit wiring of Payne Engineering Softstarter ................................ 70 Figure 3. 58. Control Circuit wiring of Payne Engineering Softstarter .............................. 71 Figure 3. 59. Power Circuit Schematic ............................................................................... 73 Figure 3. 60. SENTROL EM3 Ramp Card, Showing 2-Wire Control and 3-Wire Control .... 74 Figure 3. 61. Ramp Card Details, Showing the Location of Adjustment Trimmers ........... 75 iii

TABLES
Table 1.1. Generator Engine at Lawe Lawe Terminal ...................................................... 7 Table 1.2. Shipping Pump Parameter.................................................................................. 9 Table 3. 1. Advantages and Disadvantages of Direct OnLine Sarting ............................... 21 Table 3. 2. Voltage and Current Calculation Comparison Between Star and Delta .......... 23 Table 3. 3. Delta-Wye Impedance Formulas ..................................................................... 23 Table 3. 4. Advantages and Disadvantages of Star-Delta Starter .................................... 31 Table 3. 5. Advantages and Disadvantages of Autotransformer Starter .......................... 34 Table 3. 6. Advantages and Disadvantages of Primary Reactor Starter ........................... 36 Table 3. 7. Advantage and Disadvantage of Primary Resistance Starter ......................... 39 Table 3. 8. Advantages and Disadvantages of Shunt Capacitor Starter ........................... 40 Table 3. 9. Advantages and Disadvantages VSD Starter .................................................. 47 Table 3. 10. Setting when Using a Softstarter with Current Limit Function ...................... 53 Table 3. 11. Setting when Using a Softstarter without Current Limit Function ................ 54 Table 3. 12. Advantages and Disadvantages of Softstarter.............................................. 55 Table 3. 13. Comparison Between Starting Methods ....................................................... 55 Table 3. 14. Comparison Between Softstarter and VSD .................................................... 57 Table 3. 15. Waste Water Pump Parameter ..................................................................... 67 Table 3. 16. NEMA Locked Rotor KVA Code ...................................................................... 67 Table 3. 17. Waste Water Pump Performance Test. (a) Stand alone starting test. (b) Combination starting test ................................................................................................. 77

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CHAPTER I Background

1.1.

Chevron Indonesia Company Chevron Indonesia Company (CICo) is a subsidiary company of one

of the leading oil and gas company in the world, Chevron Corporation. Chevron Indonesia Company (CICo) operates under Chevron IndoAsia Bussines Unit (IBU) that covering operations in Indonesia and the Philippines. Besides Chevron Indonesia Company, Chevron IndoAsia Bussines Unit (IBU) also manages Chevron Pacific Indonesia, a company operating in Riau and North Sumatra provinces, as well as geothermal energy company and power company (electricity generation) in Indonesia: Chevron Geothermal Indonesia, Ltd. and Chevron Geothermal Salak, Ltd.. While in the Philippines Chevron IndoAsia Bussines Unit (IBU) manages Chevron Geothermal Philippines Holdings Inc. (CGPHI).

Figure 1.1. CICo Operation Area

Chevron Indonesia Company's concession area is divided by the Mahakams Delta into two major regions: North and South, and West Seno, a marine project in the Makassar Strait. In the northern area of operations, Chevron Indonesia Company operates in Attaka, Melahin, Kerindingan, Serang and West Seno field, and Santan Terminal. While at Southern operating area, Chevron Indonesia Company conduct its operations in Sepinggan and Yakin, Lawe-Lawe Terminal and Base Camp, Penajam Supply Base (PSB), and Pasir Ridge Balikpapan. The distribution of Chevron Indonesia Company operation area shown in figure 1.1. Attaka field gained recognition as the world's giant oil fields and is recorded as the largest offshore oil field in Indonesia. Located about 12 kilometers from Tanjung Santan, Attaka field began producing well from the first wells in 1972. Attaka processed gas from the plant extraction liquid (liquids extraction-LEX) at Santan terminal and dry gas is transported via pipeline to the Badak NGL, Bontang in East Kalimantan. Oil and gas from Sepinggan and Yakin fields sent to the Lawe-Lawe terminal located in the District of Penajam Paser Utara. Lawe-Lawe Terminal storing oil which to be exported via tankers or piped to a refinery in Pertamina Balikpapan. Gas production is also sent through a pipeline to the refinery and some used as fuel. 1.2. Lawe Lawe Terminal Lawe - Lawe terminal located in district Penajam Paser Utara, 12 mil from Balikpapan City, East Kalimantan. Lawe lawe terminal process oil and gas from southern Chevron Indonesia Company operating area, Sepinggan field and Yakin field. The crude oil result from processing in Lawe-Lawe terminal sent to Pertamina refinery and exported. While gas from Lawe lawe sent to Pertamina and another company and some used as generator fuel and another devices in Lawe-Lawe terminal.

Figure 1.2. Lawe Lawe Terminal

Oil Processing The general oil processing in Lawe lawe Terminal can be seen in Figure 1.3. Oil from Sepinggan and Yakin, with pressure 150 psig and temperatures of 85 F, met in Jumai Cape to get Lawe - Lawe Terminal. Oil entry through the pressure control to maintain the pressure of 150 psig, then passes the emergency shutdown valve and finally went to the High Pressure (HP) Separator. In HP Separator, oil having a turbulent flow through the input pipe hit the baffle or deflector plate so that decrease in velocity and flow direction changes. Gas going up to get gas processing, liquid will fall to the bottom of the vessel in which water and other heavy sediment at the bottom and oil on it. Oil from HP Separator then flows into Crude Heat Exchanger. Here oil warm up gradually with three Crude Heat Exchanger which arranged in series. The principle is exchange of energy between two fluids (oil) of different temperature. Oil output will have a pressure 70-80 psig and temperature of 100 F. Crude oil from the heat exchanger is then passed Crude Direct Fired Heater. Here oil is heated by heat generated from fuel, namely gas. Oil heated until the temperature reaches 150 F , with the

LAWE - LAWE
GAS TO REFINERY PIG LAUNCHER
PC CS - 1410

TERMINAL

PROCESS

PLANT

FLOW

DIAGRAM

PC

GAS COMPRESSOR

V - 1006 A KNOCK OUT DRUM

PC PC PC

VS-1110 ROCK BOX

GAS TO UTILITY
V - 2002

902-A GAS COOLER

TO FLARE

processing.

PIG RECEIVER
PC

GAS FROM OFFSHORE

V-1003-S GAS BOOT

PC

PIG RECEIVER
V-1002 S 501 - A CRUDE HEATER
LC LC

CRUDE OIL FROM OFFSHORE

SUCTION VESSEL

1306-B STABILIZER TANK

LC

ESDV (PL-4)
ILC

LC

V - 1000 S LOW PRESSURE SEPARATOR

AV-1003-S-1

V - 1001 S HIGH PRESSURE SEPARATOR FLASH GAS NIFE SCRUBBER

TO API SEPARATOR

TO HYDRO CYCLONE UNIT

AV-1003-S-2 501 - B CRUDE HEATER

3
PC

1203-A STABILIZER PUMPS

HEAT EXCHANGER A/B/C

1007-S DEHYDRATOR

1306 - C CRUDE OIL STORAGE TANK A M

V-1005 B

ILC

1
TO API SEPARATOR

B
2

AV-ST2 3

AV-ST1

1201 SHIPPING PUMPS AIR ELIMINATOR

4

M MV-2
TO SBM TO UTILITY

A
AV-ST3
V-1005A

PROVER LOOP

AV-ST4

1306 - D CRUDE OIL STORAGE TANK B

6

1306-A RERUN TANK

AV-RR3

M MV-14
1202 TRANSFER PUMPS
7

RERUN PUMPS

2 TO OLD REFINERY
AV-RR1

aim of breaking the water-oil emulsions weeks to facilitate further

Figure 1.3. Lawe Lawe Terminal Process Flow Diagram

REFLUSHING 1401 - A P.D. METER
AV-RR2

4
Legend :

Drawn by : Teg.02174 / January,3,1999

: Crude Oil Line : Gas Line

: By pass Line : Condensate Line

: Water Dumping Line

Oil from Direct Heated Crude entry Low Pressure (LP) Separator. LP Separator have the same principle works with the HP Separator the different only in pressure. LP Separator has a lower pressure that is 60 psig, while the temperature is 150 F. This is because after passing through the heater, oil, water, and gas is more easily to separate so it is quite done at low pressure. Oil from LP Separator then enter to Gas Boot for oil and gas separation. Then passed Crude Stabilizer Tank where the pressure is lowered close to atmospheric pressure. Decrease in air pressure causes the gas molecules are easier to escape from the oil. Crude oil output from Stabilizer Tank contains a little gas. Crude oil from Crude Stabilizer Tank passed to the Dehydrator to reduce levels of water and salt so that it falls in BS&W. The working principle of Dehydrator is the electrostatic. Dehydrator contained in a pair of electrodes (top and bottom) that generates an electric field where its voltage supplied by the transformer. When passing through the electrodes, the water in the oil will form the particles induced by the two polar opposites, then the opposite particles attract each other pulling and merge into a droplets and so on to form a large size droplets that enough to pull by the gravitational force to the bottom of the vessel. Oil from the Dehydrator then stored in the Storage Tank and then sent to the buyer. Gas Processing Gas processed at the terminal lawe-lawe seturian derived from Seturian field and some from Sepinggan field and Yakin field. Sepinggan pipeline from the field and the Yakin field meet in Jumlai Cape so that only one gas stream toward the Lawe - Lawe Terminal. While gas from Seturian field have a gas pipeline leading to the Lawe - Lawe Terminal.

Gas processed at the Lawe - Lawe Terminal comes from offshore (Sepinggan, Yakin and Seturian Field) and from the separation process in Lawe - Lawe Terminal itself (solution gas). Gas from offshore divided into two natural gas (gas produced from gas wells) and well effluent/associated gas (gas mixed in oil wells). Natural gas reservoir pressure was generally was high enough so that the compressors are not required for running it. While associated gas requires compressor to raise the pressure to flow. Gas lines from Sepinggan and Yakin Field meet at the Jumlai Cape and gathered at Knock Out Drum (KOD) along the path of the gas from Seturian Field in the Lawe - Lawe Terminal. Gas from outlet KOD divided torefinery directly, some of them to CO2 removal unit which then to the dehydration unit, other to the utility (Pertamina) and partially drained as make-up/gas blanket to the Flash Gas Scrubbers and High Pressure Separator. While solution gas from High Pressure Separator and Low Pressure Separator drained to Flash Gas Scrubber. Output Flash Gas Scrubber is used for internal process devices (for the fuel heater, glycol reboiler, generator, engine and so on). Gas from Gas Boot flowed to vapor recovery compressor whose output is used for fuel of Crude Heater. In the CO2 removal unit, a decline in CO2 levels happen. Reduction in CO2 levels process is by contacting gas with DEA (diethanol amine) in order to absorb CO2 so the gas can achieve the required composition Pertamina is 7-8%. The gas then goes to the dehydration unit, here the gas is dried with TryEthylene Glycol as absorbent / absorbent liquid is carried away by the gas. Output from the dehydration unit meet with KOD gas line to the refinery. The gas from KOD which has high dew point mixed with gas from the dehydration unit that has low dew point in order to get gas with a dew point that meets the demand (<47.7 0F).

Electricity System Chevron Indonesia Company Lawe Lawe terminal has independent power electric generation. To provide electric power for LaweLawe terminal, there are 4 generator engine with 3 gas engine operating and 1 diesel engine in stand by mode. The capacity of each engine is shown in table 1.1. No 1 2 3 4 Generator Engine Gas Engine Gas Engine Gas Engine Diesel Engine Type Caterpillar G399 Caterpillar G399 Caterpillar G399 Caterpillar D399 Rated Capacity (KW) 500 500 500 650

Table 1.1. Generator Engine at Lawe Lawe Terminal

Those generator generated voltage at 4160 V. All of them connected to busbar in 4160 V switchgear at power house. And then from the busbar at 4160 V switchgear, the power distribution divided into 5 feeders, housing feeder no.1, housing feeder no.2, process feeder no.1, process feeder no.2, and shipping feeder no.5. The distribution of electric power generated

by generator can be seen at figure 1.4. The voltage distributed by process feeder no.1 and process feeder no.2 reduced by step down transformer TR#1 4160/415-240 2000 kVA and TR#2 4160/415-240 2000 kVA. Then from transformer TR#1 and TR#2, the electric power connceted to busbar in 415 V switchgear, 415 MCC Utility 1, and 415 MCC Utility 2 at power house and then distributed to supply power electricity demand at process area. Housing feeder no.1 and housing feeder no.2 supply electricity power to domestic area, such as mess hall, shop, housing, sewage plant, store, clinic, etc. The power distribution voltage at housing feeder no.1 and no.2 also reduced to 415 V by step down transformer 4160/415-240.

Figure 1.4. One Line Diagram 4160 V Switchgear at Power House

While shipping feeder no.5 conneted to shipping MCC at power house. The voltage level is still at 4160 V. Shipping feeder no.5 serves heavy motor load, such as fire water pump (400 HP), booster pump (350 HP), shipping pump 1201A (350 HP), and shipping pump 1201B (350 HP). Shipping pump 1201A and 1201B is currently in use, but fire water pump and booster pump was dismantled. 1.3. Existing Condition of Shipping Pump Motor

1.3.1. Shipping Pump Motor at Lawe-Lawe Terminal There are two shipping pump at Lawe Lawe Terminal is used to transfer crude oil from crude oil storage tank C and D to Pertamina refinery or to tanker boat. Those shipping pump manufactured by Mitsubishi. The detail information of shipping pump shown in table 1.2. Equipment Name Tag Number Manufacture Model Number Frame Size HP Volt Ampere Hertz (HZ) RPM Power Factor (Cos ) Service Factor (SF) IP Class Insulated Class Ambient Temperature (OC) Shaft End Bearing Opp End Bearing SHIPPING PUMP LLW-PROC-PU1201A/B MITSUBISHI MKV-WVX 800LL 350 4160 44 50 980 F 40, RAISE LIMIT 80OC 7324B 6322CM

Table 1.2. Shipping Pump Parameter

Shipping pump motor is an induction motor with squirrel cage rotor type. An induction or asynchronous motor is a type of AC motor where power is supplied to the rotor by means of electromagnetic induction.

Figure 1.5. Shipping Pump

Shipping pump shown in figure 1.5 will operate if there is a oil demand from Pertamina or tanker, and that not frequently. So the shipping pump is used occasionally. The shipping pump must turn on or off manually according to oil demand (from Pertamina or when exporting). While turn on the shipping pump, there will be an high starting current taken by shipping pump motor. 1.3.2. Starting Method of Shipping Pump Motor at Lawe - Lawe Terminal Those two shipping pump motor has same starting method, autotransformer starter. The control of autotransformer starter and the transformer winding is inside the MCC shipping pump at power house. Figure 1.6. shows the existing condition of autotransformer starter of shipping pump. Autotransformer starter including winding transformer, phase line contactor, current limiting fuse and protection relay are inside shipping pump MCC box. MCC used for shipping pump MCC is AMPGARD 5000 manufactured by Westinghouse Electric Corporation.
10

(c) (a)

(b)

(d)

Figure 1.6. MCC Shipping Pump at Power House : (a) Line Phase Contactor (Air Break type) and Current Limiting Fuses; (b) Winding of Autotransformer; (c) Protecting Devices; (d) Air Break Contactor for tapping Autotransformer.

Figure 1. 7. Amperemeter Mounted at Ampgard 5000 Shipping Pump MCC

11

The current flow to shipping pump can be measured with amperemeter that installed inside shipping pump MCC. The normal current of shipping pump is 44 A (according to shipping pump nameplate). When starting shipping pump, the starting current is high and more than 75 A. Amperemeter at shipping pump MCC cant measure that starting current of shipping pump because its over ranged. The range of current measurement of the amperemeter is only 0 75 A.

Figure 1.6. Wiring Circuit of Autotransformer Starter

12

Generally, an autotransformer starter enables the start of squirrelcage motors using a reduced starting current, since the voltage is reduced during start. During start-up, the motor is connected to the autotransformers tappings. This means that the motor starts up with a reduced voltage and a correspondingly low current. The autotransformer reduces the current in the mains supply line further and in accordance with its ratio. Wiring circuit autotransformer starter shipping pump at Lawe Lawe Terminal, derived from the original picture, is shown in figure 1.8. In order to adapt the motor start characteristics to the torque requirement, autotransformer starter at shipping pump MCC equipped with 4 selectable tapping 50%, 65%, 80%, and 100%. There only two tap used for autotransformer starter shipping pump, At figure 1. The tap show value 65% and 100% , but in reality 50% and 100%. 1.3.3. Load Torque Characteristic of Shipping Pump For some applications the motor is started with reduced load torque, unloaded start. Big centrifugal pump are often started with a closed damper and this will make the start easier (shorter) but since the moment of inertia is still present the starting time might be quite long anyway. Load torque characteristic of a centrifugal pump shown in figure 1.9.

Figure 1.9 load torque characteristic of sentrifugal pump

13

The theoretical characteristic of a centrifugal pump is a parabolic starting from the origin and proportional to the square of the speed. The torque can be expressed as

Where: T = torque (Nm) k = constant n = pump speed or velocity (rpm)

14

CHAPTER II Problem Identificaton

Oil and gas processing in Lawe - Lawe terminal process devices consist of many kind of pump moved by electric motor. One of them is shipping pump unit A & B which manufactured by Mitsubishi. Result of survey, the shipping pump motor has some drawbacks, such as : 1. High motor starting current 2. High Transformer Losses 3. Obsolete starting method

2.1. High Motor Starting Current Starting current is a current taken by motor when start to change motor from idle condition to spin/operate condition. This starting current is usually high depend on motor power capacity and starting method used. Shipping pump motor in Lawe Lawe Terminal has the greatest power capacity than other motor. One shipping pump motor power capacity is equal to one over six total power generated in Lawe Lawe terminal. So when shipping pump started, it will drain much power and can cause frequency system to decrease for a while. 2.2. High Transformer Losses By using an autotransformer , there is two kind of losses consumed by the autotransformer. The losses is come from coil and core used in autotransformer. Copper used for the winding of the transformer always have the resistance although its afforded as small as possible. This resistance value absorb some power and change it into heat. So it will produce some heat to the transformer.
15

Furthermore, the core used to the transformer will be the source of losses to. Eddy current may be exist in the core of the transformer. This current will rotating in the core of the transformer and can produce heat to the metal used for transformer core. 2.3. Obsolete Starting Method Starting method used for starting shipping pump motor is by autotransformer. However autotransformer starter was better than direct on line (DOL) starter, that still produce high starting current and high drained power when motor start. Beside that, the autotransformer starter device in Lawe Lawe Terminal approximately 30 years. That is why it became an obsolete one.

Figure 2. 1 Autotransformer starter for shipping pump A and B at Lawe Lawe Terminal

Nowadays, when semiconductor technology develop rapidly, there are another starting method which offer less starting current. So in order to reduce starting current and to attain more energy efficiency, a better starting device required for starting shipping pump motor at Chevron Indonesia Company, Lawe Lawe Terminal.

16

CHAPTER III Analysis

3.1.

Motor Starting Methods 3.1.1 Direct-On-Line (DOL) DOL is the traditional and simplest method of motor starting, and most other methods are baselined against it. It is also often called across the line start. This method is the direct connection of the terminal voltage to the motor stator with no additional components, and also for this reason is most economical in terms of installation cost and ease of use. It is also one of most reliable and robust methods. Of all the starting methods it produces the highest inrush current, usually six to eight times the rated current based on the motor characteristic and the load connected to the motor, and the highest starting torque. Due to the high starting torque it has the shortest acceleration time. The DOL method is most commonly used for small motors relative to the size of the generation and system, due to the fact that the startup of a small motor will only have a low impact on the system, and in particular the voltage drop. Other disadvantage include the mechanical stress put on the motors load and the low startup efficiency due to the high reactive power consumed at startup. This approach is typically not suitable for large motors. In this methods motor can be directly connected to the generator terminals as shown in Figure 3.1.

Figure 3. 2. Direct Online Starting Ilustration

The equivalent impedance is equal to the apparent impedance:

17

In the direct-on-line methods there is two kind of operation in case of connecting the circuit. 3.1.1.1. Mechanical/Manual Operated Giving the voltage at the motor directly through mechanical contact. There is no automatic connection control for this type of starter. Mechanical / Manual Operated DOL as seen at figure 3.3, connecting the line supply that goes to the motor through switch. The disadvantage is the installation of the switches should be as close as possible to the motor so

voltage loss factors can be avoided. Besides, in this method not using connection control so if the isolation was fault, it can give a electrical shock to the operator. Therefore, DOL Starter of this type is only used for small motor.

Figure 3. 3. Wiring Circuit Manual Operated Direct Online Starting

18

3.1.1.2. Electromagnetic Operated

Giving the voltage to the motor through an electromagnetic contact. The

operating switch can be located far from the contactor, so the operator can be saver from the electrical shock. The wiring circuit of electromagnetic operated DOL shown in figure 3.4

Figure 3. 4. Wiring Circuit Electromagnetic Operated Direct Online Starting

19

Figure 3. 5. Direct Online Device

In a direct-on-line starting methods, the starting torque is very high, so the acceleraion of the motor will become fastest between the other methods. In the induction motor with the squirrel cage, there is a slip between the rotor speed and the synchronous speed. If the slip is high, the current flow through the rotor coil inducted by the stator magnetic field will be higher. Therefore, the torque produced between stator magnetic field and rotor magnetic field will be higher. When the rotor reach the synchronous speed, the torque will becoming zero, it is becase when there is not slip between the rotor speed and the synchronous speed there is no current inducted to the rotor coil. The relationship between torque and the rotor speed can be see in figure 3.6.

Figure 3. 6. Torque / Speed Curve Characteristic at Direct Online Start

20

When the motor directly connected to the line supply, it will absorb a high current, usually between six until eight times its rated current. The current will be high because of the transient condition and the lock rotor condition. The current curve can be seen at figure 3.7.

Figure 3. 7. Current Curve Characteristic at Direct Online Start

Advantage high starting torque shortest acceleration time cheapest method

Disadvantage high starting current starting voltage drop mechanical stress on the motor loads low startup efficiency due to high reactive power consumed at startup system instability for the definite power source frequency reduction for the definite power source

Table 3. 1. Advantages and Disadvantages of Direct OnLine Sarting

3.1.2

Star Delta The main principle of this method is by starting motor in star

connection, like shown by figure 3.8., then switch it to delta connection when it rech approximately the rated speed.
21

Figure 3. 8. Star-Delta Starting Ilustration

In the star-delta starting methods there are three configuration of the circuit: 1. Normal Star-Delta Starters 2. Enhanced Star-Delta Starters 3. Star-Delta Starters with uninterrupted switchover (closed transition) 3.1.2.1. Normal Star-Delta Starters The star-delta (wye-delta) starting method controls whether the lead connections from the motor are configured in a star or delta electrical connection. So, in this starting method the motor must be connected in delta connection when running condition. The initial connection should be in the star pattern that results in a reduction of the line voltage.

(a)

(b)

Figure 3. 9. Balanced Three Phase Power Circuit (a) Wye-Connected (b) DeltaConnected

22

Phase Voltages Van = Vp

Line Voltages Vab = Van + Vnb = Van Vbn = Vp+30

Phase Currents Iab = Ip

Line Currents Ia = Iab - Ica = Ip-30 Ib = Ibc Iab = Ip-150 Ic = Ica Ibc = Ip+90

Vbn = Vp-120

Vbc = Vbn + Vnc = Vbn - Vcn = Vp-90

Ibc = Ip-120

Vcn = Vp+120

Vca = Vcn + Vna = Vcn - Van = Vp+150

Ica = Ip+120

Table 3. 2. Voltage and Current Calculation Comparison Between Star and Delta

Figure 3. 10. Delta-Wye Impedance Conversions

Table 3. 3. Delta-Wye Impedance Formulas

23

If we assumse that the voltage when the motor connected in delta condition is 100%, when the motor connected to star connection the voltage will becoming 100/3 equal to 57.7%. Then the current is reduced to 1/3 of the current at full voltage, but the starting torque is also reduced 1/3 to 1/5 of the DOL starting torque. The staring torque is approach to the square of the voltage applied:

The transition from star to delta transition usually occurs once nominal speed is reached, but is sometimes performed as low as 50% of nominal speed. The star-delta method is usually only applied to low to medium voltage motors. The operation of the star-delta method is simple and rugged, and is relatively cheap compared to other reduced voltage methods with only additional contactors added to the cost. However, the system cannot be modified once installed without considerable rework. Closed-circuit transitions can be performed to avoid open-circuit current surges. The device normally consists of three contactors, an overload relay and a timer for setting the time in the star-position (starting position). This starting method only works when the application is light loaded during the start. If the motor is too heavily loaded, there will not be enough torque to accelerate the motor up to speed before switching over to the delta position. When starting up pumps and fans for example, the load torque is low at the beginning of the start and increases with the square of the speed. When reaching approximate 80-85 % of the motor rated speed the load torque is equal to the motor torque and the acceleration ceases. To reach the rated speed, a switch over to delta position is necessary, and this will very often result in high transmission and current peaks. In some cases the current peak can reach a value that is even bigger than for a D.O.L start. Applications with a load torque higher than 50 % of the motor rated torque will not be able to
24

start using the start-delta starter. The load torque characteristic and the motor torque characteristic can be seen in figure 3.11.

Figure 3.11 Load and motor torque of star-delta starter

While this method has significant advantages over conventional full voltage starting, the disadvantage is that it requires more panel space, more components, and most importantly a motor that has all its winding terminations available to the outside so the wye connection can be created as seen at figure 3.12.

Figure 3. 11. Motor Winding Termination Using Star-Delta Starter 25

Starting in star, the main contactor connects the mains to winding endings U1, V1, W1. The star contactor shorts winding endings U2, V2, W2. After successful run-up, the star contactor switches itself off and the delta contactor connects terminals U1/V2, V1/W2,W1/U2. When changing from star to delta, attention has to be paid to the correct phase sequence, figure 3.13, the correct connection of the conductors to motor and starter. Incorrect phase sequence can lead to very high current peaks during the cold switch-over pause, due to the easy torque reduction following re-start. These peaks can damage the motor windings and stress the controlgear unnecessarily. The rotation of the motor has to be considered as well.

Figure 3. 12. Phase Sequence Connection

A sufficient time period has to be maintained between the star contactors deenergisation and the energisation of the delta contactor, in order to safely extinguish the star contactors disconnecting arc before the delta contactor is energised. During a switch-over which is too fast, a short circuit may develop via the disconnecting arc. The switch over time period, however, should be just long enough for an arc disconnection, so that the speed decreases as little as possible. Special timing relays for a star-delta switch over fulfil these requirements.

26

3.1.2.2. Enhanced star-delta starting If the torque during normal star-delta starting is insufficient to accelerate the drive in delta connection to the approximate operational speed, then the enhanced star-delta start is utilised. With an increased torque, however, the current consumption during start-up also increases. A difference is made between: 1. Combined star-delta starting 2. Partially wound star-delta starting Both types require motors with accordingly tapped windings. The same guidelines for normal star connected starters apply to motor connection and contactor operation. 3.1.2.2.1. Combined star-delta starters In this case, the motor windings are usually divided into two equal halves. During start, half a winding is switched in delta, the other half in star. Therefore, the term combined is used. This results in a correspondingly higher starting torque. The wiring circuit can be seen at figure 3.14.

K1M = Main contactor K2M = Delta contactor K3M = Star contactor

Figure 3. 13. Wiring Circuit of Combined Star-Delta Starter 27

3.1.2.2.2.Partially wound star-delta starting In this case, the motor windings are also subdivided. During star connection only the main winding, a part of the entire winding, is used. The wiring circuit can be seen at figure 3.15.

K1M = Main contactor K2M = Delta contactor K3M = Star contactor

Figure 3. 14. Wiring Circuit of Partially Wound Star-Delta Starter

3.1.2.3. Uninterrupted star-delta starting The term open transition is used to describe this method because the motor is momentarily disconnected from the line when changing from the wye to the delta configuration. The wiring circuit can be seen at figure 3.16. This method has one important disadvantage. Depending on the loading of the motor and the timing of this transition the resulting surge in current and torque could produce electrical and mechanical shocks on the system as seen at figure 3.16.

28

Figure 3. 15. Speed Characteristic Curve of Uninterrupted Star-Delta Starting at Open Transition

In some cases the instantaneous current peaks can exceed even the locked rotor current for short durations. Electrically the consequence of the instantaneous peaks could be power fluctuations or losses. Mechanically the increased torque resulting from the current spike could be enough to damage system components.

K1M = Main contactor K2M = Delta contactor K3M = Star contactor K4M = Transition contactor R1 = Transition resistors
Figure 3. 16. Wiring Circuit of Uninterrupted Star-Delta Starter 29

This connection prevents a drop in the motor speed during the switchover from star to delta, and therefore, the following current peak is kept low. Before the star contactor opens, a transition contactor (K4M) closes the motor circuit via resistors in delta. This prevents an interruption of the motor current during switch-over and the motor speed remains practically constant. Afterwards, the delta contactor K2M creates the final switching status and throws off transition contactor K4M. 3.1.2.4. Star-delta Characteristic In tis method initially the motor connected to the star connection, so the torque of the motor will be decrease down to approximately 33% of full load torque. When the rotor speed reach a value then the connection of the motor will be changed to delta connection and giving more torque of the motor, the torque speed characteristic can be shown at figure 3.18. In case of the voltage applied to the stator winding decrease when it is connected to star connection, so the current will be decrease to 33% current of full voltage, as seen at figure 3.19. Then when the connection changed to delta connection, there is some peak current and the torque will be increase directly.

Figure 3. 18. Torque/Speed Curve at Star-Delta Start

Figure 3. 17. Current Curve of Star-Delta Start 30

Advantage simple starting methods cheap starting current reduction

Disadvantage rugged starting when transition starting torque is low motor should have a typical input terminal condition high current when transition open condition when transition time of open condition should be done to avoid short circuit motor can stop when open condition

Table 3. 4. Advantages and Disadvantages of Star-Delta Starter

3.1.3

Autotransformer Starter An autotransformer starter enables the start of squirrel-cage motors

using a reduced starting current, since the voltage is reduced during start. Contrary to a star-delta connection, only three wires to the motor and 3 motor connections are required. During start-up, the motor is connected to the autotransformers tappings. This means that the motor starts up with a reduced voltage and a correspondingly low current. The autotransformer reduces the current in the mains supply line further and in accordance with its ratio. The autotransformer starter has a good torque-current take-up ratio based on the taping used.

Figure 3. 19. Autotransformer Starting Ilustration

31

In order to adapt the motor start characteristics to the torque requirement, auto-transformers are usually equipped with some selectable tappings. When the motor has almost reached its rated torque, the star connection on the transformer is opened. Open transition is simpler for logic but can cause current transients during the transition between taps. The transformers partial windings act as reactans in series to the motor windings, and therefore, like the uninterrupted star delta connection, the motor speed does not drop during switch over. After the main contactor has been switched in, the motor windings are applied to the full mains voltage. Finally, the transformer is disconnected from the mains. Depending on tapping and the motors starting current ratio, the starting current amounts to 1 until 5 times of nominal current. The wiring circuit can be seen at figure 3.21. The available torque is reduced in ratio to the starting current. With the star and autotransformer contactors closed, the motor is under reduced voltage. Consequently the torque is reduced as the square of the applied voltage.

Figure 3. 20. Wiring Circuit of Autotransformer Starter

32

As we have derived above, as the voltage to the motor winding is reduced, the current to the motor is reduced in direct proportion while the torque value is reduced by the square of the reduction of voltage. A common torque / speed curve for an autotransformer is shown below in Figure 3.22 and compared to the across the line torque / speed curve. The across the line curve is shown in red and the autotransformer curve is shown in blue.

Figure 3. 21. Torque/Speed Curve for an Autotransformer Starter

Some of the advantages of the autotransformer is the reduction in line current as compared to motor current due to transformer action. The disadvantage of the autotransformer are size, cost, limitation of taps, and logic required to implement. At the time before the tap contactors open to disconnect the motor from the transformer and another contactor closes connecting the motor to the supplies. This can be explained, when the transformer is energizing, it produces inrush currents that are rich in harmonic components for a certain period. Hence, an overvoltage waveform appears caused by the third harmonic resonance in the wiring circuit. When the third harmonic currents
33

as such high which freely circulate in the wye side, causes the Total Harmonics Distortion as much as 18.9%. After the transformer tapping takes place, the triplen harmonic currents will reduce to the lowest, when the currents are in balanced condition.
Advantage reduction in starting current can use some tap changing Disadvantage large size high cost in autotransformer limitation of taps harmonic in tap changing rugged in starting losses because of autotransformer Table 3. 5. Advantages and Disadvantages of Autotransformer Starter

3.1.4

Start via Reactans or Resistors The voltage applied to the motor is reduced by ballast reactans or

resistors, as is the starting current. The starting torque is reduced by the square of the current reduction.

Figure 3. 22. Starting via Reactans or Resistor Ilustration

The series reactance or resistance , Zp, can be added to the apparent motor impedance so the equivalent impedance is:

The stator Voltage at the motor side is calculated as:

34

3.1.4.1. Primary Reactor Starting During the off state, the motor resistance is low. A large percentage of the mains voltage is reduced at the ballast reactans. Therefore, the motors starting torque is considerably reduced. As the torque increases, the voltage applied to the motor increases due to a reduction in current consumption and the vectoral voltage division between motor and the ballast reactance. This leads to an increased motor torque. After a successful run-up, the reactans are short-circuited. The starting current is reduced depending on the required starting torque.

Figure 3. 23. Wiring Circuit of Primary Reactor Starting

35

A common torque / speed curve for a primary reactor starter is shown in Figure 3.25. and compared to the across the line torque / speed curve. The across the line curve shown is shown in red and the primary reactor starter curve is shown in blue.

Figure 3. 24. Torque/Speed Curve of Primary Reactor Starting

One of the advantages of the primary reactor starter is the reduction in line current with less heat dissipation than the primary resistor starting circuit. The disadvantage of the primary reactor starter is the poor power factor caused by the additional inductance in the start circuit and the limitation of initial voltage setting.
Advantage Reduction in starting current Less heat dissipation then primary resistor starting Simple method for motor starting Starting torque can be choose by calculating reactance value Disadvantage Poor power factor Use three external reactance for three phase motor losses because of external reactance used rugged starting

Table 3. 6. Advantages and Disadvantages of Primary Reactor Starter 36

3.1.4.2.Primary Resistance Starting In this case, cost-efficient resistors are used instead of the abovementioned reactans. The wiring circuit can be seen at figure 3.26. This method is less helpful in reducing the starting current for the same torque requirement, because the motor torque reduces as a value of the square of the voltage and the voltage applied to the motor increases only due to the motors reduced current consumption during increasing speed. It is better to reduce the ballast resistor step by step during start. But this requires considerably more switch gear. Another possibility is the use of encapsulated wet (electrolytic) resistors. For these resistors, the ohmic resistance reduces in line with the temperature increase caused by the starting currents heating capability.

Figure 3. 25. Wiring Circuit of Primary Resistance Starting

As we have derived above, as the voltage to the motor winding is reduced, the current to the motor is reduced in direct proportion while the torque value is reduced by the square of the reduction of voltage. A common
37

torque / speed curve for a primary resistor starter is shown below in Figure 3.27 and compared to the across the line torque / speed curve. The across the line curve is shown in red and the primary resistor starter curve is shown in blue.

Figure 3. 26. Torque/Speed Curve of Primary Resistance Starting

One of the advantages of the primary resistor starter is the reduction in line current while maintaining an improved power factor. The

disadvantage of the primary resistor starter is additional heat dissipation during start and limitation of initial voltage setting. They tend to be very large due to the heat dissipation requirement and, to change the initial voltage to the stator, the resistance must be changed which is usually a very time consuming and expensive option.
Advantage Reduction in starting current Good power factor then primary reactance starting Able to get smooth tapping with any kind of resistance Disadvantage Additional heat dissipation Use more tapping control to get more smooth tapping Losses because of external resistance 38

Table 3. 7. Advantage and Disadvantage of Primary Resistance Starter

3.1.5

Shunt Capacitance Connecting a capacitor in parallel to the motor can help

compensate the reactive demand from the motor during startup by supplying a leading current and thus improve the power factor while still achieving high starting torque because of the full voltage. This provides some relief to the supply source. The shunt capacitance may be left connected if they are properly rated so as to provide power factor correction; or removed as the motor approaches rated speed. The shunt capacitance that is left connected should never be sized larger than the motors magnetizing current. Capacitor starting may be used in conjunction with other starting methods. In general, capacitor starting is used for relatively large motors that need fast starting or improved efficiency during startup. Capacitor starting is a reliable and robust method for motor starting on weak electrical system.

Figure 3. 27. Shunt Capacitance Starting Ilustration

To implement the affect of the capacitor starting the equivalent impedance of the load is calculated as the apparent induction motor impedance in parallel with the capacitance, Zc = -jXc. The equivalent impedance is calculated:

One of the disadvantage of this method is there is a ferroresonance between capacitor and the reactans of the motor. Transients due to shunt capacitor switching may result in failure of the motor. The study shows that
39

energizing a motor and shunt capacitors at the same time can cause transient voltages that affect the motor provided that the transients product have the resonant frequency near one of the harmonics frequency. This will in turn produce substantial overvoltages that last for many cycles at the harmonic frequency.
Advantage reduction in starting current improve power factor high torque Disadvantage ferroresonance between capacitor and reactance of the motor transient due to capacitor switching can make harmonic frequency Table 3. 8. Advantages and Disadvantages of Shunt Capacitor Starter

3.1.6

Frequency Converter The frequency converter is sometimes also called VSD (Variable

Speed Drive), VFD (Variable Frequency Drive) or simply Drives, which is probably the most common name. The drive consists primarily of two parts, one which converts AC (50 or 60 Hz) to DC and the second part which converts the DC back to AC, but now with a variable frequency of 0-250 Hz. The block diagram of VSD can be seen at figure 3.29. As the speed of the motor depends on the frequency this makes it possible to control the speed of the motor by changing the output frequency from the drive and this is a big advantage if there is a need for speed regulation during a continuous run. In many applications a drive is still only used for starting and stopping the motor, despite the fact that there is no need for speed regulation during a normal run. Of course this will create a need for much more expensive starting equipment than necessary. By controlling the frequency, the rated motor torque is available at a low speed and the starting current is low, between 0.5 and 1.0 times the rated motor current, maximum 1.5 x In. Another available feature is softstop, which is very useful, for example when stopping pumps where the problem is water hammering in the pipe systems at direct stop. The softstop function is also useful when stopping conveyor belts from transporting fragile material that can be damaged when the belts stop
40

too quickly. It is very common to install a filter together with the drive in order to reduce the levels of emission and harmonics generated.

Figure 3. 28. Frequency Converter (VSD) Block Diagram

The AC variable speed drive consists of three main components: 1. Rectifier: The rectifier is connected to the supply network and generates a DC voltage supply which feeds the main DC link elements. For three-phase AC, six diodes are used, as seen at figure 3.30.

Figure 3. 29. Rectifier Circuit with 6 Diodes

Typically there are three pairs of diodes, each pair, though, is not the same kind of double diode that would be used for a full-wave single-phase rectifier, the rectified signal shown at figure 3.32. Instead the pairs are in series (anode to cathode). Typically, commercially available double diodes have four terminals so the user can configure them as single-phase split supply use, for half a bridge, or for three-phase use.

41

Figure 3. 30. Three Phase Signals

Figure 3. 31. Full-Wave Rectification Signals

For an ideal three-phase full-wave rectifier, the average output voltage is: Where: Vdc Vpeak = the DC output voltage = the peak value of half wave, = 3.14159

42

2. Intermediate circuit:

Figure 3. 32. Intermediate Circuit

The intermediate circuit as seen at figure 3.33 stores and smoothes the pulse direct voltage by using capacitors and inductors. The intermediate circuits capacitor C buffers the mains energy, which requires a high capacity. The motor connected to the drive draws energy from the intermediate circuit, and the capacitor is partially discharged during this process. The capacitor can only be charged when the mains voltage exceeds the intermediate circuits voltage. This means that the energy is provided by the supply when the mains voltage is close to its maximum. This results in current peaks which add up if several drives are switched in parallel. Therefore, an intermediate circuit DC link reactor is installed for higher powers. This iron core choke ensures that the current flow period on the mains side is delayed and thus current peaks are reduced. 3. Inverter

Figure 3. 33. Three Phase Inverter Circuit 43

Using the DC voltage, the inverter make a variable frequency and voltage with the required frequency and supply which can be varied to control speed/torque of a 3 phase induction motor, the common circuit of 3 phase rectifirer shown at figure 3.34. The inverter is the last main drive element in front of the motor. Various switching devices are used such as BJT (Bipolar Junction Transistor), GTO (Gate Turn Off Transistor), FET (Field Effect Transistor), IGBT (Insulated Gate Bipolar Transistor). Modern AC drives are usually equipped with IGBT. The new generations of these semiconductors achieve high performances of up to approximately 350 kW. The inverters components act as switches (controlled by a microprocessor) and depending on the frequency, switch positive or negative voltage to the motor winding. For most ac drives, the frequency and voltage changes are achieved by means of pulse width modulation (PWM). For a small total harmonic distortion, control pulse for the inverter can use a SPWM (sinusoidal pulse width modulation), as seen at figure 3.35.

Figure 3. 34. Pulse Width Modulation Signal 44

In this method we have two different signal one is carrier signal and the other one is reference signal. The carrier signal is a triangle signal and the reference signal is a sinusoidal signal that have the same frequency to the inverter output. In this case the frequency of carrier signal must be higher than reference signal. Because of in this case is used for three phase inverter, so the carrier signal and the reference signal can be see in figure 3.36.

Voltage

Time Figure 3. 35. Carrier and Reference Signal of PWM

4. Control circuit The control circuit is responsible for the operation, monitoring and protection of the entire AC drive. It is here that all input signals to the drive are acted upon to generate the most appropriate way to control the Inverter itself. Since the output of the VSD can have a variable voltage and variable frequency, the VFD can provide full load torque throughout the speed range of 0 rpm to rated rpm of the motor. Ideally, the motor torque is proportional to the square of the ratio of stator applied voltage. Therefore, to provide full load motor torque throughout the speed range of 0 rpm to full load RPM, the voltage output of the VSD normalized to the motor nameplate voltage must
45

stay in proportion to the output frequency normalized to the rated motor frequency. This is known as a constant torque volts to hertz. In practicality, even though Rs and Rr are much less than Xe, they are not zero and, as such, when the applied stator frequency is reduced the applied voltage is reduced but not by as much as the reduction in stator frequency. This is because, when the stator frequency is reduced, the value of the denominator on the right is reduced but not by the same scale as the reduction in frequency due to the constant values of Rr and Rs. Because of this, the denominator of the full equation is reduced but by an amount slightly less than the magnitude of the reduction of frequency. To maintain full torque, the voltage must be reduced in proportion to the denominator. Since the reduction of the denominator is slightly less than the reduction of applied frequency, then the reduction of the voltage normalized to motor nameplate voltage is slightly less than the reduction of applied frequency normalized to the motor nameplate frequency. For example, in an ideal application when starting a 50Hz, 4160 VAC motor at an initial frequency of 1 Hz, the ideal value for motor voltage at 1Hz would be (1/50)*4160 = 83,2 VAC. The curve of voltage/frequency can be seen at figure 3.37.

V(vol t) 4160

50

f(Hz)

Figure 3. 36. Voltage/Frequency Curve of Control Circuit

46

Since the VSD is applying a variable frequency, it is maintaining the motor at or above full load speed at all times and, therefore, it maintains motor current draw at or below motor full load amps at all times, like seen at figure 3.38. This capability of the VSD to maintain full load torque

throughout the speed curve while maintaining motor current at or below full load amps makes the VSD an excellent method of reduced voltage starting.

Figure 3. 37. Torque/Speed Curve for an VFD set to 10%(6 Hz) Increments

Advantages The lack of a torque pike during transition The ability of high values of starting torque The ability to set the peak current draw and peak torque value The lack of any mechanical contactors The VSD has no moving parts and no arcing occurring during transition like electromechanical soft start units The maintenance of VSD is easy Since motor current normally never exceeds full load amps of the motor, the threshold is usually 2 times motor full load amps.

Disadvantages VSD usually expensive because of using many power electronic devices Losses because of power consumsion by the component such as mosfet or IGBT

Table 3. 9. Advantages and Disadvantages VSD Starter 47

3.1.7

Softstarter In a softstarter the value of voltage given to the motor stator is made

variable. It has thyristors in the main circuit, and the motor voltage is regulated with a value of firing angle given to the thyristor, which can be seen at figure 3.39. The softstarter makes use of the fact that when the motor voltage is low during start, the starting current and starting torque is also low.

KM1 FR1 Q1

Main Contactor Overload Relay Softstarter

Figure 3. 38. Softstarter Single Line Diagram

Figure 3. 39. Voltage Signal Output

One of the benefits with this starting method is the possibility to adjust the torque to the exact need, whether the application is loaded or not. Another feature of the softstarter is the softstop function, which is very useful when stopping pumps where the problem is water hammering in the pipe system at direct stop as for star-delta starter and direct-on-line starter. The softstop function can also be used when stopping conveyor belts to prevent material from damage when the belts stop too quickly.
48

By using an softstarter the voltage is reduced during the start sequence with the result that the motor torque is reduced. During the start sequence the softstarter increases the voltage so that the motor will be strong enough to accelerate to the nominal speed without any torque or current peaks.

Figure 3. 40. Torque/Speed Curve when Using a Softstarter

Because the initial voltage given to the motor is smaller, so the torque of the motor will be decrease. But, the voltage of the motor will be increase in case of rotor speed increase, then the motor torque will be increase like a graph shown in figure 3.41.

Figure 3. 41. Current Curve when Using a Softstarter

49

In the softstarter, the starting current will not as high as a current absorb in direct-on-line connection. The starting current will reduced to a nominal value and increase based on the motor speed like shown in in figure 3.42. In the softstarter included soft stop there are three condition: a. Initial voltage b. Start ramp c. Stop ramp

Figure 3. 42. Start Ramp and Stop Ramp Diagram of Softstarter

a. Initial voltage Sometimes named pedestrian voltage or torque, this is the point from where the softstarter starts or stops its ramps. The torque of the motor will drop with the square of the voltage and if the voltage is set too low, for example 20 %, the starting torque will become 0.22 = 0.04 = 4 % only, and the motor will not start from the very beginning. Therefore it is very important to find a level that is just high enough to make the motor take off directly to avoid unnecessary heating because of lock rotor condition. b. Start ramp Start ramp is the time from were the softstarter start its ramp (initial voltage) until full voltage is reached. The ramp time should not be too long, as this will only result in unnecessary heating of the motor and a
50

risk of the overload relay to trip. If the motor is unloaded the start time for the motor will probably become shorter than the set ramp time, and if the motor is heavily loaded, the start time will probably become longer. c. Stop ramp Stop ramp is used when a soft stopping of the motor is required, for example a pump or a conveyor belt. The stop ramp is the time from full voltage until stop voltage (initial voltage) is reached. If the ramp time is set to zero the stop will be like a direct stop. 3.7.1. Current limitation Current limit can be used in applications where a limited starting current is required, or at a heavy-duty start when it is difficult to achieve a perfect start with the setting of the initial voltage and the start ramp only. When the current limit is reached, the softstarter will temporarily stop increasing the voltage until the current drops below the set limit, and then continues ramping up to full voltage.

Figure 3. 43. Action of Current Limiter on the Output Voltage

From the graph shown in figure 3.44 we know that the voltage given to the motor will not increase during the current has reach the current limit.

51

Figure 3. 44. Current Limit Function in Softstarter use

Because the voltage will not increase during the current has been reach the current limit, so that the current will not increase. Then when the current start to decrease the voltage will start rising again. In the different load value, the setting of start ramp, stop ramp, initial value, and current limit will be different appropriate to the system requirement. For an example there is some type of setting the softstarter to the different system:

52

Example of softstarter settings without current limit function:

Table 3. 10. Setting when Using a Softstarter with Current Limit Function

If fragile material, use 10 seconds.

53

Example of softstarter settings with current limit function:

Table 3. 11. Setting when Using a Softstarter without Current Limit Function

54

1) If fragile material, use 10 seconds.

Advantage Disadvantage possibly to adjust the torque to the reduction of starting torque exact need losses because of power electronic possible to use softstop function used reduction in starting current harmonic because of switching soft acceleration methods there is no torque peak initial voltage to avoid lock rotor condition current limiter function acceleration time can be arranged Table 3. 12. Advantages and Disadvantages of Softstarter

3.2.

Starting Methods Comparison Table 3.12 show the common problems when starting and stopping motors

with different starting methods.

Type of Starting Method Type of Problem Slipping belts and heavy wear on bearings High inrush current Heavy wear and tear Directon-line Yes Yes Yes Star-delta / primary impedance Medium No Yes (loaded start) Yes Medium Yes Shunt Capacitor Autotrafo Medium No Yes (loaded start) No No No No

Drives No

Softstarter No

on gear boxes No Damaged goods / Yes Yes Yes Yes products during stop Water hammering in p Best Yes Yes Yes Yes system when stopping Solution Yes Transmission peaks Yes Yes Yes No Table 3. 13. Comparison Between Starting Methods

No Reduced No

As we have learn before, a correct choise for the motor starting is need to given more attention for the best result. In this case, the shipping pump motor is a big motor, so it need to analise the best starting method used for this motor.

55

A direct on line method is very bad for this motor, it is because the starting current will be very high and can make the system become instable. A star-delta method can not be choosen for this motor. In the shipping pump motor only there are three outputs terminal. It mean that the motor internally connected into delta connection, so the star connection can not be used for this motor. A primary impedance starting for this motor actually can be used, but the motor starting will be rugged. If we want to make the starting smoother, more contactor will be needed for this method. A shunt capacitor is not good enough for this motor. The ferroresonance can make the motor do not operating well and can make heat disipation by the ferroresonance. Besides, the starting current with this method is still high enough. An autotransformer starting is the current condition used for this motor. The starting current is still high enough and the tapping only happen in twice. A softstarter is a good choise for this motor because the softstarter can make the starting current lower and the motor starting will become smooth. On of the disadvantage of this methods is there are harmonic because of switching of the thyristor but generally this method is good enough for this motor. A variable speed Drive is the best choice for this motor. It is because the starting torque is bigger then the other starting methods. But in this case, the cost for a VSD is very high. It can be concluded that it is more effective to buy one more generator then buy a variable speed drive. For the comparison between softstarter and variable speed drive can be seen in Table 3.13.
Description Advantages SOFTSTARTER Simple to achieve lower starting current. VARIABLE SPEED DRIVE Motors maximum torque is possible to be utilised for starting 56

 Moderate cost effectiveness below specific voltage and power level. Ability to control stopping time.

purpose. Full flexibility to adjust starting time. Simplest means to achieve lowest possible starting current (even below nominal current) Ability to control stopping time. VSD has no additional voltage drop on the network during start and can start against full load

Starting torque reduced proportionally with starting current. Starting time prolonged only. Motor have to be engineered / Disadvantages derated to meet specific starting torque and current requirement. Starting cycle is limited on both motor and softstarter. There are harmonic because of switching methods

Highest investment cost. Losses because of the power electronic component used

Table 3. 14. Comparison Between Softstarter and VSD

3.3. Selected Starting Method Simulation For the next study about starting methods of an induction motor, some simulation can be done in a simulation program. In this case PowerSIM program will be used to simulate some different starting methods to know the differences characteristic of them. For this study we compare the differences among the direct-on-line, autotransformer, and softstarter methods. For this simulation we use an induction motor connected in delta connection to the three phase power supply 4160 volt 50 Hz. The induction motor

57

is a squirrel cage motor and the parameter for this simulation is showed in Figure 3.46.

Figure 3. 45. Motor Parameter for Simulation

The rotor of the induction motor used connected to the load with the moment of inersia about 1000 kg.m2. 3.3.3. Direct-on-line For this methods the motor connected directly to the supply voltage. And the schematic diagram of this method showed in Figure 3.47.

Figure 3. 46. DOL Simulation Schematic Diagram

58

The voltage supply is three phase with a voltage is 4160 volt and the frequency is 50Hz. The motor connected to the load and have a speed sensor to detect the speed of the rotor. Current sensor used to this application and connected to the RMS block to get the RMS value of the current each line. The speed of the motor will increase fast because of the torque of the starting is high. One of the advantage of this method is the nominal speed will be reach in a short time. The motor used in this case have six poles and the frequency applied to this motor is 50 Hz, so the synchronous speed is:

Figure 3. 47. Graphics of Motor Speed in DOL Starting

For direct on line starting have many disadvantage such as very high starting current, high pressure in bearing, and for the definite power supply it can influence the stability of the system like the decrement of frequency and operation of under frequency relay.

59

The current characteristic when using direct on line method can be seen in Figure 3.49. The current will be very high at first time connected to the line and than go down to the nominal current.

Figure 3. 48. Graphic of Motor Current in DOL Starting

3.3.2. Autotransformer For starting an induction motor using autotransformer, we need two autotransformer with different step output that can be applied to the load. The step base on the data from lawe-lawe terminal will done in two step, first in 50% than go to 100%. When the motor connected to the 50% tap, the voltage applied to the motor will reduce half of its nominal voltage. Therefore the slip of the motor will be higher, so the rotor start to move but the starting current will be reduced than the direct on line method. The 50% tap will be done in sone delay then change it to the 100% tap, and then the motor will be by passed to the system. In this case, for the impedance of each autotransformer used is two milihendry. The schematic diagram of this starting method can be seen in the Figure 3.50.

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Figure 3. 49. Autotransformer Simulation Schematic Diagram

When it connected to the 50% tap, the speed of the motor will increase slower than when it by passed to the system, it because when it connected to 50% tap, the voltage applied to the motor will be reduced, so the torque of the motor will be reduced to. Then when it has reach its delay value, the voltage applied to the motor will become its full voltage, so the torque of the motor will increase directly and the acceleration of the motor will become higher. Therefore in this methods will take more time to reach its nominal speed then compared to the direct on line system.

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Figure 3. 50. Graphic of Motor Speed in Autotransformer Starting

For the characteristic of the starting current of this method can be seen in the Figure 3.52. When it connected to the 50% tap the current will be reduced, but when it changed to the by pass system, the current will be increase directly to its maximum value, then go down to the nominal current.

Figure 3. 51. Graphic of Motor Current in Autotransformer Starting

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3.3.4. Softstarter Almost equal to the autotransformer method, the voltage applied to the motor will lower at the first time, then increase to its nominal voltage value. But the step of increment will be done in many step, so the increment of the voltage will be very soft. When the voltage has reach its nominal value, the motor will be by pased to the line voltage.

Figure 3. 52. Softstarter Simulation Schematic Diagram

For this simulation, the TRIAC is used to control the voltage applied to the motor. To control the TRIAC, a microcontroller should be used to make a trigger for this component. Therefore in this simulation use a simplified C block to generate the trigger. Then when it has reach its maximum value, the microcontroller will give some signal to make a by pass system to the motor. The source code of simplified C block can be seen bellow: static double n=1,sudut_sulut=0.0065,status=0; double Tperiod; Tperiod=0.01; if(status==1) {y2=1;} if(t>=((n*Tperiod)+sudut_sulut)-Tperiod) {
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y1=1; n=n+1;

if(sudut_sulut>0) { sudut_sulut=sudut_sulut-0.000001; if(sudut_sulut<=0){status=1;} } } else { y1=0; }

Because the source used to this motor is three phase voltage source, so there is a difference between the phase angle. The line is R, S, and T, line R has 00 phase angle, line S has 1200 phase angle, and line T has 2400 phase angle. Therefore, by using time delay block, the trigger source for line R can be used for the other line. For the speed characteristic can be seen in figure bellow. By using this method, the increment of the motor speed will take more time than direct on line and autotransformer method. So, the speed of the motor will going up slowly.

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Figure 3. 53. Graphic of Motor Speed in Softstarter

For the current characteristic of the softstarter will be lower as we can see in Figure 3.55. For the first time, the torque of the motor used to agains the lock rotor torque. Then, when the lock rotor condition has been passed, the torque of the motor will be increase so the current of the motor will increase directly. Because of of its switching method and the reactance component of the motor, so there is some harmonic distorsion by this method. By using this method, the starting current will be reduced, based on this simulation the starting current is not as very high as the starting method by using direct on line or aotutransformer.

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Figure 3. 54. Graphic of Motor Current in Softstarter

3.2.

Comparison : Waste Water Pump Softstarter 3.4.1. Waste Water Pump at Lawe Lawe Terminal At Lawe Lawe Terminal there are 4 motors that already use softstarter as its starting device, waste water pump A, B, C, and D. The type of motor used for those pump is an induction motor which has same type with shipping pump motor. The complete information about waste water pump parameter can be seen in table 3.14.
Waste Water Pump #A,C,D Manufacture Type Power Speed Rated Voltage\Phase\Frequency Ampere Reliance Electric Type P, frame 444TS 125 HP 2960 RPM 415 Volt \ 3 phase \ 50 Hz 159 Ampere Waste Water Pump #B Manufacture Type Power Speed Rated Teco Frame 444TS 125 HP 2950 RPM

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Voltage\Phase\Frequency Ampere

415 Volt \ 3 phase \ 50 Hz 168 Ampere

Table 3. 15. Waste Water Pump Parameter

From waste water parameter data at table 3.14, the starting current (direct on line start) of waste water pump can be calculated using following formula. (for three phase motor)

(for single phase motor) Where : IL HP = Motor starting current = Motor horse power

KVA/HP = Constant depend motor type according to NEMA Locked Rotor KVA Code E = Motor Voltage

Code kVA/HP Approx Mid. Range Value A 0.00-3.14 1.6 B 3.15-3.54 3.3 C 3.55-3.99 3.8 D 4.00-4.49 4.3 E 4.50-4.99 4.7 F 5.00-5.59 5.3 G 5.60-6.29 5.9 H 6.30-7.09 6.7 J 7.10-7.99 7.5 K 8.00-8.99 8.5 L 9.00-9.99 9.5 M 10.00-11.99 10.6 N 11.20-12.49 11.8 P 12.50-13.99 13.2 R 14.00-15.99 15 Table 3. 16. NEMA Locked Rotor KVA Code

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So, the starting current of waste water pump with DOL starting is :

The calculation result shown that waste water pump starting current is 2294 ampere, its 14 times bigger than waste water pump normal current, 160 A. By this result known that when starting with DOL start, waste water pump will drain high starting current and also more power from supply. This is will cause a bad effect to the motor and the electricity system. 3.4.2. Payne Engineering Softstarter : 18EM3 4 150 HP3 Softstarter used for waste water pump motor starter is a softstarter product made by Payne Engineering Company. Payne Engineering Company was founded in Princeton, New Jersey in 1959, Payne Engineering Company (now Payne Controls Company) initially supplied wind-tunnel

instrumentation for V/STOL testing, DC drives, variable frequency AC motor controls, and strain-gage force measuring systems. With the then limited availability of the very expensive G.E. and Westinghouse prototype thyristors, the first line of solid state relays and power controls were introduced.

Figure 3. 55. Payne Engineering Softstarter 18EM3-4-150HP3

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The softstarter 18EM3-4-150HP or called SENTROL EM3 is a solid state reduced voltage motor starters designed to start three phase AC motor softly, by applying adjustable, automatically increasing voltage ramp to the stator windings on application of a control signal. Adjustable starting voltage and decreasing voltage ramp settings are also provided. Provision for two-or three wire control and a form C auxiliary contact are standard features, and a thermal overload relay is provided for motor overload protection.

Figure 3. 56. Wiring Circuit of Payne Engineering Sofstarter

The Payne Engineering softstarter model 18EM3-4-150HP3 has two main wiring circuit, the power wiring and control wiring shown at figure 3.58. The explanation of each wiring describes in the next section.

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Power Circuit Power circuit is a wiring circuit to connect AC supply to motor. Input terminal (L1, L2, and L3) receive AC voltage from supply, beside output terminal (T1, T2, and T3) deliver AC voltage to motor. At power wiring circuit there are two protection device, fuse and overload relay. The fuse placed in input terminal, whereas overload relay placed after output terminal. The current transformer (CT) of overload relay has rating 600/5 and ratio 115. Overload relay has an output NC contactor (normally close contactor) which wired to control wiring.

Figure 3. 57. Power Circuit wiring of Payne Engineering Softstarter

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The SCR and diode used for adjusting AC voltage is in series with input terminal and output terminal. Gate input SCR is triggered by pulse wave received from Sensor/VBO Card. At power wiring there are also step down transformer, control transformer, used to supply low AC voltage to control module. Input transformer is at 460 V from two of three phase line and it protected by a fuse while the output is at 24 V. Control Circuit Control circuit of Payne Engineering softstarter 18EM3-4-150HP3 is used for control and adjusting initial voltage and starting/stopping time. This circuit consist of three module, Ramp Control Board, Pulse Card, and Sensor/VBO Card. Those circuit wired as shown at picture 3.60.

71 Figure 3. 58. Control Circuit wiring of Payne Engineering Softstarter

Ramp Control Board Board used for adjusting initial voltage and acceleration/deceleration time. This board consist input terminal and output terminal such as : 1) Terminal H and J. Input voltage terminal from secunder control transformer. Rated 24 V. 2) Terminal A,B,C and D. Those terminal can be combined become two wire control or three wire control depend on user control connection desired. The explanation of this control will be described in the next section. 3) Start Volt, Accel , and Decel trimmers. Used for adjusting initial voltage, starting time and stopping time. 4) Terminal G, F, E. Auxiliary terminal used for custom combination. Terminal G-F form a normally close contactor, while terminal F-E form a normally open contactor. 5) PL1. Signal control output to Pulse Card Pulse Card This module will generate SCRs trigger pulse. The triggered pulse is depend on voltage and accel/decel adjustment at ramp control board. It has six output terminal, those are : 1) GATE 1 : trigger pulse for SCR 1 2) REF 1 : trigger pulse reference for SCR 1

3) GATE 2 : trigger pulse for SCR 2 4) REF 2 : trigger pulse reference for SCR 2

5) GATE 3 : trigger pulse for SCR 3 6) REF 3 : trigger pulse reference for SCR 3

Sensor/RC/VBO Card This card has function of zero crossing detector. Has the same output terminal like Pulse Card output terminal.

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Softstarter Connections Load Connections Connect a three phase load output to terminals T1, T2, and T3. A three phase AC induction motor should be connected to the output terminals shown in the general schematic diagram (Figure 3.59). The horsepower, amperage, and voltage ratings of the connected motor must never exceed the maximum stated starter ratings.

Figure 3. 59. Power Circuit Schematic

Power Connections Connect proper three phase power to terminal L1, L2, and L3, according to figure 3.59. Input voltage must match the starter nameplate rating. Use on another voltage may damage the device. Control Connections

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SENTROL EM3 solid state reduced voltage starters are actuated by the application of an external control signal (90-220 VAC), and may be configured for either two or three wire control.

Figure 3. 60. SENTROL EM3 Ramp Card, Showing 2-Wire Control and 3-Wire Control

Two wire control : apply proper control voltage to terminals A and B to turn starter on: removal of the control voltage turns the starter off. Three wire control : use push button configuration as shown in figure 3.60. Seal contact : a normally open seal contact on terminals C and D, rated 2 amps at 120 VAC (1 amp at 220 VAC), closes on application of control voltage to terminals A and B.

Auxiliary contacts : Form C auxiliary contact at terminal E, F, G operates at the end of the Accel Ramp and the beginning of Decel Ramp. Rated 2 A at 120 VAC (1 A at 220 VAC)

Set-up and Adjustment SENTROL EM3 starters, which one is 18EM3-4-150HP3 used for waste water softstarter, are preset for 10 second accel and decel ramp times,
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and for start volts of 40% of rated input. All SENTROL EM3 consist of 3 adjustment, each should be set for maximum performance of each motor/load combination.

Figure 3. 61. Ramp Card Details, Showing the Location of Adjustment Trimmers

a) ACCEL Adjustment 2700 trimmer sets the length of the open loop increasing voltage starting ramp. Field adjustable from 0 20 seconds. Clockwise adjustment increases ramp time. Actual time required for motor to accelerate from standstill to rated speed depends on motor/load characteristic. b) DECEL Adjustment 2700 trimmer sets the length of the open loop decreasing voltage starting ramp. Field adjustable from 0 20 seconds. Clockwise adjustment increases ramp time. DECEL ramp removes voltage from motor gradually on shut down, but is not a brake, nor does it affect
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motor overrun or free wheeling on high inertia loads. Actual time required for motor to decelerate from full speed to stand still depends on motor/load characteristics. c) START VOLTS Adjustment 2700 trimmer set initial voltage level applied to the motor windings when starter is actuated, from which point the accel ramp begins. Field adjustable from 0-60% of line voltage. Clockwise adjustment increases the start volts level.

3.4.3. Waste Water Pump Performance Test Those calculation result will be compared to performance of existing waste water pump starting current with softstarter. To know the affect of using softstarter for starting waste water pump A, B, C, and D, a performance test was done. By that, the data of starting current each pump, normal current each pump, and current when operating pumps in combination can be

known. Table below will show the data of performance test waste water pump which already using softstarter.

No. 1 2 3 4

Pump WW A WW B WW C WW D

Normal Current (ampere) Ph. R Ph. S Ph. T 121 121 119 120 117 119 114 117 117 123 118 122

Starting Current Peak (ampere) 470 633 475 480

% Starting Current 390.582 533.427 409.483 396.694 % % % %

(a)

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No. Combination 1 2 3 4 5 6 7 A-B A-C A-D C-D A-B-D A-C-D B-D-C

WW pump A R S T 106 107 105 94 98 93 112 112 110 95 95 96 97 94 93

Normal Current (ampere) WW pump B WW pump C R S T R S 108 106 106 108 109 100 96 97 93 95 93 93 88 89 91 90 101

T 106 99 90 88

WW pump D S

111 106 94 96 95

105 101 90 90 89

107 104 91 92 91

(b)
Table 3. 17. Waste Water Pump Performance Test. (a) Stand alone starting test. (b) Combination starting test

From performance test data, known that starting current for waste water A is 3.9 times bigger than its normal current. Starting current for waste water B is 5.3 times bigger than its normal current. Starting current for waste water C is 4.09 times bigger than its normal current while starting current for waste water D is 3.9 times bigger than its normal current. From that performance test result, by using softstarter, the starting current of motor can be reduced from 14 times to 4 times its normal current. This result shows that using softstarter is better than using DOL starter, autotransformer starter, or wye-delta starter.

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CONCLUSIONS AND SOLUTIONS

From above working through and discussion, several conclusions and solutions can be found as follow : Shipping Pump motor still use autotransformer starting method with 2 voltage taps, 50% and 100%. Using autotransformer as starting method/device bear transformer losses such as, core loss, copper loss, and harmonic component. Shipping pump at Lawe Lawe terminal has 2th greatest power, 350 HP. The motor has high starting current and the starting of that motor cause system instability. Need to upgrade starting method of shipping pump motor technology using softstarter in order to reduce motor starting current and minimize the affect of starting motor to electricity system. For motor which already use softstarter, waste water pump motor, the starting current reduce from 14xIn (by direct on line) become 4xIn.

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REFERENCES

Chevron, Electrical One Line Diagram of Lawe-lawe Terminal Chevron, Shipping pump wiring diagram Westinghouse Electric Corporation. Class 11-602 AMPGARD 50L2, Schematic Diagram Basic Motor Formulas and Calculations. Baldor Electric Company, copyright 2007 Descriptive Bulletin. AMPGARD 2500 and AMPGARD 5000, medium voltage fused starter. Westinghouse Electric Corporation Kjellberg, Magnus.2003.ABB Softstarter Handbook ABB. Medium Voltage Solid State Starter http://www.engineeringtoolbox.com/pumps-speed-torque-d_1114.html

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engineeringtoolbox.com http://www.ittwww.pl/Files/1196840.pdf Eltamaly.Ali M.Hardware Implementation of Softstarter of Three Phase Induction Motor.King Saud University Tinamics Co., Ltd.Basic of Low Voltage Softstarter Tinamics Co., Ltd.Medium Voltage Digital Softstarter Powersim Technologies Inc. 1999. PSIM User Manual Blaire, Thomas. 3 phase AC motor starting methods. Florida. jacobson, David AN.Examples of Ferroresonance in a high voltage power system Solcon. medium voltage softstarter applicationn solution H.H. Goh,M.S.Looi,B.C.Kok.2009. comparison between direct on line, star delta, and autotransformer induction motor starting method in terms of power quality.hong kong Solceson, Mark G. 2006. Softstartered induction motor modelling and heating issues for different starting profiles using a flux linkage ABC frame of reference Rockwell Automation.1997.basic for practical operation motor starting Rockwell Automation.Wye-delta and solid state starter application guide

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