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Solving the LV vs MV Dilemma When
Optimizing Costs for Motor Management

A Guide to Large Pump Applications in Mining
schneider-electric.com/motor-management
www.schneider-electric.com
Solving the LV vs MV Dilemma When Optimizing Costs for Motor Management

A Guide to Large Pump Applications in Mining
5 reasons why you should read

this document, and (re)consider
motor management
1 2 3 4 5
Motors directly Motors are Motors are Motors are Motors can be
impact industrial the foundation the largest critical assets the opportunity
electrical of all industrial consumer of for predictive to make a
distribution and processes energy (90%) in and preventive strategic choice
equipment heavy industry maintenance between LV
and MV
2 Large Pump Applications in Mining - Technical Guide

Summary
Introduction................................................................p. 4
The LV or MV Dilemma - A Lever for Optimizing the Cost of Motor Management.......................p. 4
Click on the
text to go to the
A
corresponding
What Are the Challenges When Optimizing Motor Management?...................................................p. 5 page
The Decision Triangle - End Users, Design Engineers, and Equipment Manufacturers............p. 6
Scope of the Motor Management Solution..............................................................................................p. 7
Large Pump Applications in Mining.............................. p. 9

Where are large pumps typically found in open pit mining operations?........................................p. 10
B
Pump Characteristics....................................................................................................................................p. 12
Two Major Families of Pumps......................................................................................................................p. 13
Motor Management Equipment....................................... p. 15 C

Electric Motors - The Interface Between the Application and the Electrical System..................p. 16
LV and MV - Relative Comparison of Asynchronous Motors.............................................................p. 17
Motor Starting and Control - An Adequate Solution
Leads to Optimized CAPEX and OPEX.....................................................................................................p. 18
Starting Method - Arrangements and Performance Comparison.....................................................p. 19
Motor Starter Sharing - An Economic Option for Multiple Pumps in Parallel................................p. 20
Variable Speed Drives - Operational Control and Energy Savings..................................................p. 21
Motor Protection and Control - Keeping the Process Up and Running..........................................p. 22
Process Control - For Consistent, Economical and Safe Operation................................................p. 24
Power Quality - Making the System Sustainable...................................................................................p. 25
Motor Asset Management - Increasing Motor and Process Availability.........................................p. 26
EcoStruxure - IoT-Enabled Architecture for Motor Control and Monitoring..................................p. 27
LV or MV for Large Pumps?............................................. p. 28

A Holistic Motor Management Approach Will Help Make a Better Choice....................................p. 29 D
Three Case Studies............................................................ p. 30

LV/MV Cost Comparison...............................................................................................................................p. 32 E
Case Study Context - Open Pit Mine Electrical Distribution Overview...........................................p. 33
Direct On Line Application Case..........................................................................................................p. 34
Soft starter Application Case.............................................................................................................p. 38
Variable Speed Drive Application Case...........................................................................................p. 42
Large Pump Applications in Mining - Technical Guide 3

Introduction
The LV or MV Dilemma - A Lever for Optimizing
the Cost of Motor Management
Motors consume more than 90% of the electrical energy in heavy industries and are
the major loads defining the electrical distribution system and architecture design.
Depending on their rated power, motors can be connected to low voltage (LV) or medium voltage (MV)
electrical distribution systems.
In the 100-800 kW range both connection levels are feasible and the decision is subject to technical,
economic, and people-related criteria. Established practices and habits are just as important as the
technical and economic arguments.
Motor technology and design are related to the voltage level. The choice of LV or MV can impact
starting current, mechanical torque, inertia, and reactive power consumption. The voltage selection
for large motors entails a different motor management design for the same application and motor
power in LV and MV.
The following aspects need to be considered:

• Electrical distribution architecture
• Capital expenditure (CAPEX) related to the necessary investment in
equipment, software, etc.
• Operation expenditure (OPEX) related to operational performance,
maintenance costs, and energy efficiency
• Total cost of ownership (TCO) of the installation
This diagram compares generally established practices for voltage level

selection and their reasonable limits. It shows that switching to MV often
occurs much earlier than necessary while there might be a hidden cost
minimizing optimization potential.
Motor Rated Voltage

(V)
13800
11000 Typical limit between
voltage levels
6600
5500
LV
or Extension limit
690 MV?
400
100 200 800 2500 3800 4500 6000 15000 25000

Motor Rated Power
(kW)
Practice and Limits of Electrical Equipment for Motor Feeders

What Are the Challenges When Optimizing

Motor Management? A
Electrical motors are an asset in electrical installations. Motor management optimization deals with the Adequate voltage selection
can achieve up to
design of an adequate, yet simple solution, for integrating motors in industrial processes and electrical
systems, while addressing several challenges:
• Optimizing investment
• Increasing uptime
20%
savings in CAPEX
• Reducing operating and maintenance costs
• Improving energy efficiency
• Minimizing the impact on the industrial process and the electrical system
Purpose of This Guide…

To explain the To describe the Motor To provide multiple To allow end users to
technological differences Management approach guidelines and make the most of their
between as a key to optimizing resources to help installation by selecting
LV and MV motor investment and in decision making. the most suitable and
management and operating costs. consistent solutions for
the impact on installation Motor Management.
design, motor control
and protection selection,
power quality, etc.
Note: Although this guide focuses on pumping applications in mining, the guidance and conclusions
presented are also valid for the Oil & Gas and Water & Wastewater industries.

Introduction
The Decision Triangle - End Users, Design
Engineers, and Equipment Manufacturers
Choosing LV or MV connection voltage is a dilemma for end users and especially for
design engineers. Often, for convenience or to minimize change and reduce risks,
engineers prefer to repeat previous systems to avoid dealing with the fundamental
questions around design.
At the same time, the optimal voltage selection could have an important impact on project profitability.
This is where equipment manufacturers can play a significant role in overall optimization.
End users Design engineers

Objectives:
Objectives:
• Minimize design
• Optimize CAPEX,
process time
OPEX, and TCO
• Minimize CAPEX
Expectations:
• Meet application needs
• Reliable and safe
• Cover eventual
equipment
evolutions
• Easy to maintain by
• Guarantee
personnel on site
performance
• Lowest possible
• Use approved solutions
investment cost
• Lowest energy Potential side effects of a
consumption Equipment conservative approach:
• Lowest footprint manufacturers • Cumulative safety
margins
• Large number of
suppliers Objectives: • Range effects and
• Respond to the request unexpected costs
• Simple in principle
• Be selected as supplier • Prioritization of
• Fit for purpose
manufacturer
•… Values:
• High-end solutions
• In-depth knowledge of
products and solutions
• Awareness on range
effects
• Ability to help with
overall optimization
Key points to remember

• Voltage level selection is a compromise between end users, design engineers and
equipment manufacturers.
• It is part of the entire feeder design and requires a case-by-case approach.

Scope of the Motor Management Solution Go to:

EcoStruxure for Mining
Scan or
click on
QR code A
Motor management is part of a complete industrial installation with 3 levels:
In Motor Applications
EcoStruxure Architecture
Apps, Analytics & Predictive maintenance and

Services services, based on cloud
analytics, for proactive and
Cloud Analytics Services preventive maintenance
Edge Control/
Process automation and
Process
supervisory systems for
Automation
local asset monitoring
Communication Software
Connected Connected Products,

Products to make data available
Power Quality Circuit breaker Protection Start and Operate Motor for analysis
and contactors Relay
1 Circuit breakers and fused contactors associated with

protection relays are typically used to connect, protect and
start motors.
2 Soft starters or variable speed drives are used to start and

2
Start and operate motors by adapting the electrical and mechanical
Operate
characteristics to the load and the network.
5
3 Cables are mainly sized according to installation requirements.
Their conductive cross-section is defined by normal and fault
3 currents. The control mode selection can influence cable
sizing and bring optimization benefits.
4 Motors are essentially defined by application requirements.

4 In high power ranges, their optimization can bring overall cost
savings in terms of reactive power consumption, heat losses,
upstream transformers and generator sizing.
5 Power quality concerns extra power consumption and

financial penalties from utility or equipment malfunctioning.
Motors act on power quality through their control mode.


Large Pump Applications B

in Mining

Large Pump Applications in Mining

Where are large
pumps typically
found in open pit
mining operations?
Large pumps are used in multiple
applications in the mining industry,
including slurry pumping, dewatering,
drainage, and jetting.
More than
70%
of them will be connected
and controlled via contactors
30%
will use a variable
speed drive
Exploration & Extraction
Process Exploration & Extraction Processing

Applications Mine dewatering Material grinding and classifying
Fluid Water and non-settling slurry Cyclone feed and fresh water
Pump technology Centrifugal Centrifugal
Motor power range Up to 400 kW Up to 1000 kW
Typical connection voltage LV and MV LV and MV
Flow Constant Constant
Operating mode Intermittent Intermittent

Processing
Material Handling
Material handing
Comminution Slurry pumping Concentrating and refining Transportation
Process water Settling slurry or tailings Process water and leach acids Settling slurry transportation
Centrifugal Positive displacement Centrifugal Positive displacement
Up to 400 kW Up to 1500 kW 110 – 300 kW 300 – 2500 kW
LV and MV LV and MV LV LV and MV
Variable Variable Variable Variable
Continuous Continuous Continuous Continuous

Large Pump Applications in Mining

Pump Characteristics
Pumped liquids can be divided into three main categories, depending on their viscosity and content:
• clear liquids: clear water
• non-settling slurry: usually in drainage, concentrating, and dewatering
• settling slurry: formed by raw material diluted with water for pipeline transportation
A global overview of this classification is illustrated below:
Slurry (Slurry Sand Gravel Dredge)
Clear liquid Non-settling < 50 μm Settling > 50 μm

Grinding & Classifying
Process
Separating
categories
Concentrating
Process water
Utilities Dewatering
Slurry pipeline
Centrifugal
Positive displacement
Mining Applications and Usual Liquid Categories
Definitions:
Head = H1 + H2 + Losses
Head and flow are two of the main characteristics of a pump.
The head measures The flow measures the volume Best efficiency point,
H2
the vertical height that of liquid, usually in m3/h. or BEP*, is defined as the
the pump can lift the liquid The flow varies with the head head and flow combination
Pump
and is given in meters. and vice-versa. giving the highest efficiency H1
and lowest wear on the pump.
* Specific to centrifugal pumps.

• The type of liquid being pumped determines the kind of pump technology to be used.
• For financial reasons, most pumps in mining are centrifugal.
• Slurry pumping applications often use positive displacement pumps, typically rated up to 1500 kW.

Two Major Families of Pumps
Centrifugal pumps: Positive displacement:

More common More efficient
Centrifugal pumps are the more economical and Positive displacement pumps are better adapted
widely used technology. These pumps are to the constraints of slurry pumping and slurry
adapted for clear and non-settling liquids. They pipelines. These pumps operate at constant
can be associated with variable speed drives for speed and can reach significant head. They are
energy savings through variable loading. often driven with variable speed drives.
Proper centrifugal pump operation is dependent Positive displacement pumps are operated at
on the pressure and viscosity of the liquid at the constant flow and high efficiency, independent of
suction end and maintaining this is achieved the pressure or viscosity of the pumped material.
through adequate upstream material processing.
Head/Flow capacities* Head/Flow comparison at fixed speed Load torque comparison
Head Water pressure

(meter) (Bar) Head Torque
10000 1000
1000 100
100 10
10 1 Flow
Flow 0 0 Speed
1 10 100 1000 10000 Rated Rated
(m3/h)
Positive displacement pump

Reciprocating
Rotary Centrifugal pump
* Reference: I. J. Karassik, J. P. Messina, P. Cooper, C. C. Heald, Pump Handbook Third edition, McGraw-Hill, 2001
Note: Slurry pumping implies dealing with variations in viscosity.

Centrifugal pumps often operate at less than best efficiency point. This increases pump wear and maintenance.
Centrifugal pumps are preferred to positive displacement pumps for higher flow levels and can have higher rated power.


Motor Management Equipment


Electric Motors - The Interface Between
the Application and the Electrical System
There are two major
motor technologies:
asynchronous and
synchronous.
In pumping applications
asynchronous motors prevail by
far, hence our focus on this
technology in this guide.
Asynchronous motors have a simple and robust construction and are much more economical than
synchronous motors. They are designed for a high starting current because it is necessary to obtain
sufficient torque and stability during operation. As a consequence, starting high-power motors is
always an open question.
Motor current
(pu of rated)
Speed
0 20 40 60 80 100 (% of rated)
Typical Current of MV Asynchronous Motor
Asynchronous motors also have a non-unity power factor and require capacitor banks for reactive
power compensation. They are frequently used with centrifugal pumps. Robustness and relative ease
of maintenance are important decision factors for these motors. LV and MV motors are both
standardized according to IEC 60034.
Key point to remember

Asynchronous motors are the predominant motor technology used for pumps in mining.

LV and MV - Relative Comparison of Asynchronous

Motors
Comparison Characteristics LV Motors MV Motors
Economic benefit
Footprint
Efficiency
Power factor
Low starting current
High starting torque
Repair
Service life
C
Torque
(pu of rated)
2.5
2.0
LV motor
1.5
MV motor
1.0
Load
0.5
Acceleration torque
0 Speed
20% 40% 60% 80% 100% (% of rated)
Comparison of LV and MV Motor Torque With Respect to Pump Torque
Motors under 100 kW are usually LV whereas motors above 800 kW are usually MV.
It is the range between 100 kW and 800 kW that poses the dilemma of selecting LV or MV.
Key point to remember

The electromechanical behavior of LV and MV motors is different due to different motor design.


Motor Starting and Control - An Adequate Solution
Leads to Optimized CAPEX and OPEX
Optimal motor starting and operational control are fundamental to the industrial
process and electrical installation sustainability.
Options to consider:
Direct On Line Advanced Starting Modes Variable Speed Drives

Direct On Line is a Advanced starting modes modify Variable speed drives provide
common starting motor behavior through voltage the following additional benefits:
method for its and/or frequency modulation • starting with higher than
simplicity and and help to reduce: rated torque required by
low cost. • starting current and voltage drop positive displacement pumps
It may impose • initial starting torque and • minimized motor heating
significant stress, mechanical stress, particularly during starting
however, on both water hammer effect with pumps • increased number of
the network and the • sizing constraints on transformers starts
mechanical load. or generators per hour
WHAT ARE THE
POTENTIAL IMPACTS
Advanced starting modes are beneficial in the long term since they avoid oversizing and the need
for frequent maintenance on the electrical and mechanical equipment. OF UNSUITABLE
MOTOR CONTROL?
Inadequate control
can result in an
Network Impact
increase in failures
or premature wear
DOL of bearings and
pump impellers.
Advanced starting modes
Soft
staRter
VSD
CAPEX
DOL: Direct On Line Soft Starter VSD: Variable Speed Drive

Starting Method - Arrangements and Performance

Comparison
DOL Soft starter VSD
(By-pass
if VSD
used as
a starter)
Starting Equipment Standard DOL Soft Starter VSD

CAPEX Initial cost benefit
Footprint saving
Weight reduction C
Engineering simplicity
OPEX Ease of equipment

maintenance
Pump energy and

maintenance savings
Control flexibility
Motor Starting current control
Starting torque control
Pump adequacy Centrifugal
Positive displacement
Large Motor Starting 101:

Discover the Constraints
Click on the picture


Motor Starter Sharing - An Economic Option
for Multiple Pumps in Parallel
In MV applications, a single soft starter or drive is often used to start several pumps
sequentially, saving on equipment cost and footprint. A redundant soft starter or
drive can be added in order to increase availability. The cost of LV soft starters is
lower and labor savings make preferable individual installations.
Mutualized soft starter Mutualized drives as a starter
M M M M M M
Redundancy is possible
for critical applications:
Starting busbar one motor at a time

Feeding busbar after motor start
M M M

The main criteria for selecting optimal motor control are:
• Process requirements: flow variation, pressure, dynamics. Slurry pumps do not have the same
constraints in terms of torque, pressure, and viscosity as water pumps.
• Necessary torque for starting: Centrifugal pumps will have quadratic torque, increasing with
speed, while positive displacement pumps will exhibit almost constant torque from zero to
rated speed. Starting methods will differ for each.
• Frequency of starts: Intermittent starting will wear the motor bearings more rapidly,
as well as the pump itself.
• Size of the pump: Higher power pumps will require starting methods that avoid voltage
drops and parallel load disconnection.
• Motor voltage: Low voltage motors may need a soft starter to reduce their high starting torque.
Medium voltage motors may need a VSD to increase their overall torque.
KEY SOLUTIONS Autotransformer LV soft starter MV soft starter

starter
FOR ADVANCED ATS48 Motorpact RVSS
MOTOR CONTROL Motorpact RVAT
> Click on the images to learn more about our products

Variable Speed Drives - Operational

Control and Energy Savings
Not only appropriate for starting, variable speed drives are
also used during operation to:
Adapt the motor Save energy in some Maintain operation
speed and torque to applications such at the best efficiency
the application needs as pumping point
Energy costs represent 40% of the TCO of a typical pump operated at rated speed
with flow control through mechanical valves. With VSDs, optimized motor control
can bring up to 30% savings on energy consumption.
VSDs can easily operate the pump at their optimal efficiency point and reduce wear and maintenance.
The fault current contribution of any motor with VSD is significantly lower than when operated in C
direct on line. In some cases the reduced motor short-circuit current contribution can also optimize
busbar sizing.
Selection of VSD voltage levels is highly impacted by cable technology and

distance to the motor.
In LV applications, shielded cables will reduce In MV applications, multi-level inverter

the effect of EMC but will increase capacitances technologies greatly improve the voltage
to earth and limit the length to several hundred waveform provided to the motor and allow
meters. Adding a wave-smoothing sinus filter will operation over several kilometers without
increase maximum length, but will also increase specific constraints on cables or the sinus filter.
the cost and footprint of the overall solution.
Modern variable speed drives go far beyond motor speed and torque control.
Embedded functions allow multiple advanced services to manage power,
energy, process, and protection.
KEY SOLUTIONS LV drive MV drive

The services oriented drive: A new
FOR ADVANCED ATV600 ATV6000 kind of energy management device
MOTOR CONTROL


Motor Protection and Control - Keeping
the Process Up and Running
Motor and feeder protection is part of a global concern for safety, security, and
process availability. It includes protection of:
Personnel (operators The process The electrical network The motor

and maintenance staff) feeding the motor
Protection is achieved by switchgear design and intelligent electronic devices.

Switchgear is an enclosure consisting of current The design of LV and MV switchgear must be
switching equipment, measuring devices, compliant with electrical standards that meet internal
intelligent electronic devices, etc. This is all housed arc and compartmentalization requirements, etc.
in a protective cabinet that allows personnel to The main switchgear standard for LV equipment is
work safely on the electrical installation. IEC 61439-1/2 and for MV IEC 62271-200.
Switchgear can be a deciding factor regarding the footprint and weight of the overall solution.
In MV, circuit breakers and contactors are installed In LV switchgear, several motor feeders are
individually in cubicles, with typical footprints with integrated in a panel. The number depends on the
fuse contactors around 0.35 - 0.6 m². size of the motors and the diversity factor, related to
the expected operation.
For higher power motors when only circuit
breakers are used, this footprint is around For 400 V, this can be up to 4 x 110 kW, or 3 x 160 kW,
0.88 - 0.91 m². or 2 x 250 kW, which is a surface gain. For long
distances, more cables will be required per phase.
This cable-related constraint may impose the need
for installation in more panels, thus canceling out the
footprint advantage.
KEY SOLUTIONS FOR LV power distribution MV motor control MV primary distribution

and motor control center switchboard
MOTOR PROTECTION
AND CONTROL Blokset PIX MCC MCset

Motor Protection: 5 reasons to

choose circuit breakers over fuses
Intelligent electronic devices (IED) are protection relays that are associated with
circuit breakers or contactors. The difference between LV and MV relays can be in:
Number of inputs Number of outputs HMI Communication Number of integrated

protocols protection functions
Main protection functions common to

LV and MV relays:
Protection type Typical functions
Current-based Earth fault and short-circuit
Current unbalance
Thermal overload
I>
C
Number of starts per hour
Long start or excessive starting time
Phase undercurrent
Voltage-based Voltage unbalance
Voltage phase loss M M
Voltage phase reversal
Undervoltage
Overvoltage
Consequences of motor failure
In MV relays there are specific machine When a motor fails, it means the process itself
protection functions: is no longer available, and results in:
• Machine differential • loss of production
• Stator windings and/or frame temperature • Increased maintenance costs
• Pole slip (for synchronous motors) • unacceptable risks in any critical process

• Motor protection is adapted to the customer need and depends on how critical the motor is to the operation.
• MV or LV relays offer similar protection.
• MV installations will require more cabling and space as current transformers are not integrated in the relay.
KEY SOLUTIONS MV protection LV Intelligent Motor Contactor for high-

FOR MOTOR relay Management system power motors
PROTECTION AND Easergy P3 TeSys T TeSys F
CONTROL


Process Control - For Consistent, Economical,
and Safe Operation
Process control systems (PCS) enable automatic control, monitoring, and remote
diagnostics of the mining process.
Process Control System

Edge Control/ EcoStruxure
Hybrid DCS
Process Automation
WHAT ARE
PLC
THE BENEFITS
OF A PROCESS
CONTROL SYSTEM?
• Improved operational
efficiency
Connected Products
• Lower total cost of
ownership
• Lower energy costs
• Lower maintenance
costs
• Lower labor costs
MV protection LV protection Variable Remote I/O IMCC
relay relay speed drive • Lower risk of error
Connected products consist of advanced motor Edge control and process automation consists of
protection and control products, sensors, and a distributed control system (DCS) with integrated
Intelligent Motor Control Centers (IMCC). These cyber security and:
products also provide feedback and diagnostics • Programmable logic controller (PLC)
for edge control and process automation, bringing • Supervisory control and data acquisition
intelligence and increased process availability. (SCADA) system
• Remote I/O system.
To ensure good interoperability, featured data is transmitted via network protocols commonly
used in industrial automation such as Modbus TCP/IP, Modbus Serial, EtherNet IP, or Profibus DP
in LV applications and IEC 61850 in MV.
LV and MV installations will have similar features for process control. Except for a slightly higher
amount of cabling of LV devices, there is no particular constraint for the selection of the motor
connection voltage from this aspect.
KEY SOLUTIONS FOR PLC Modicon EcoStruxure Remote

M580 Hybrid DCS I/O
PROCESS CONTROL
SYSTEM

Power Quality - Making the System Sustainable
Capacitor banks, harmonic mitigation systems, and transformers ensure the correct
operation of motors in the process with minimal impact on the power system.
As a rule of thumb, LV motors may have a slightly lower power factor and require a slightly higher
reactive power compensation. The power factor difference depends on the motor manufacturer.
Capacitor banks are used for power factor LV drive technology often has standard variable
WHAT IS THE
correction (PFC). They are usually installed on speed drives, generating high harmonic currents.
IMPACT OF POOR
the same busbar as the motors. In MV, there are Active or passive harmonic filters are generally
POWER QUALITY?
also individual capacitors per motor. suitable for installations where several LV drives
are connected to the same busbar. Specific low Inadequate power
harmonic LV drives for large motors are an quality or equipment
C
3 safety measures for motors with
individual power factor correction sizing may lead
efficient means of reducing harmonic levels
without increasing the switchboard size. to overheating
or vibration in
MV drive technology - The most popular MV
the motors and
drives, such as multi-level inverters with
accelerate their aging
embedded multi-pulse transformers, have the
and replacement.
advantage of being almost a linear load with
a high power factor. No harmonic reduction It can also cause
equipment is required. parallel load
disconnection and
Transformer power and short-circuit voltage
production losses.
define the voltage drop, especially during motor
starting, and the impact of harmonic currents
on busbar voltage. Large motor starting is a
constraint for the system and requires careful
analyses for the sizing of the transformer.
Up to 800 kW, DOL starting is generally not
an issue in MV installations.
Capacitor bank Active Low harmonic Transformers

KEY SOLUTIONS (power factor harmonic filters 3-level LV VSD (outdoor and
FOR POWER correction) AccuSine PCS+ indoor)
ATV680
QUALITY VarSet drive systems Minera


Motor Asset Management - Increasing Motor
and Process Availability
Condition assessment and predictive technologies help to avoid motor and
application failures in the early stages, with remote or local monitoring services.
Asset management services consist of the continuous monitoring of critical LV and MV motors and
their related loads. A service bureau platform is used by experts on the premises of the equipment
manufacturer. Experts use analytics to diagnose potential problems and they provide event reports
and notifications of any necessary action that can help to:
• Prevent downtime, increase system continuity, ensure safety, and optimize asset lifetime
• Determine maintenance adjustments for cost optimization and risk mitigation.
Asset Management Services

Apps, Analytics &
Services
Schneider Electric Expert dashboards Schneider Electric Proactive maintenance

cloud analytics Service Bureau recommendation
Edge Control/
Process Automation
SE gateway & Customer Portal

edge analytics
Local monitoring of assets is achieved through the installation of dedicated

monitoring devices, known as “edge analytics,” and realized in the process
control layer of the industrial installation. Asset management solutions are
mostly defined by the criticality of the motor for the industrial process and
do not influence voltage level selection.
• Portfolio management
• Operational performance
KEY ASSESSMENTS
• Motor condition
• Maintenance workspace EcoStruxure EcoStruxure
Maintenance Advisor Asset Advisor

EcoStruxure - IoT-Enabled Architecture

for Motor Control and Monitoring
In Heavy Industries
Motor Management Approach
In Motor Applications
EcoStruxure Architecture
Apps, Analytics &

Services OnLine
Condition
Monitoring
C
End-to-End Cybersecurity
Cloud and/or On Premise
Edge Control/ Alarming

Process
Automation
Embedded
HISTORIAN
Connected
Products Acquisition
Metering
Motor Application Analyses
Customer Needs
EcoStruxure Power Scan or

click on
Visit our webpage to discover your possibilities QR code
schneider-electric.com/ecostruxure-power

LV or MV for Large Pumps?

LV or MV for Large Pumps?

A Holistic Motor Management Approach Discover how
CAPEX decisions
Will Help Make a Better Choice depend on:
•C
ustomer objectives,
leading to starting
The holistic Motor Management approach, developed by Schneider Electric, mode selection
is based on our high level of expertise and proven solutions. It ensures that • Cable length,
all decisions are made only after careful analysis of the application and the leading to LV or
industrial power system. MV choice
"ANALYZING" STEPS "DEFINITION/PROPOSITION" STEPS
PRIORITY #1 PRIORITY #2 PRIORITY #3
EXPERT SERVICES MOTOR

CUSTOMER ADVANCED POWER MOTOR ASSET
FOR MOTOR PROTECTION
NEEDS MOTOR CONTROL QUALITY MANAGEMENT
APPLICATIONS & CONTROL
Key analyses Key analyses Key factors Key factors Key assessments Key assessments
• Motor • Voltage level • Process • Power supply • Power factor • Operational
application • Power supply compliance • Motor control • Harmonics performance
• Electrical characteristics • Motor and load type • Energy • Motor condition
installation • Short-circuit torque • Motor operating efficiency monitoring
• Economical currents for starting mode • Scalability of
objectives • Mechanical and • Frequency of • Motor criticality the application
• Maintenance thermal stress starting
• Communication
practices • Cable sizing • Voltage stability requirements
• Operational • Footprint
requirements optimization
Customer Objectives Starting and Operation D

Method
DOL Soft Starter VSD
Solution simplicity -
Frequent starting -
High starting torque -
Limited voltage drop -
Reduced mechanical stress -
Lower heating -
Harsh environment - -
Variable speed - -
Energy saving - -
Footprint optimization -

Motor Management Approach -

Three Case Studies

Three Case Studies

Three typical mining applications illustrate how the motor management
solution is developed for LV and MV connections and the related advantages
and drawbacks of each.
The main factors to consider are:
• Application requirements
• Motor feeder main components
• LV/MV cost comparison
• Schneider Electric solution overview for each voltage level
1 3 typical applications
CUSTOMER
NEEDS
2 Technical feasibility
EXPERT SERVICES
FOR MOTOR
APPLICATIONS
3 Decision key points

MOTOR
ADVANCED POWER MOTOR ASSET
PROTECTION
MOTOR CONTROL QUALITY MANAGEMENT
& CONTROL

Case Studies
LV/MV Cost Comparison
Typical Feeder Composition

Equipment costs are compared.
1 The costs of the LV and MV versions of
1 Enclosure
a complete single feeder are compared
2 for a given motor power.
2 Protection
All feeder elements are sized according
to motor power and short-circuit current.
3 Starting and
operating mode
4 Start and
3 4 Power quality
Operate
5 Connection
5
6 Cable
6
7 Motor
7 Global CAPEX
The result of the comparison is given as a LV to MV cost ratio. It limits the

effect of option-related variation and allows the results to be generalized.
LV/MV ratio < 1 - Benefit is for LV solution

LV/MV ratio > 1 - Benefit is for MV solution
Non-technical factors such as habits, available voltage levels, and need

for personnel competency improvement can influence the choice.
Even if a solution is more expensive, it may be preferred on the basis of
such contextual reasons, but this may also be the case when the difference
in equipment cost between the two voltage levels is negligible.
A margin, noted as context-dependent, is also considered to illustrate
these variabilities.

Case Studies
Case Study Context - Open Pit Mine Electrical
Distribution Overview
One of the most common electrical distribution architectures used for open pit mines is the double radial
system. This consists of a main MV switchboard with two incomers and a normally open bus section.
Each half-busbar is supplied by a transformer loaded to 50% of its capacity but sized to supply the
total load. If one transformer fails, the associated incomer circuit breaker trips and the bus section
closes to transfer the total load to the other transformer. Double radial architectures offer a good
compromise between energy availability, equipment redundancy, and overall cost.
The three examples concern:
Utility Network
HV • Clear water pump in communition
• Non-settling slurry pump in mine
dewatering
HV
• Slurry pump for material transportation
MV
MV NO The pump feeders are sized in the following

typical environment:
2
MV NO MV MV
Exploration &
• Altitude < 1000 m
Extraction • Ambient temperature -5°C to 35°C
Exploration & Extraction
dewatering
M ? Mine dewatering
• Relative Humidity < 90%
Grinding
Mine
LV NO LV LV
Classifying • Ambient air not significantly poluted
Separating
• Protection IP31
M • No seismic risk
• Insignificant vibrations
1
MV NO MV MV
Processing
Comminution
Communition
M ? Slurry pumping
Concentrating
LV NO LV LV
Processing
MV NO MV MV
3
Slurry pipeline
Material
M ? Handling
Slurry pipeline
E
LV NO LV LV
Handling
Motor power considered for each motor starting method:

Direct On Line Soft Starter Variable Speed Drive
200 kW 315 kW 400 kW

1 Direct On Line Application Case
Processing/Communition
Motor Pump Electrical network

• Motor power: • Type of pump: • Short-circuit power:
200 kW centrifugal high
• Frequency of starting: • Fluid:
2/week clear water
Pumping clear water with a centrifugal pump can be achieved with Direct On Line starting when not frequent
and not subject to water hammer.

Analyze Analyze results Control solution Protection Power quality Asset management
objectives
• DOL LV
• Simplicity • RVAT
• Frequent starting • RVSS • LV contactor Circuit breaker Power factor Asset Advisor
• High starting torque + relay correction bank
• VSD
• Limited voltage drop • PQ MV
• Reduced mech. • Protection
stress • Asset management • MV contactor Contactor + Individual power Asset Advisor
• Lower heating fuse + relay factor correction
• Harsh environment
• Variable speed
• Energy saving
• Footprint
optimization
Cable Length Cost Impact Comments

LV/MV In the 400 V variant the economic benefit from
200 kW LV/MV cost ratio the equipment cost is visible for a cable length
around 100 m. Longer cables require
7
changing to 690 V or switching to MV.
6
5
0.4/6.6 kV
4 For 690 V the cable length has a much smaller

3 impact. The LV or MV choice will be mainly
2 MV benefit 0.69/6.6 kV defined by additional technical or personnel-
1 Equal related factors.
± 0.5 Tolerance
LV benefit
0
100 200 300 400 Cable length
(m)

LV Reference Architecture
EcoStruxure™ Architecture
Apps, Analytics
& Services Asset
Advisor
Edge Control/
Process
Automation 5 M580 Hybrid DCS
Connected
Products
VarSet Blokset TeSys T TeSys F 6 Com'X 210
1 2 3 4
2
1 PCF bank
2 Motor Control Center 5 6
3 Protection relay
4 Contactor 3
5 PLC
6 Gateway
MV Reference Architecture
Apps, Analytics
& Services Asset
Advisor
Edge Control/
Process
Connected
Products
Motorpact FVNR Easergy P3 Com'X 210
4
1 2
1
1 Motor control switchboard
Direct on line is the basic and
3 4
2 Protection relay most frequent architecture for
3 PLC motor control. This is why the
2 LV and MV variants are very
4 Gateway
similar.
In LV, the capacitor bank used

for power factor improvement E
is separated from the motors
on a dedicated feeder on the
main busbar.
In MV, this solution exists but

the capacitor bank can also
be integrated in the cubicle
containing the motor feeder.
In this case, the capacitor is
sized individually for the motor
and operates only when the
motor is connected.

1 Direct On Line Application Case
General Recommendation
The case study analysis is extended in motor power. Context-dependent areas are defined around
the LV/MV equivalence limits, based on the same tolerance as before.
The choice of MV or LV is recommended above and below these areas respectively.
Motor power
(kW)
800
630
MV
400
Equilibrium
315
0.4 = 6.6 kV
200
Context-dependent
110
LV
0 100 200 300 400 Cable length
(m)
Motor power
(kW)
800
630
MV
Context-dependent
400
Equilibrium
315
0.69 = 6.6 kV
200
110
LV
0 100 200 300 400 Cable length
(m)
Three zones are distinguished in the comparison graphs:
"LV" "MV" "Context-dependent"

where LV connection is where MV connection is where the connection is subject to the
recommended recommended abovementioned cost variation factors
Key takeaways
The use of 400 V for large pumps is rapidly limited by cable length. This voltage level is suitable
for lower power and numerous motors, where the supplying switchboard will be close to the
pumps.
At 690 V, motors can reach much higher power. The context-dependent zone is larger as the
decision to go to MV may impose the need to review the electrical distribution architecture.
This is why this LV level is preferable for longer cable lengths.


2 Soft starter Application Case
Exploration and Extraction/Mine Dewatering

315 kW centrifugal low
>1/day non-settling slurry
High flow amplitude in dewatering is achieved by parallel pumping at rated speed. Risk of settling material requires
progressive starting to avoid water hammer effect. soft starter also remains a robust solution as it operates only during starting.

objectives
• DOL LV
• Frequent starting • RVSS • LV Soft starter Circuit Breaker Power Factor Asset Advisor
• High starting torque + Relay Correction Bank
• VSD
• Limited voltage drop • PQ MV
stress • Asset management • MV Soft starter Contactor + Individual Power Asset Advisor
• Lower heating Fuse + Relay Factor Correction
• Variable speed
• Energy saving
• Footprint
optimization

LV/MV The individual motor power to be connected
315 kW LV/MV cost ratio in the system is increased with a soft starter
4
due to the starting current reduction action.
3
In the example, the motor power is compatible
with a 690 V installation, but not at all common
2
for 400 V, usually limited at 200 kW.
MV benefit 0.69/6.6 kV
As in the case of direct on line starting, the
Equal
1 decision for LV or MV is mostly dependent on
± 0.5 Tolerance
non-economic factors, even for longer cable.
LV benefit
00 100 200 300 400 Cable length

(m)

Apps, Analytics
& Services Asset
Advisor
Edge Control/
Process
Connected
Products
6 Com'X 210
VarSet Blokset TeSys T ATS 48
1 2 3 4
2
1 PFC bank
2 Switchboard
5 6
3 Protection relay
3
4 Soft starter
5 PLC
6 Gateway
Apps, Analytics
& Services Asset
Advisor
Edge Control/
Process
Connected
Products
Motorpact RVSS Easergy P3 4 Com'X 210
1 2
1 Motor control
The proposed architectures
switchboard with 3 4 are very similar as they
integrated soft starter
contain the same elements at
and PFC capacitor 2 the respective voltage levels.
2 Protection relay The motor protection can
3 PLC also be achieved in a simpler
4 Gateway
manner through the
overcurrent and thermal E
protections integrated in the
motor starter. The selection
is dependent on the criticality
of the motor and its power.
In MV, the motor protection

relay contains a number of
protections which are
M activated according to the
project and application
requirements.

2 Soft starter Application Case
This case study analysis is extended in motor power. Context-dependent areas are defined around
Motor power
(kW)
1000
800
630
MV
400
Equilibrium 0.4 = 6.6 kV
315
Context-dependent
200
110
LV
0 100 200 300 400 Cable length
(m)
Motor power
(kW)
1000
800
Context-dependent
MV
630
Equilibrium
0.69 = 6.6 kV
400
315
200
110
LV
0 100 200 300 400 Cable length
(m)

recommended recommended abovementioned cost variation factors
Key takeaways:
Compared to the DOL architecture, the use of soft starters slightly increases the applicable cable length for 400 V application.
This is mainly due to the MV soft starter cost, which remains high for the motor power range, compared to its LV equivalent.
In the 690 V variant, the soft starter use increases the maximum acceptable motor power compared to the DOL case.
The equilibrium between LV and MV is obtained for longer cables. The MV solution becomes context-dependent from zero
cable length between 400 and 630 kW. Compared to the DOL case, the context-dependent zone is larger, leaving room for
the non-economic factors in the decision.


3 Variable Speed Drive Application Case
Material Handling/Slurry Pipeline

400 kW positive displacement low to high
2/h slurry
Dense material, subject to settling, needing higher torque to start. VSD is recommended, as it also minimizes voltage
drop in more sensitive process environments.

objectives
• DOL LV
• Frequent starting • RVSS • LV VSD Circuit Breaker AFE VSD option Asset Advisor
• High starting torque + Relay or active harmonic
• VSD
• Limited voltage drop filter
• PQ MV
stress • Asset management • MV VSD Contactor + (not necessary) Asset Advisor
• Lower heating Fuse + Relay
• Variable speed
• Energy saving
• Footprint
optimization

LV/MV The use of VSD for motor control gives an
400 kW LV/MV cost ratio important advantage to the 690 V solution.
4
The reason is mainly the cost advantage of
3
LV equipment.
The 400 V variant also benefits from the VSD
0.4/6.6 kV
2 LV to MV cost difference and remains within
MV benefit
the scope of consideration for cables
Equal 0.69/6.6 kV
1 up to 250 m.
± 0.5 Tolerance
LV benefit
0 100 200 300 400 Cable length
(m)

Apps, Analytics
& Services Asset
Advisor
Edge Control/
Process
Connected
Products ATV600
(AFE option) 5 Com'X 210
AccuSine Blokset
1 2 3
2
1 Active The proposed LV architecture
harmonic filter 4 5 comprises two feeders,
2 Switchboard
one for the motor and another
for the harmonic filter.
3 Variable speed drive This solution has been
(low harmonic option) identified as more frequent
4 PLC and suitable for mixed power
5 Gateway and multi-motor applications
with VSD.
3
For single motor applications,
the VSD should be of low
1 harmonic type, shown as
optional on the connected
products layer. With a low
harmonic VSD the second
feeder is eliminated.
This is also the solution that
will be cost-compared with
the MV equivalent.
Apps, Analytics
& Services Asset
Advisor
Edge Control/
Process
Connected
Products
Motorpact Easergy P3 ATV 6000 5 Com'X 210
1 2 3
1
1 Motor control
switchboard 4 5
2 Protection relay
2
3 Variable speed drive
4 PLC
5 Gateway
E
3
The MV drive multi-level
technology makes it naturally
a low harmonic drive. In some
cases the architecture may
contain a grounding switch
used for discharging the
cables on the motor side.

3 Variable Speed Drive Application Case
This case study analysis is extended in motor power. Context-dependent areas are defined around
Motor power
(kW)
1200
1000
MV
800
Context-dependent
630
Equilibrium
0.4 = 6.6 kV
400
315
200
110
LV
0 100 200 300 400 Cable length

(m)
Motor power
(kW)
1200
1000
MV
Context-dependent
800 Equilibrium
0.69 = 6.6 kV
630
400
315
200
110
LV
0 100 200 300 400 Cable length

(m)

recommended recommended above mentioned cost variation factors
Key takeaways:
This variable speed drive LV to MV comparison is one of the most complex.
For both LV voltage levels the context-dependent zones are large and the applications remain
interesting in LV even for longer cables. The origin of this extended LV application field is the higher
cost of the VSD in MV for the considered power range.


More Information
on Motor Management
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Solving the LV vs MV Dilemma When

Optimizing Costs for Motor Management

Solving the LV vs MV Dilemma When Optimizing Costs for Motor Management

5 reasons why you should read

2 Large Pump Applications in Mining - Technical Guide

Large Pump Applications in Mining.............................. p. 9

Motor Management Equipment....................................... p. 15 C

LV or MV for Large Pumps?............................................. p. 28

Three Case Studies............................................................ p. 30

Large Pump Applications in Mining - Technical Guide 3

The following aspects need to be considered:

This diagram compares generally established practices for voltage level

Motor Rated Voltage

100 200 800 2500 3800 4500 6000 15000 25000

4 Large Pump Applications in Mining - Technical Guide

What Are the Challenges When Optimizing

Purpose of This Guide…

Large Pump Applications in Mining - Technical Guide 5

End users Design engineers

Key points to remember

6 Large Pump Applications in Mining - Technical Guide

Scope of the Motor Management Solution Go to:

Apps, Analytics & Predictive maintenance and

Connected Connected Products,

1 Circuit breakers and fused contactors associated with

2 Soft starters or variable speed drives are used to start and

4 Motors are essentially defined by application requirements.

5 Power quality concerns extra power consumption and

Large Pump Applications in Mining - Technical Guide 7

8 Large Pump Applications in Mining - Technical Guide

Large Pump Applications B

Large Pump Applications in Mining - Technical Guide 9

Large Pump Applications in Mining

Exploration & Extraction

Process Exploration & Extraction Processing

Pump technology Centrifugal Centrifugal

Motor power range Up to 400 kW Up to 1000 kW

Typical connection voltage LV and MV LV and MV

Flow Constant Constant

Operating mode Intermittent Intermittent

10 Large Pump Applications in Mining - Technical Guide

Centrifugal Positive displacement Centrifugal Positive displacement

Up to 400 kW Up to 1500 kW 110 – 300 kW 300 – 2500 kW

LV and MV LV and MV LV LV and MV

Variable Variable Variable Variable

Continuous Continuous Continuous Continuous

Large Pump Applications in Mining - Technical Guide 11

Large Pump Applications in Mining

Slurry (Slurry Sand Gravel Dredge)

Clear liquid Non-settling < 50 μm Settling > 50 μm

Mining Applications and Usual Liquid Categories

* Specific to centrifugal pumps.

Key points to remember

12 Large Pump Applications in Mining - Technical Guide

Two Major Families of Pumps

Centrifugal pumps: Positive displacement:

Head/Flow capacities* Head/Flow comparison at fixed speed Load torque comparison

Head Water pressure