UR Upgrade Program

2 UR Upgrade Program

9/9/2015

Outline

1. Introduction

2. Why Upgrading?

3. Who Is Affected?

4. How to Upgrade?

5. Benefits of the New Upgraded UR

1. Introduction

. . . Proven State of the Art Family of P&C Systems

UR Protection and Control Devices

• Common hardware

• Plug and play modules

• Reduced stock of spare parts

• Reduced maintenance cost

• Swappable modules

Modular design that delivers unparalleled flexibility and fights obsolescence

2. Why Upgrading?

Lifespan of Digital Protection Relays… • Determining lifespan factors of any digital relays are based on environmental

conditions, application of the relay and individual component age.

• Old relays may:

• Lower the reliability and process uptime

• Increase in service/maintenance costs

• Lower personnel safety

Proactive action is crucial → Solution: Retrofit

• Lower the electrical equipment lifespan

• Not comply with new requirements (i.e.

smart grids)

• Have problem with replacing components

unavailability due to obsolesce

• Typical lifespan Bathtub curve

• Infant Mortality

• Weak Solder joint; cracked ceramic caps or silicon die;

Design margin issues

• Steady State

• Single event burnout; Silver/NiCr corrosion; Opto-

isolator/LED degradation; Airborn particles

• Wearout

• Electrolytic caps; solder joint fatigue; connector

corrosion; Package delamination

UR Power Supply Life Expectancy Continuous Design Improvements

1H Power Supply – 1998 -> 2004

• Design life 10 years @40DegC, confirmed by field return data

• At 10 year point, the device failure rate is expected to increase at a rate of 1% per year

• Life of Electrolytic capacitors affected by heat and electrical stress

• Analog subsystem susceptible to failure of C27/C28 (8V Rail) (GER-4477)

• Failure of 27/C28 (8V Rail) may result in incorrect metering and false trip

RH Power Supply – 2004 -> 2014 (Jun)

• Utilized newer Capacitor technology to increase design life of 15 years @40DegC

• At 15 year point, the device failure rate is expected to increase at a rate of 1% per year

• Added 200mS ride through capability

• KEMET Capacitor batch issue described in GER4012B (2005/2006)

SH Power Supply – 2014 (Jun)

• Eliminated C27/C28 & others, leaving only 1 long life reservoir capacitor for ride through

• Utilized new technology to give design life of 40 years at @45DegC

• 28% more output power, without increase in heat dissipation

• Micro controller on board to manage output rail sequencing

• Voltage rail monitoring to ensure analog & digital subsystems operate correctly

Solutions – Retrofit by Replacing

• Cost of new relay, accessories and spare parts

• Re-engineering costs(new drawings, settings,

trainings, tests, etc.)

• Panels modification costs(new cut-out, door,

blank/drop-in plates, wiring, relocation, etc.)

• Service, maintenance and outage costs

Validate complete IED

-New complete hardware

-New complete Firmware

Create new Engineering standards

-Create new drawings

-Create new settings files with re-configured I/O

-Create testing procedures

-Retrain all staff on new IED & S/W

Remove existing IED

-Disconnect all wiring

-Remove IED

Create new panel cut-out

Install new IED

-Install IED

Reconnect all wiring

-Test all wiring (point – to-point)

Commission new IED

-Test all IED functions

-Test all I/O from and to other devices and equipment

-Test all wiring

-Perform system tests

Months Months Days Days 1-2 Days

Solutions – Retrofit by Upgrading Using UR Replacement kits

• No need to replace the relay

• Not offered by all vendors

• No panel modification needed

• Compatible with the existing protection and control system

• Limited service, maintenance and outage costs

• Enhanced functionalities and new generation relay features

• Relays more than almost 10-year old are concerned.

Modular design provides seamless upgrades resulting in average savings of 50% on retrofit project.

10 UR Upgrade Program

9/9/2015

UR Upgrade Program Fast Replacement – Eliminates Rewiring & Reconfiguration Unique Modular draw out mechanism (no panel cut-out required)

Easy upgrade & retrofit without disturbing existing wiring

Draw out aged relay modules and install new modules - plug & use (no reconfiguring of I/O wiring to fit new terminal boards)

Minimize training & labor hours required for commissioning – reduce service costs (no wiring test and terminal inspection required, No tools required (replace all modules))

• UR Setup software compatibility (easy transfer of existing protection setting schemes)

• File conversion, file version selector, and file comparison tools for quick setpoint file modifications

Validate Only changes

-Only new CPU and DSP

-New firmware features

Update existing Engineering Standards

-Update drawings

-Convert settings files

-Update testing procedures

-Train staff only on changes

No need to remove existing UR

-Disconnect only communication wiring

-UR chassis remains

-No new panel cut-out

Replace UR modules

-Remove old modules

-Install new modules

-Reconnect communications wiring

Maintenance test UR

-Check all analog values

-Test enabled functions

-Test all UR I/O only

Weeks Weeks <1 Hour Hours Hours

11 UR Upgrade Program

9/9/2015

UR Upgrade Program Easy transition to enhanced next generation functions

Upgrade for a better reliability and security

• Proactive approach to compensate for electronic component aging

• New technological advancements on UR protective relaying systems

• Commitment on enhanced product performance improvement

Simplified process for ease of upgrade transition

• Arrange for advance replacements to meet scheduled outages

• Hardware upgrade kits available with an Upgrade Guide for seamless upgrades

Economical solution to revamp existing installed base products

• Proactive upgrade would minimize maintenance labor costs and maximize process uptime

• Offers special discounted rates on upgrade

3. Who Is Affected?

13 UR Upgrade Program

9/9/2015

Upgrade Recommendation Upgrade recommended for UR Devices 10 years and older

The recommended replacement for UR relays (versions 3.5 or below):

• CPU versions T, U, V DSP versions L, M, N, R, S

• Firmware versions: 7.xx and above

If existing standards dictate other versions, they can be offered.

CPU and DSP modules have to be changed, i.e. version 3 DSP’s are not compatible with later versions.

UR 3 DSP Recommended UR 7 DSP

8A 8L

8B 8M

8C 8N

8D 8R

UR 3 CPU Recommended UR 7 CPU

A T, U or V. If 2 serial ports required, UR 9E

C T or U

D T or U

UR Relays with Firmware 3.5 and below CPU Cross Reference

UR Relays with Firmware 3.5 DSP Cross Reference

4. How to Upgrade?

15 UR Upgrade Program

9/9/2015

Upgrade Process Simple selection, Fast replacement, Easy set-up, Economical

Determine if upgrade is required.

• UR model and serial numbers

• Existing firmware version

Obtain the replacement

kits.

• CPU-type required

• Specific firmware required

• Additional software options

• Contact local GE sales office

Settings conversions.

• By latest EnerVista UR setup software

Modules replacement

• Follow UR3 upgrade guide (GET-8550)

Pre-in-service checks and

testing

• Visual verification

•In-service maintenance tests

•Out-of-service maintenance tests

“Do it yourself guide: Upgrade guide!”

5. Benefits of the New Upgraded UR

Single Platform, Scalable Solution

“Incrementally Scalable” Single Platform Solution

UR Feature Enhancements-I Proactive approach towards enhanced quality, reliability and functionality

Protection • Multiple new applications • Breaker and a half capabilities for D60 and L90 • Breaker failure support for B30 and G60 • Incipient cable fault detection for F35 and F60 • New Trip Bus for all UR models • Watt-metric ground for D60, F60 and L90 • Voltage-dependent overload and Broken Rotor Bar for M60 • 100% stator and rotor using the GPM and Split-phase protection (G60)

• Teleprotection Inputs/Outputs for: • B30, C30, C60, D60, F35, F60, G60, M60, T35 and T60

Control • Enhanced breaker control:

• block open/close; • double-point status per phase with alarming

• Autorecloser extended to 4 shots, selectable activation modes and breaker initiated • Additional control functions (Capacitor, PID regulator, AVR)

UR Feature Enhancements-II From Firmware V3.50 to V7.xx

Monitoring • New elements for Power system components (CTs) monitoring

• Breaker arching for B30, C60, D60, F35, G60, L90, M60, T35 and T60 • PMU functionality on D60, L90, G60, G60, F60, T60 • Internal hardware monitors on DSP and voltage rails

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

Reliability • Enhanced environmental monitoring and capabilities • New DSP failure mode with enhanced diagnostic DSP • Enhanced design, validation and manufacturing processes

UR Feature Enhancements-III Bringing more to power system installations…

Software • Selected settings auto-configuration • One click records retrieval • Settings templates and more

Security • Role-based access control • Audit & recovery

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

Platform Enhancement • Enhanced CPU and DSP • Upgraded I/O & inter relay modules • New power supply • Multiple languages

UR Hardware Enhancements More Powerful CPU and Power Supply…

CPU

• Speed: much faster (400MHz vs. 64MHz) • Memory: 8 times more for events and oscillography and much faster (from SDRAM to DDR2) • Three independent Ethernet ports (MAC and IP addresses) • Maintains backward compatibility with existing hardware • Three types of CPU Modules

Power Supply

• Higher input voltage range (88 to 400VDC vs. 88 to 300VDC) • Overall output power increased (45W vs. 35W) • Voltage Rail monitoring on all rails vs. none • Isolation voltage level (2300VAC vs. 2000VAC) • limited use of electrolytic capacitors for ride-through 1 vs. 27 in LV & 10 in HV) • Microcontroller based power supply control vs. none • Over temperature protection vs. none

22 UR Upgrade Program

9/9/2015

• Best solution for relay retrofit without replacing it

• Not offered by other vendors

• Lower service, maintenance and outage time

• Enhanced reliability, Improved Performance

• Easy transition to enhanced next generation relay systems

• Ease of upgrade / replacement

• Compatibility with smart grid emerging needs.

• Use of well known UR strengths

• Under 10 year warranty coverage

Summary