AIR h £= Guosat EnGineerina Guivevine Selection of Protective Relay Systems and Settings 3eLo7' 1 03 for Typical Plant Electrical Equipment {9 ure 2008 ago tot 19 RESPONSIBLE GROUP: Electrical Engineering CURRENT CONTACT: David Goldsmith | Denotes Revision Table of Contents Section Title Page 1 Purpose 2 2 Scope 2 a Related Documents 2 4 Protection Study 3 5. Auxiliary Devices 3 6 Plant incomers 4 7. Transformer Protection 5 8 Medium Voltage Motors ~ Induction and Synchronous 8 8. Synchronous Motors 2 10, Auto-Transformer / Captive Transformer Feeders 13 11. Expander Generators, 4 12, Co-Generation (Synchronous Generators) 14 13. Arc Flash Requirements 15 Appendix A _ANSI/IEC Relay Symbols 16 Appendix 8 Typical Auto Transformer Scheme 7 Appendix C Option to Eliminate LV Incomer 18 I Appendix Formulae for Calculating Grading Margins 19 ‘Authorization for this document is on fie in ihe GEO Standarde Department. All information herein is the confidential property of Air Products and Chemmcals, inc, unless another source is shown. This information is subject fo retum on demand and must not be disclosed or reproduced without prior wniten consent, ‘i Posts and Chemical a, 20081 1 2 24 22 23 24 25 26 34 3.2 3.3 3EL07003, Rev. 2, Page 2 of 19 PURPOSE, This global engineering guideline describes suitable protection schemes for use in the protection of the electrical systems and equipment generally encountered in Air Products plants. Suggested settings are given where possible, although the engineers completing the protection study must satisty themselves that the protection settings adopted do not compromise plant safety or reliability. SCOPE This global guideline details standard protection schemes and relay settings for Air Products facilities including incomers, motor feeders, transformer feeders, and earthing systems (the term ‘earthing is used throughout rather than grounding). Protection systems for Low Voltage (LV) Switchboards have also been included, although reference should be made to the Air Products standard schematics for LV switchboard feeders. This guideline is subdivided by equipment and the recommended relays for that equipment. This guideline will not cover every circuit scenario, and in these cases the engineer should decide how best to apply the recommendations contained within this guideline to the circuit required. ‘The manufacturer technical literature shall be used when selecting and setting protection relays. This guideline is not intended to duplicate manufacturers’ standard information. When multi-function protection relays are applied, their use should be limited to the protective functions described in this document. Protection relays shall not be changed whilst the main circuit is energised without the approval of Global Support Services (GSS) Electrical Management. RELATED DOCUMENTS Air Products Engineering Documents 3EL02010 Motor Instrumentation 3EL02015 —_Specitying Speed Switches for Electric Motors 3ELO7004 Facility Electrical Primary Protection Requirements 4WEL-52124 NEMA E2 Motor Controllers 4WEL-52130 ANSI Low Voltage Switchgear 4WEL-52150 Metalciad Switchgear 4WEL-52151 Type 1 - Brushless Exciter Synchronous Motor Full-Voltage Starting Switchgear Unit 4WEL-52183. Type 3 - Induction Motor Full-Voltage Starting Switchgear Unit 4WEL-52154 Type 4 - Main incoming Line Switchgear Unit AWEL-52155 Type 5 - Plant Feeder Switchgear Unit 4WEL-52156 Type 6 - Load interrupter Switchgear Unit 4WEL-52157 Type 7 - Source Protection Equipment Group 4WEL-52158. Type 8 - Single Motor Autotransformer Starting Switchgear Unit 4WEL-P12 IEC Medium Voltage Switchgear AWEL-P13 IEC Low Voltage Switchgear Institute of Electrical and Electronics Engineers, Inc. (IEEE) IEEE Standard 242 IEEE Recommended Practice for Protection Coordination of Industrial and ‘Commercial Power Systems (IEEE Buff Book) Other Reference Material Alstom Protective Relay Application Guide ‘ABB Protective Relaying Theory and Applications ‘Allinformation herein s the conlidential property of Ar Producls and Chemicals, Ine, unless anoWer source mS Shown This information is subject to return on demand and must not be disclosed or reproduced without prior writen consent. "2A Products and Chemis, Ic, 20083EL07003, Rev. 2, Page 3 of 19 4. PROTECTION STUDY 4.1 The overall electrical protection coordination study shall be performed during plant design. A relay setting schedule for each site shall be prepared. Both documents and copies of relay setting software shall be maintained for the life of the plant, 4.1.1 Ina project for which distribution equipment is purchased from several suppliers, for example circuit breakers and fused contactors, particular attention should be paid early in the project to ensure correct coordination with the utlity protection scheme. 4.1.2 The study shall include: Identification of protection equipment and setting ranges Discrimination curves (time current curves)/Grading Margins Principal calculations Detailed relay settings Relay setting software and version number 4.1.3 Required grading margins shall be selected and quoted in the study. If these margins cannot be ‘met because of system constraints, the study should state what measures have been taken to mitigate the impact. This documentation will assist future evaluations of the study, and in turn may Prevent needless setting changes which, if implemented, may risk plant reliability and/or safety. 4.1.4 When possible, settings should be based on equipment test data. 4.2 Equipment suppliers should be asked to advise appropriate fuse ratings required to protact their ‘equipment. Verification of selection shall be made by the Air Products electrical engineer. 4.3 Power System Studies shall be completed to establish maximum and minimum fault current levels, arc flash incident energy levels, motor starting volt drops and, when necessary, transient stability calculations. 5. AUXILIARY DEVICES 5.1 Application of the trip circuit supervision, relay self-diagnostic, and lockout device(s) are generally Universal to most sections of this guideline. 5.1.1 Trip Circult Supervision (74): This function continuously monitors the trip supply, the trip circuit wiring, the shunt trip coil, and all trip contacts for integrity irrespective of the circuit breaker status. A failure of the trip circuit would not trip the breaker, but arranged to alarm and inhibit closure. Trip Circuit supervision is not typical for ANSI (U.S.) applications. 5.1.2 Protection Relay Self-Diagnostic (74): The relay self-diagnostc (internal fault alarm) on microprocessor based relays shall be alarmed to the plant distributive control system (DCS). This function continuously checks the relay for healthy operation and is commonly referred to as relay watchdog. A relay malfunction would not trip the breaker, but arranged to inhibit closure. 5.1.3 Lockout/Tripping Relay (86): LockoutTripping Relay 86 shall be arranged to open the circuit breaker on receipt of a trip signal and inhibit closure until reset. Fast-acting protection functions should be arranged to trip directly with repeat contacts operating the lockout relay. This function may be incorporated into a multi-function protective device. 5.2 Earthing Switches: When supplied with switchgear is generally fault make rated, Interlocks are provided on IEC switchgear to prevent re-opening of an earth switch in under two seconds. In this time itis anticipated that protective devices will have operated and the supply disconnected. To be Certain of this backup, earth fault protection should be arranged to trip in under two seconds. ‘Allinformation herein is the confidential property of Ar Producis and Chemicals, ne, unless anole’ Source shown This information is subject to return an demand and must not be disclosed or reproduced without prior written consent. "OAM Products and Chemicals Ine, 25085.3 6 61 | 62 63 6.4 6.4.41 65 66.1 6.6.2 '3EL07003, Rev. 2, Page 4 of 19 DC battery charger: When supplied for switchgear applications, an undervoltage and malfunction alarm should be provided. The alarm setting shall be 90% of the nominal DC operating voltage. PLANT INCOMERS. ‘A primary protection device such as an incoming circuit breaker that is owned and maintained by Air Products is required at all owned and operated facilities (including joint ventures). More detailed requirements can be found in 3ELO7004. Protection at facility plant incomer(s) is largely determined by the nature of the feed to the plant. Itis highly desirable to ensure full protection coordination with the supply provider's feeder device (whether they fall under client or supply authority). By achieving this, any disturbance is contained within the switchgear under Air Products control and there is no reliance on third parties equipment. {f the incoming protection device is upstream of a main plant step-down transformer, refer to Section 7 for the protection requirements. On high reliabilty plants or where there are concerns on the quality of the electric supply, Consideration shall to given to installing a multi-function power metering system. The metering ‘system should include the capability for analyzing power quality issues. The abiity to tie this data Into a communication stream to be analyzed remotely shall also be considered ‘The following protection devices shall be considered: 50,l>> _ Highset Overcurrent with time delay 51> Inverse or Fixed Time Overcurrent SIN,lep> Inverse or Fixed Time Residual Overcurrent Protection 81G,le> Earth (Ground) Fault Protection 74 ‘Trip Circuit Supervision / Relay Watchdog 36 Lockout Relay Incident arc energy calculation results may necessitate additional protection considerations. For ‘example, definite time relays with delayed high sets can be used to reduce arc fault times (refer to paragraph 6.6.1). ‘The following protection devices may be used for general system protection depending on the type of equipment to be protected. This protection may be provided by single relays acting across the switchboard or individually by the motor protection relays (MPR). The preferred protection philosophy includes these functions in each individual (MPR). Refer to paragraphs 8.3.1 and 9.3. 27AC,U< Undervoltage 81,f<_Underfrequency Protection Phase Overcurrent Protection Highset Overcurrent Protection (50): Multunction protection relays typically incorporate the high set element (50) with an adjustable time delay. Use of a time delay on the highset element provides for selective coordination with downstream loads. Coordination with the line-side customer or serving power utility protection setting must also be maintained. Time Delayed/Lowset Overcurrent (51): The incoming phase overcurrent device should be set to protect the entrance equipment such as cable, bus duct, switchgear bus/circuit breakers, etc., and provide back-up protection to downstream loads. The pick-up and time delay should coordinate with largest load-side feeder and with the line-side customer or serving power utiity protection setting, “Allinformation herein is the confidential property of Air Products and Chemicals, In, unless another source fe Showy This information is subject to retum on demand and must not be disclosed or reproduced without prior writen consent "Ai Products and Chemas, ne, 2008Ie7 6.71 672 7A TAA 72 724 7.22 9EL07003, Rev. 2, Page 5 of 19 Earth Fault Protection Time Delayed Residual Overcurrent (51N): A residual overcurrent device connected in the neutral of the three-phase current transformers can provide protection for earth faults. A typical pickup up to 20% of the primary current transformer (CT) rating is recommended with a delayed inverse or definite time characteristic curve to allow for coordination with downstream devices. On ow resistance earthed systems, zero sequence overcurrent protection (51G) may be required to improve sensitivity. Zero Sequence Earth Fault (51G): A core balance CT for a dedicated earth fault input into the relay should be considered to improve sensitivity for low resistance earthed systems. The pick-up should be set up to 20% of the resistor's 10-second rating. A delayed inverse or definite time characteristic curve should be used to allow for coordination with downstream devices. TRANSFORMER PROTECTION ‘The following protection devices shall be considered for transformer feeders fed from circuit breakers or latched contactors: HRC Fuses (Medium Voltage (MV) contactor feeders only) 26, @> Transformer Winding Temperature (alarm at DCS) 50,b> Highset Overcurrent 51> Inverse or Fixed Time Overcurrent 50G,IE>> Highset Earth (Ground) Fault 51G,IE> Inverse or Fixed Time Earth (Ground) Fault 51N,lep> Inverse or Fixed Time Residual Overcurrent Protection (where applicable) 63 ‘Sudden Pressure Relay/Buchholtz 87,1 Biased Differential Protection (transformers over 5 MVA) a Transformer Oil Level (alarm at DCS) 74 ‘Trip Circuit Supervision / Relay Watchdog 86 Lockout Relay ‘The following protection devices should be used for the Low Voltage (LV) Al Circuit Breaker (ACB) incomer: 50,l>> _ Highset Overcurrent (where applicable) 51,> Inverse or Fixed Time Overcurrent 5IGIE> Earth (Ground) Fault 74 ‘Trip Circuit Supervision Relay (not typical for ANSI applications) 86 Lockout Relay (not typical for ANSI applications) ‘Temperature Protection: Temperature protection devices on transformers shall be sat to alarm rather than trip the unit. Depending on the type and arrangement of the transformer, temperature protection can be afforded in different ways. Dry-type/cast-resin transformers use RTDs embedded in the transformer secondary windings. ‘+ Liquid-filed transformers use RTDs to measure the liquid temperature and a current-based unit to model the thermal capacity of the winding. When forced cooling is provided, the temperature control and protection units should be located at the transformer. ‘¢ Ast stage (HI) to initiate start of the cooling fans. ‘2nd stage (HI Alarm) to alarm on rising temperature. Recommended settings should be provided by the transformer manufacturer. ‘Allinformation herein is the confidential property of Air Products and Chemicals, Ic, unless another source me show This information is subject to return on demand and must not be disclosed or reproduced without prior wniten consent. AK Prods and Chemica, in, 2008[73 | 7.34 734A 7.342 732 73.24 7.33 73.3.2 7.34 3EL07003, Rev. 2, Page 6 of 19 Protection of Transformers with a Medium Voltage Secondary Winding ‘Transtormer Primary Highset Overcurrent (50): Where transformers are fed from circuit breakers, protection against short circuits shall be provided by a high set overcurrent function. The current setting should be chosen to remain stable to inrush currents (up to 12 times rated current for transformers above 2500 KVA and eight times rated current for transformers 500-2500 KVA) with a 0.1 second duration, and to be stable for short circuits on the secondary system, which should be cleared by the downstream device. If the interrupting device is a circuit breaker, the high- set can be set with no intentional delay. To avoid nuisance tripping this instantaneous trip setting should be greater than the transformer inrush and secondary let-thru current. Secondary let-thru current is defined as the maximum secondary fault current through the transformer (without secondary motor fault contribution) referred to the primary side voltage. ‘Where transformers are fed from fused isolators or contactors, protection against short circuits shall bbe provided by high rupture capacity (HRC) fuses. The ratings of the fuses shall be selected to protect the transformer and feeder cables while remaining stable to inrush currents. Fuse ratings shall not exceed 300% of full load current (FLC). If a definite time (DT) setting is used in conjunction with the fuse characteristic curve, it shall delayed to allow sufficient time for transformer inrush. The DT setting should be evaluated along with the fuse characteristics to avoid damage of the ‘contactor. This requires the protection relay characteristic curve not to be set mora sensitive than the fuse curve for values above the interrupting rating of the contactor. Damage can occur when ‘attempting to interrupt currents beyond the contactor's rated interrupting capacity. ‘Transformer Primary Time Delayed Overcurrent (51): In general, the relay pickup should be equal to the cable or the transformer current rating, whichever is lower. Time delay should place the relay operating curve below the transformer withstand, but above the LV protection curves with allowances for grading margins. When transformers are fed by fused contactors, the overcurrent protection relay (51) setting should be evaluated along with the fuse characteristics to avoid damage of the contactor. Refer to the efinite time setting that was discussed in paragraph 7.3.1.2. ‘Transformer Primary Earth Fault Protection: Generally, part of the overcurrent device both high- set, (instantaneous or definits time) and low set [inverse definite minimum time (IDMT) or definite time] capabilities may be required to address earth faults in the MV cable and all parts of the transformer primary windings. The output of the relay should be arranged to trip and lock out [via a lockout relay (86)] tha primary protective device. Time Delayed Residual Overcurrent (51N): A residual overcurrent device connected in the neutral of the three-phase current transformers can provide protection for earth faults. A typical pickup up to 10% of the primary CT rating is recommended with a delayed inverse or definite time characteristic curva. The delay is required to avoid tripping due to residual current unbalance (spill currents) due to transformer inrush. Some multi-function protection relays have the capability tofiter out the DC offset and harmonic components of the residual current unbalance, On low resistance earthed systems, zero sequence overcurrent protection (51G) may be required to improve sensitivity. Zero Sequence Earth Fault (50G): On medium voltage systems that are low resistance earthed, a core balance CT for a dedicated earth fault input into the relay should be considered to improve sensitivity. The pick-up should be set up to 10% of the resistor's 10-second rating and coordinate with the upstream protection setting. No intentional delay is required since transformer inrush or motor starting should not adversely affect the CT output, Transformer Secondary Earth Fault (51G): This provides backup earth fault protection for the downstream devices on the MV switchgear supplied by the transformer. Generally Air Products MV systems are low resistance earthed. The selection of the earthing resistance should consider minimizing damage to equipment and being able to detect faults. Air Products plants are typically earthed using a 400A neutral earthing resistor (NER), “Alinformation herein s the confidential property of Ar Products and Chemicals, na, unless aniher source ie shown This information is subject to return on demand and must not be disclosed or reproduced withaut prior wniten consent. "A reduc and Chemicals, In, 20087.3.4.1 7.3.4.2 [74 7.44 TAAA TAIZ 7.4.2 7.4. 7422 7.4.3 ‘Al information herein s the confidential property of Air Products and Chemical 3EL07003, Rev. 2, Page 7 of 19 ‘The backup earth fault protection is usually an inverse or fixed time overcurrent relay connected by € current transformer on the earthing resistor (or transformer Xo connection), The pick-up on the time overcurrent relay should be set up to 20% of the resistor's 10-second rating and should coordinate with the downstream protection. This relay should be used to trip a device on the high side of the transformer. The output of the relay should be arranged to trip and lock out [via a lockout relay (86)] the primary protective device, and the secondary protective device if available, When an earth resistor is supplied by Air Products, there must aways be an automatic circuit ‘opening device on the high side of the transformer to protect the resistor. Ifa high side opening device is not available, a solidly earthed system should be used unless an approved method is, found to protect the resistor. Protection of Transformers with a Low Voltage Secondary Winding Highset and Overcurrent (50/51): Separate relays shall be provided for both the MV feeder and the LV incomer citcuits. The following inter-trip philosophy applies forall IEC applications and for ANSI applications only when LV switchgear circuit breakers are used. ‘The MV lockout relay (86) should be arranged to operate for any of the electrical protection trip conaitions associated with the MV circuit, transformer protection devices, or a signal from the LV Circuit lockout relay (inter-trip LV to MV). ‘The LV circuit lockout relay should operate only from the electrical protection trip conditions associated with the LV incomer circuit. However, an auxiliary contact from the MV feeder should be connected directly into the LV incomer trp circuit such that any time the MV feeder is opened, the LV ACB will automatically open (inter-trip MV to LV) and to inhibit closure. This eliminates the possibilty of back feeding the MV winding and ensures orderly re-energization of the system post fault clearance. Transtormer Secondary Earth Fault (51G): This provides backup earth fault protaction for downstream devices on the LV switchgear supplied by the star winding of the transformer, The relay setting shall be coordinated to allow the downstream devices to clear a faut first. Protection shall be provided by a time-delayed protection element, operated by a CT in the transformer ‘secondary neutral to earth connection. ‘The output of the relay should be arranged to trip and lock out [via a lockout relay (86)] the LV ACB, Where provided, and trip and lock aut the MV feeder switching device. Consideration should be given to the use of an independent CT and relay for backup protection, particularly if there is no effective backup protection upstream, LV Incomer Protection: Subject to compliance with nationaVlocal codes, the LV Incomer circuit breaker may be omitted provided that the MV isolating device is located in the same room and is clearly identifiable as the isolating device for the switchboard, This philosophy can also be applied to LV distribution boards, variable speed drives, and heater control panels fed from a switchboard in the same room. When the LV Incomer is omitted, the following protective functions are stil required (on the LV system, but shall be arranged to trip the MV device, Refer to Appendix C for application ‘examples, S1,f> Inverse or Fixed Time Overcurrent 51N,lEp> Inverse or Fixed Time Residual Overcurrent Protection 51G,l> Stand-by Earth Fault (where applicable) 64 Restricted Earth Fault (where applicable) 86 Lockout Relay The, unless another source 6 shown This information is subject to return on demand and must not be aisclesed or reproduced without prior wniten consent, © lr rosucts and Chemis, a, 200878 76 7.64 7.62 7.63 “Ailiniormation herein is the confidential property of Ar Products and Chemicals, ic, '3EL07003, Rev. 2, Page 8 of 19 Blased Ditterential Protection (87): This protection is provided on transformers over 5 MVA. The relay detects phase faults within the protected zone and also high level earth faults on the MV winding by monitoring any difference between the current into and out of the transformer. This Protection provides rapid clearance of transformer faults without affecting coordination, as it Temains stable for out of zone faults. The differential current element should incorporate 2" and 4" (4" if available) harmonic restraints that provide security against inrush currents during transformer energization. For generator-connected transformers, or following a load rejection, the transformer may experience an excessive ratio of volts to hertz, that is, become overexcited. Since the 5" harmonic is a characteristic of over-excitation it is recommended that the 5” harmonic restraint is ‘enabled on cogeneration applications. Tank Pressure/Gassing Protection: Protection against tank overpressure or oil gassing shall be provided according to the following table. Breathing Transformer | Sealed Transformer TEC (typical) IEC ‘ANSI Buchhoitz Trip N/A’ NA ‘Sudden Pressure Relay (SPR) NA NA. Trip Pressure Relief Device Trip Trip ‘Alarm Buchholtz Protection (63): The Buchholtz device detects gas migration from the transformer tank to the conservator. A rapid movement of a quantity of gas is likely to have been caused by a failure of the winding insulation. This element should be arranged to trip the MV Feeder. A gradual build-up of gas is symptomatic of a fault developing or poor oil quality. This element should be arranged to alarm only. Set points should be advised and set up by the transformer manufacturer. ‘Sudden Pressure Relay (63): The SPR detects the occurrence of a potentially destructive over- pressure event, The device looks at the rate of pressure increase and sends a trip signal to the MV Feeder if a rate exceeding a safe threshold is detected. The device typically will incorporate a seal- in-relay that latches the output relay and lights an indicator until it is reset. Its typically applied to transformer units over 5 MVA or on a critical load. Pressure Relief Device: The device is a disk-type pressure relif davice that operates at a pre- determined pressure. To indicate the device has operated, a brightly colored actuator arm is ‘ypically provided. MEDIUM VOLTAGE MOTORS ~ INDUCTION AND SYNCHRONOUS. ‘The majority of protection functions for medium voltage motors are similar for both induction and synchronous motors. The following protection functions shall be used for either medium voltage induction or synchronous motors. Some of these devices or functions may be located in either the ‘switchgear or excitation control panel. 27AC,U< AC Undervottage 27DC DC Undervoltage (as described in Section 8.5) 46,12 Negative Phase Sequence 47,U> Phase Reversal 48 Incomplete Sequence Timer (reduced voltage starting and synchronous) 50,f>> Highset Overcurrent St,l> Inverse or Fixed Time Overcurrent 50G,le> Earth (Ground) Fault Protection 87, 1d> _ Differential Protection - typical for motors 1500 hp / 1000 kW and larger 95 Stall Protection ilass another sources shown, This information is subject to return on demand and must nat be disclosed or reproduced without prior wnitien consent. ‘As Products and Chemie, ne 2008att a1. a2 824 8244 8.2.1.2 822 82.2.1 3EL07003, Rev. 2, Page 9 of 19 ‘Additionally, motor winding thermal protection shail be provided through the plant control system (OCSIPLC) by motor RTD input to the control system, 49 Thermal Overload 49A Winding Over Temperature The following auxiliary devices should also be provided: 74 Trip Circuit Supervision / Relay Watchdog 86 ——_Lockout/Tripping Relay 86S Source Protection Lock-out (Used in conjunction with 27DC per Section 8.6.1— typical for ANSI applications) For motors rated lass than 1500 hp / 1000 kW and fed from citcult breakers, a second (back-up) protection relay is not required if back-up earth fault and overcurrent protection is provided by Upstream device(s) located on Air Products owned and operated equipment. Refer to paragraph 8.2.5 for back-up protection relay requirements on motors rated 1500 hp / 1000 KW and larger. Overcurrent Protection Highset Overcurrent (50); The protection of motors and the cables supplying the motors for high current short circuit faults will depend on the type of motor starting equipment. For motor applications aver 7 KV or above 4000 hp/2983 kw, metal clad switchgear using circuit breakers for starting and stopping duty along with fault clearing will be used. For motors under 7 kV and 4000 hp/2983 kW or less, fused interrupting contactors may be used. The medium voltage contactors typically will not be required to interrupt the higher fault current but will use the fuses for clearing a fault ‘On motor applications with circuit breakers, a high set instantaneous current relay setting should be used to trip the breaker for short circuit faults in the motor or feeder cables to the motor. A setting of 190% of the full voltage Locked Rotor Current should be adopted. This will ensure no false tripping {rom the asymmetrical current associated with the inrush to the motor. When microprocessor relays are used that incorporate minimal transient overreach, a setting range of 125-150% of locked rotor current may be considered. ‘When a motor is fed from a fused MV contactor, protection against short circuits shall be provided by hhigh rupture current (HRC) fuses. The ratings of the fuses should be selected to protect the motor feeder cables, permit the required frequency of starts, and to rapidly clear a motor short circu fault. Note: The fuses will not clear MV earth faults where neutral earthing resistors are used (reference Section 8.2.3). Motor Overcurrent (51)/Thermal Overload (49): Protection against overloads due to excessive ‘mechanical load or a locked rotor shall be provided by a multfunction motor protection relay with adjustable currenttime curves, and thermal memory with variable trip times dependent on prior loading. These relays model the thermal capacity of the machine by continuous computation of the current input and the initial thermal capacity. This model enables the motor to be fully used, while stil keeping within the motor thermal withstand characteristics. Such relays generally provide Stall Protection (98) and Restricted Start Protection. These elements trip the motor in the event of a stall locked rotor current after running), and prevent restart until there is suticient thermal capacity remaining in the machine to withstand the high currents during run up, The thermal overtoad pickup level should be set to 105% Full Load Current (FLC). The time setting of the relay should be set to provide 2-5 seconds coordination time between the relay time curva and the motor starting curve, but must remain below the motor’s withstand curve. For different power system configurations, the starting curves corresponding to both the strongest and weakest sources shall be plotted. ‘inlass arvather source Ts shown. ‘confidential property of Ar Products and Chemical Tereinis Ths information is subject fo retum on demand and must ot be disclosed or reproduced withoul prior written consent. D Air Preis and Crema ne, 20083EL07003, Rev. 2, Page 10 of 19 Note: There is often a Resistance Temperature Detector (RTD) option in electronic motor protection relays; this option should not be used. Air Products’ standard is to monitor stator RTDs in the plant DCs. Note: The engineer should consult with the motor supplier (and auto-transformer supplir if appropriate) to determine the appropriate hot and cold motor starting times and ensure that these are included in the relay settings, if possible, and included in the plant operation manual. Note: An alarm point of 100% motor full oad current is incorporated in the DCS. 8.2.3 Earth Fault (50G): Earth fault protection that is sensitive to phase to earth faults occurring between the motor stator winding and the core/frame, in the motor terminals, or in the connecting cable is required. Residually connected earth fault protection is not acceptable on medium voltage (MV) motors. 8.2.3.1. Sensitive protection is required when the MV system earth fault level is limited by resistors. A core balance current transformer (CT) (typically 50:1 or 50:5) in the MV switchgear shall be used to provide the input to the relay, and a low set, instantaneous element to trip the circuit breaker. 8.2.3.2 The motor feeder shall have instantaneous protection, which would be set as low as possible, but not low enough to be tripped by the system capacitive current. 50G trip setting up to 10% of the ‘motor bus earthing resistor value, but typically not higher then 50A. 8.2.3.3 For applications on medium voltage systems that are solidly earthed, the available earth fault current may be high enough to saturate a low ratio earth fault current transformer. This type of application should be reviewed with starter / switchgear supplier to confirm CT and relay performance. Note: In contactor/E2 starters a time delay might be required to allow the fuse to clear high level faults, preventing the contactor opening on a fault above its breaking capacity. 8.2.4 Negative Phase Sequence (46) (Unbalance): This protects the rotor from overheating due to any unbalance in the stator winding currents, Negative phase sequence currents can arise from an unbalance in the supply line voltages due to unbalanced parallel loads, excitation, or motor faults. If a recommended set point is not available from suppliers, a setting of 15-20% of FLC and a time delay of approximately 3 seconds shall be adopted. 8.2.4.1 Negative sequence currents in the stator produce a reaction field rotating in the opposite direction to the rotor field. Double frequency currents induced in damper windings and solid rotor poles give rise to a heating effect in proportion to the square of the negative phase sequence current. 8.2.4.2 The heating effect in the rotor can be severe and cause damage to the machine. 8.2.5 Differential Zone Protection (87): This provides high-speed sensitive protection for a motor's stator windings and possibly feed cables against phase-phase faults and high level earth faults ‘while remaining stable for out ot zone faults. Protection is achieved by measuring any imbalance in the current flow into and out of the protected zone. This provides rapid clearance of motor faults without affecting coordination. Differential zone protection shall be applied on motors rated 1500 hp / 1000 kW and larger. 8.2.5.1. For owned and operated plants (including joint ventures), the motor differential protection incorporated in switchgear units shall be provided by a discrete relay, separate from the ‘multifunction digital motor protection relay. For sale of equipment (SOE) plants and fused MV contactors, the motor differential protection may be integrated into a single motor protection relay. 8.2.5.2 Generally the three CT scheme is preferred, looping the star point connection leads back through the feeder set of CTs located in the motor terminal box or surge cubicle. 8.2.5.3 A 50A primary CT should be adopted as the steady current in the system should be zero. The relay should be set to the order of 2.5% of the motor FLC or equal to the earth fault setting, whichever is, the lower. “Alinformation herein the confidential property ofA Products and Chemicals, Me, unless another source & shown This information is subject to return on demand and must not be disclosed or reproduced without prior written consent. 1A Products and Chemizas ie, 200882.5.4 8.2.5.5 8.2.5.6 a3 83.4 83.2 84 844 843 8.4.3.1 8.4.3.2 | as 3EL07003, Rev. 2, Page 11 of 19 The six CT scheme (using two sets of matching Class X CTs located in the circuit-breaker feeder and in the neutral ends) may be adopted where the cable size is too great to allow looping through the CT. To ensure identical characteristics the same manufacturer should supply both sets of CTs (switchgear or motor), Where the six CT scheme is adopted, the relay might be exposed to high voltages if one CT saturates ahead of another. To protect the relay against these voltages, nonlinear and stabilizing resistors may be required. Additional requirements such as calculating the CT knee point voltage should be considered. ‘Some modem electronic protection relays use separate inputs for the two sets of CTs. In these cases class X CTs, stabilizing and nonlinear resistors may not be requited. Voltage Protection: The protection functions may be provided by a single relay acting across the entire switchgear (typically mounted in the incoming or VT section) o individually by the motor protection relays. Undervoltage Protection (27AC): Undervoltage protection is provided for two functions. One: setting is used to prevent closure of motor feeders if the supply voltage is not high enough. A. setting of 90% of busbar voltage should be selected. The second, a lower voltage setting, is used to trip the motors protecting them from overload if the supply voltage gets too low. This should be set high enough to protect the motor from damage due to low voltage operation, but also low enough ‘80 as not to trip on the voltage dip due to motor starting. A setting range of 70-80% is suggested for the low voltage contact, with a time delay of 300 mSecs up to 6 seconds depending on system historical data, Phase Reversal (47): If the actual system phase rotation is opposite from system rotation as set into the motor protection relay, the motor will be blocked from starting. ‘Thermal Protection Winding Over-Temperature (494): if there is a failure of a motor's cooling system, a motor can ‘overheat without exceeding the full load current. Winding Tempsrature Monitoring should be provided by RTDs embedded in the stator windings. The current practice is to wire these to the plant control system for monitoring, alarm, and trip. Note: Additional guidance is provided in 3EL02010. Incomplete Sequence Timer (48):_A timer shall be used to ensure that the starting sequence has been completed before damage to the motor can occur. The failure to complete a start sequence shall trip the motor and starting system and an alarm initiated. The time should be set between the calculated start time and the maximum start time according to the manufacturer's data. Run up Stall Protection (98): If a motor’s calculated run up time is greater than 90% of its safe stall time, a speed switch shall be used to confirm that the motor has started to tum after a start Refer to 3EL02015. ‘Speed setting should be at approximately 10% running speed. Time delay settings will be dependent on the calculated motor run up curve and safe stall time, but should be approximately double the calculated time to run up to 10% speed. Failure of the motor to reach the set speed in the set time would result in the start being aborted, Synchronous machines might reach a position of stability below synchronous speed during run up. To protect against this condition, a second speed switch should be employed to ensure the motor reaches synchronous speed. This signal may also be used to trigger the excitation of the motor. (Alternatively an undercurrent relay may be used to detect the drop off of starting current as described below), DC Undervoitage Protection (27D): Circuit breakers used as motor starters shall include an undervoltage release (UVR) mechanism in case ofa failure of the DC control voltage. Ailinformaiion herein the confidential property of A Products and Chemicals, Ic, unless anolrer source & shown This information is subject to return on demand and must not be disclosed ar reproduced without prior witten consent. Ar Prodits and Chemias inc, 200885.1 85.2 92 924 9.3 9.3.1 9.3.44 36107003, Rev. 2, Page 12 of 19 ANSI applications shall have a direct-acting undervoltage release trp coll wired in series with the switchgear door or field-mounted emergency stop pushbutton, The UVR will be supplemented with ‘an adjustable DC undervoltage relay (27DC or 27S) set to trip the motor(s) offing if the DC voltage drops below 85% of nominal for more than 1 second. The 27DC shall trip and block-close the circuit breaker via an 86S lockout relay. Refer to 4WEL-52157, Type 7 - Source Protection Equipment Group for ANSI-designed plants. ‘As a minimum for IEC applications the UVR shall cause the opening of the breaker after the control voltage has fallen below the lavel where the trip coil can operate. This functionality may be provided by either a release built into the breaker or by means of a separate relay. If a separate relay is used, this shall have the abilty to adjust the voltage and time delay as required. SYNCHRONOUS MOTORS ‘The following protection functions shall be used specifically for the protection of synchronous. motors. These devices may be located in the switchgear or excitation control panel. 53 Field DC Undervoltage Bi,f<__Underfrequency 78(55) Out of Step (Power Factor) Fleld DC Undervoltage (53) (On manual excitation contro! a DC undervoltage relay shall be used to monitor the excitation control circuit OC voltage. The relay contact will be used as a permissive for starting to ensure the DC for field application is on prior to starting. For vendor-supplied automatic excitation control panels, this function may be included as part of the panel controls. Underfrequency Protection (81) Loss of Mains: Underfrequency protection should be used to trip the medium voltage synchronous motors off line when the line voltage is lost and the frequency decays. When the voltage source is lost, the motors in the plant will continue to generate a voltage, but the frequency of that voltage decreases as the compressor/motor system decelerates. Induction ‘motors, without a sustained source of field excitation will have the generated voltage decay very quickly and is dependent on the motor open circuit time constant. Synchronous motors, with a separately supplied field excitation will generate voltage for a longer period. The combination of different ratings and types of medium vottage in the plant will result in a different length of time for the protective relays to sense this decaying back generated voltage from the switchgear voltage transformers. The underfrequency relay function detects this decrease in the back generated voltage frequency and trips the breakers or opens the starters to ensure the motors are disconnected from the line prior to the utility reclosing its main feed. If the motors are not disconnected from the supply when source voltage is restored, there is a possibilty of the incoming source voltage and the motor internal voltage being out of phase. This can result in high currents and torque that can damage the motor, coupling, or driven equipment. ‘The undertrequency protection should typically be set at 0.5 Hz below normal frequency (59.5 or 49,5) with a total time delay of 6 cycles. Some relays have an inherent time delay and this should be checked to avoid introducing an additional delay. Because of the economic impact of tripping a synchronous motor off-line, the engineer may be required to perform a more detailed analysis. For this detailed analysis historical utility system information should be reviewed along with motor frequency and undervoltage tolerances, compressor torsional limits, and a compressorimotor deceleration calculation performed. The engineer can then ensure the line reclosing does not occur before the motors are disconnected and determine an optimal setting for the underfrequency trip The required running tolerances for voltage and frequency are defined as follows: a, Plus or minus 10 percent of rated voltage, with rated frequency b. Plus or minus 5 percent of rated frequency, with rated voltage c. A combined variation in voltage and frequency of 10 percent (sum of absolute values) of the rated values provided the frequency variation does not exceed plus or minus 5 percent of rated frequency. Til formation herein is the confidential property of Arr Producis and Chemicals, Ine, unless anoiher source is shown — This information's subject fo etum on demand and must not be disclosed or reproduced without prior written consent. © Ar Preduts and Chama ne, 200836107003, Rev. 2, Pago 13 of 19 |f an appropriate underfrequency setting can not be found, rate of change detection should be considered with a setting in the 0.5 Hz to 1.0 Hz per second range. 9.3.2 While underfrequency protection is typically only required on synchronous motors, the engineer should be aware on larger, more important induction motors that are applied to systems with reclosing devices that underfrequency protection may be necessary. 9.4 Pull Out Protection/Out of Step (58/78): This protection function senses when a motor loses synchronism through overload or field failure by measuring power factor. With the field energized loss of synchronism may result in significant torque and current pulsations causing mechanical damage to shatts, couplings, and gear boxes. With the field de-energized the motor will act like an induction motor. Large and potentially damaging currents will be induced in the rotor. Note: Power factor at pull out is typically 0.85-0.95. Pole siip will see the motor swing through zero power factor. 9.4.1 The standard relay setting is to trip on motor lagging power factor of 95% with a 1 second delay. ‘The trip is blocked during starting until after synchronizing by a time delay relay or by the motor protection relay providing this function. 9.4.2 Where an out of step protection relay is provided as part of a supplier-provided excitation panel, the ‘supplier's standard relay may be used subject to Air Products approval, 8.5 Undercurrent Relay (37): When required by the motor manufacturer, it might be necessary to ensure @ motor is up to speed before applying the exciter field. This may be achieved by detecting the drop off of the inrush circuit. A typical setting would be to drop out at approximately 1.5 times {ull load circuit or as recommended by the motor supplier. This device may also be used to initiate ‘changeover of supplies in an auto-transformer starting sequenc 8.6 Diode Supervision (58): This should not be specified, but is acceptable if supplied at no extra charge from the excitation panel supplier. Where brushless machines are used, protection should be provided to detect and indicate faults in the rotating rectifier diodes of the excitation circuit (i.e., ‘both broken and short circuited diodes including a diode fuse blow). The relay is connected in series with the excitation circuit ofthe pilot exciter and should be arranged to trip for a diode short circuit condition, and alarm for diode open circuit condition, 10, AUTO-TRANSFORMER/CAPTIVE TRANSFORMER FEEDERS 10.1 Two power circuit solutions exist for the arrangement of auto transformer or captive transformer start schemes with slightly different protection arrangements. In broad terms the protection requirements are those of both a transformer and a motor. A typical autotransformer protection Scheme is shown in Appendix B. The following elements are required, 10.1.1 To protect the transformer: 26 Transformer Winding Temperature (alarm at DCS)* 49 Thermal* 50,l>>Highset Overcurrent 51,f> Inverse or Fixed Time Overcurrent 50G,lE> Earth (Ground) Fault 63 Buchholtz (when appropriate, refer to paragraph 7.10.1 for details) 63 ‘Sudden Pressure (when appropriate, refer to paragraph 7.10.2 for details) 1” Transformer Cil Level (alarm at OCS) 86 Lockout Relay “not used on autotransformer starting 1 10.1.2 To protect the motor refer to Sections 8 and 9, Allisformation herein s the confidential property of Ar Products and Chenvcals, Wic, unless anolher source shou This information is subject 10 return on demand and must not be disclosed or reproduced without prior wntten consent, ‘Air Predicts and Chama, In 200810.2 10.3 Waa 12. 124 122 12.3 ‘3EL07003, Rev. 2, Page 14 of 19 To ensure that the CTs feeding the Motor Protection Relay "see" the starting current, a set of CTS is required in the motor line or neutral leads. CTs are also required at the feeder circuit breakers to provide overcurrent and earth fault protection for both the auto transformer and motor feeder cable, which would not be covered by the CTs in the motor terminal bow/ine or neutral leads. and recommended settings are in Sections 7, 8, and 9. Details of the protection device: EXPANDER GENERATORS Expander generators shall generally be treated as cage induction motors. Additional protection shall be provided to protect the expander from prolonged operation without gas passing through it. The operational arrangement ofthis protection shall be determined in consultation with the machinery group and controls group. It is acceptable for a directional power signal to be sent to the DCS and this protection function to be performed in the DCS. Altematively, a ime-delayed Reverse Power Relay (32) may be employed. Where a reverse power relay is used, itis important that the starting configuration of the turbine is considered as the run up time of the machine may be longer than the available delay time on the relay. The most common solution is for a separate timer relay to be used as a trip enable. In this case itis important to ensure that the reverse power relay auto resets, as otherwise the drive will trip once the time has timed out irrespective of whether the machine has started generating or not. ‘A degree of care is required when setting up the motor protection relay for expander generators as some protection devices will not acknowledge a drive as running ifthe start-up current is not ‘seen by the relay. This is possible where an expander is started using gas, rather than starting the drive ‘as a motor and then introducing the gas. (CO-GENERATION (Synchronous Generators) The electrical engineer must provide and coordinate system protection and synchronizing schemes with the connecting utility and/or customer. Depending on the size of the generator, and the number of generators in the electrical system, stability and load shed studies need to be considered to determine the operating modes of the generator. The critical parameters while synchronizing synchronous generators to electrical systems are delta, phase angle, delta frequency, and delta voltage magnitude. If a synchronous generator is allowed to be connected to an electrical system outside of established levels for these critical parameters, severe system disturbances as well as damage to the generator, prime mover, and generator breaker may result. ‘Typically synchronous generators have a gas or steam turbine as the prime mover. Often the slectrical protection relays are located in the generator control panel and can be supplied as part of the turbine/generator control package. The following relays are an example of typical devices to provide synchronous generator protection: Generator overexcitation (24) Generator undervoltage (276) Reverse Power/anti-motoring (32-1) Loss of excitation (40-1,2) Current unbalance/negative phase sequence (46) System Phase Fault (51V) Generator over vottage(59) Stator Ground Detection (64G1)(59GN) Generator over/under Frequency (810-1,81U-1) Generator Differential (87G) Voltage Transformer fuse failure (VTFF) Synchronizing undervoltage relay (27BS-1,2) Breaker Failure Protection Relay (50/62BF 628F) Bus ground detection relay (598N) “Ailinformation herein ihe confidential property of Ar Producis and Chemnicals, Inc, unless another source i Shown. This information is subject to return on demand and must not be disclosed or reproduced without prior wntten consent. Ai Products nd Chemical, ne, 20083EL07003, Rev. 2, Page 15 of 19 12.4 Ifthe on-site generation during normal operation results in net export of power to the utility, means to identity a lost utity connection shall be provided. Overlunder voltage (Dev 59/27) and overlunder frequency (Dev 61) protection is required to sense loss of connection and to separate the plant from the remaining portion ofthe grid prior to the utility re-energizing the connecting circuit. The overfunder voltage will be based on normal voltage variations of the system, but typically +10% to -15%, with 1.0 second delay. Over frequency set at mains frequency plus 1.0 Hz with 0.5 to 1 second delay. Under frequency settings are usually established by the ulilty. The use of rate of change of frequency should be considered as a more positive means of separation detection. 12.4.1. Plants with a significant portion of the electrical load supplied by synchronous generation (induction expanders or stand-by diesel generators are not included) should include alternative protection requirements. 12.4.2 When the generation is insufficient to power the entire plant load, some means of load shedding will be required. This might be initiated by the inter-tia circuit breaker opening, or frequency decay. 13, ARC FLASH REQUIREMENTS. 13.1. Anarc flash study will calculate the incident energy level using the bolted 3-phase fault current along with the trip time. Trip times are determined from protective device settings and the arcing fault current values. The incident energy level is then used to determina plant personnel protective ‘equipment requirements for operation and maintenance activities at Air Products facillies, Protective device settings will impact not only plant reliability but also personnel safety; therefore, each protection relay overcurrent setting should be evaluated to determine the incident energy for the downstream protected location weighed against the selective coordination between protective devices. 13.2 It may be necessary in some circumstances to change protection settings to reduce the arc incident energy level during maintenance activities, ‘Allinformation herein's the confidential property of Ar Products and Ohemeals, I, unless anole’ source Show This information is subject to retum on demand and must not be disclosed or reproduced without prior wntten consent. ‘Ar Products and Crema ne, 2008'3EL07003, Rev. 2, Page 16 of 19 Appendix A ANSIIEC RELAY SYMBOLS Sepeon man) ono Coain ast] cea {ee | | overspend 2 = Inve tee et fut | fers] | [_ Sees 2 caiman sie | Underpeed relay Mu ee Define te cath faut | saay re: i — | Oetanceresy a | Ge] Meerctemtonmatel! gy | fuse | Sevsren ray me T Ovmtempestscreny | 26 a Power fate oy — | Undewotane ea a7 Te] | Ovmningeray | 59 U Orestanal overpower | 32 To] | Newralponedipicenent | say Za ey Pe ‘cay fot Underpower rey ” Pe Earthly a Undearetrey a Te] | Diestenatovereirentehy| 57 > ] Wegtnesequeneceiy | 46 Ta] | ovectisatenth tuttnay | 670 ah Negative: semmnee vole a7 ‘hase angle relay 7 oF ‘ony Tramaeay 49 4 Autores lay | [ST Innes veraarent 0 be Underrepenay rl supoaren fry aw F recetneoeairet | 51 Ovrkequeny ley a0 p | iterntaieeey | or le “Tilinformation herein is the confidential property of Arr Products and Chemicals, na, unless another source Shown This information is subject fo retumn on demand and must not be disclosed or reproduced without prior written consent lr Products and Chania, In, 20083EL07003, Rev. 2, Page 17 of 19 ‘Appendix B ‘Typical Auto Transformer Scheme “ilinformation herein i the confidential property of Ai Products and Chemicals, Ine, unless another source s Shown: This information is subject to return on demand and must not be disclosed or reproduced without prior wniten consent alr Prods ad Chama, ne, 20083EL07003, Rev. 2, Page 18 of 19 ‘Appendix C Option to Eliminate LV Incomer MV LATCHED CONTACTOR MV SWITCHGEAR LV SWITCHGEAR/MCC Lv SWITCHGEAR/MCc > EARTH BUSHING CT MAY BE USED IN PLACE OF RESIOUALLY CONNECTED SIN. (ON SOLIOLY EARTHED SYSTEMS, CT SATURATION SHOULD 8E CONSIDERED, WHICH TYPICALLY NECESSITATES PHASE AND EARTH CT TO HAVE THE SAME PRIMARY CURRENT RATING. Til infomation heren i the confidential property of Air Products and Chemicals, Inc, unless another source Is Shown. This information is subject fo return an demand and must nol be disclosed or reproduced without prior written consent, ’At Pris and Chemica ne, 2008a3 A ALAA A142 AS ANA ANS2 A153 A154 As A161 A162 3107003, Rev. 2, Page 19 of 19 Appendix D Formulae for Calculating Grading Margins Calculating Grading Margins The following formulae for calculating grading margins are taken from the Alstom Protective Relay Application Guide. Between IDMT relays Grading margin t'= (2Em + Ecr) t/ 100+ ty +t +t, Where: Ea = Relay Timing Error (7.5 % for electro mechanical relays, § % for static) Eor= CT Error (Dependant on Class) Circuit breaker opening time Wver shoot time (0.05 Sec for electro mechanical relays, 0.03 for static) safety Margin (.1 Sec for electro mechanical relays, 0.08 for static) {t= operating time of the upstream device. Between DT relays Grading margin t' = (2Eq) t/ 100 + ty + ty +t, (CT error neglected.) Coordination with fuses: When coordinating an IDMT relay with a fuse the grading time should be taken as: 0.4 + 0.15 Wher fuse operating time ‘The best solution is obtained using an extremely inverse characteristic, with a current setting of 3 times the fuse rating. ‘The following are the typical operating characteristics: Standard Inverse Very Inverse Extremely Inverse Long Time standby E/F =o The following are the typical motor characteristics: Cold Curve Hot Curve Where: tip time @ 6 x |, ultiple of set current I overload setting (pu) (1.05) I= Running current as pu of s ial property of Air Products and Chemicals, Ie, unless anatier Source fe ShOnT: This information is subject to returm on demand and must not be disclosed or reproduced without prior writen consent. DAK Products and Chama Io 2008.