Introduction to Surge Protection

Transcription

1 KL Automation Engineering Sdn Bhd Introduction to Surge Protection By Abu Bakar bin Yahya

2 OBJECTIVE 1. To give awareness on lightning and surge effects. 2. To discuss on unexplained surge effect DEGRADATION EFFECT. 3. To discuss on surge protection solution.

3 INTRODUCTION Scope: Project/Installation in Malaysia Some data analysis is based on study report carried on Malaysia condition and get from local researchers and newspapers.

4 FAQ on Surge Protection 1. We never had lightning problem, why we need Surge protection? 2. We do not get much lightning, why should we have problem? 3. We already installed lightning conductor, why we need surge protection? 4. All my data lines run inside the building, why should I need surge protection?

5 2 Costs due to Surge Effects Damaged Equipment Costs of replacement of equipment system includes I/O cards, processors, loop-powered transmitters, IS barriers System/Operation Downtime Most expensive cost What would it cost if your plant closed for a day or even for 1 hour?

6 2 Costs due to Surge Effects Tangible Costs Damaged equipment --> System downtime ->Lost operation -> lost business opportunities Hidden Costs Spurious faults --> system unreliability Reduced equipment lifetime

7 2 Surge Damages

8 3 Comprehensive Protection 1. Direct Strike Effects Lightning Protection System 2. Electrical Surge Surge Protective Device (SPD)

9 3 Automation products - Failure Analysis Causes of Short Equipment Life Lack of maintenance 25% Water 5% 22% Fire 3% Theft and vandalism Other 15% Storm 1.57% 28% Overvoltage (lightning discharge and switching operations) Damage in electronics: Analysis of approx. 7,737 damages Ref:Contingency planning insurance data

10 Causes of Surges External Causes Lightning - Direct hit Distance Lightning - Transients on Utility lines Internal Causes Switching of electrical motors Air conditioner compressors Power overloads

11 4 Lightning Induced Surge Surges can infiltrate a system 4 ways (even if a UPS has been installed) Direct coupling (direct strike) Inductive coupling (magnetic field) Capacitive coupling (electric field) Resistive coupling (potential difference) Damages to sensitive electronics equipments

12 Failure Modes of Equipment Catastrophic Failure (5%) Safe Operating Area Equipment Degradation (95%)

13 Surge Effects to Electronics Burn-Out (Catastrophic Failure) Board Damage & Failure System Down System Failure Upsets (Annoying) Memory Loss Data Errors Random System Failure Degradation (Un-noticed Damage) Break-Down of ICs Loss of Circuit Traces, or Insulation Shortening of Component MTBF

14 Definition Surge Protective Device A device that is intended to limit transient over-voltages and divert surge currents. It contains at least one non-linear component [IEC , definition 3.1]

15 Components in SPD Gas Discharge Tube Metal Oxide Varistors Silicon Avalanche Diodes Typical Applications Primary component in signal/data SPD Strengths High Surge Current Capacity Typical Applications AC power protectors Strengths High Surge Current Capacity Typical Applications Signal and data protectors High speed data protectors Strengths Very fast reacting

16 Principle of SPD Diverting surge current to earth Clamping output voltage to a safe level Protect and Survive; wait for next surge SPD located nearest to the equipment that need to be protected

17 Where you put your SPD? AC Power Protection Data & Signal Protection Network & Telecommunication Protection Special Protection

18 Basic Protection Guidelines Protect incoming / outgoing cables Protect both ends of cables linking between 2 buildings or to outdoor equipments

19 Location of SPD Typical usage:- Hazardous area > < Safe area Power AC / 24V Recommended : MA15/D/2/SI for 220VAC SPD X SPD SPD Isolator I/O card DCS/Flow computer Recommended : TP48 / SD32X Recommended: SD32X for AI/AO/DI/DO SDRTD for 3 wire RTD SD07X for 4 wire RTD SPD Recommended : SD16R for Modbus SD07X for Normal RS485 SPD Communication item

20 Incoming Surge SPD DC Power

21 SPD Surge diversion Incoming surge

22 To system

23 Signal and Control Lines SD Series Signal and Control Lines MA15 Incoming Power

24 Transmitter Field Devices TP Series

25 Benefits 10 years NO FUSS WARRANTY Intensive research (Lightning Lab test) Full power lab test (Paper figure match lab test figure) Wide acceptance, famous and preferred in Petronas Wide variety of products for O&G

26

27 TQ very much