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UNIVERSITY OF SYDNEY – SCHOOL OF ELECTRICAL ENGINEERING
ELEC 5204 POWER SYSTEMS

2009 Mid-Semester Assignment (B) – Design of an Industrial Distribution Network

Introduction
This assignment is due Monday 23 May, 2009.

The objective of this assignment is to do the protection design of the high voltage, low voltage
and DC distribution network of a major industrial installation.

The main supply substation steps “sub-transmission” voltages of 33 kV down to “medium


voltage distribution” voltages of 6.6 kV for distribution within the plant and contains two,
33/6.6kV transformers that feed the main customer 6.6 kV bus. There are two distribution
substations off the main customer 6.6 kV bus – a general distribution supply substation with a
single 6.6kV/415V transformer and a variable speed drives (VSD) substation with a single
6.6kV/690V transformer, which provides a dedicated supply to a 3-phase, 6-pole rectifier to
supply the 5 dc motors in the VSDs. The 415 volt supply form the general distribution
substation supplies a range of different loads such as small motor drives, office loads, lighting
and the like. In addition, there is a local generator, a large synchronous motor drive and a large
induction motor drive connected directly to the 6.6 kV bus.

The 33/6.6kV main substation can operate with either 1 or two transformers. The local generator
may also operate or not, depending on circumstances such as fuel availability and amount of
total load connected. The fault levels experienced on the system will vary according to the
number of transformers in service and the availability of the local generator. All lines in the
plant are either heavy cables or bus-ways with negligible impedance. In addition, system
upstream impedance from the 33 kV bus can be ignored and all impedances can be assumed to
be totally inductive in nature.

A single-line diagram of the system and details of the transformers, generator, rectifier and
motors are shown in the attached file “Model Industrial Network”. You can assume a
“coincidence factor” of 85% between the general 415 volt loads and all other loads on the plant.
The 415 V motors are 85% efficient and the large motors and dc motors 90% efficient.

The substations and network are all three-phase. All transformers are delta-star (HV:LV) with
the star points solidly earthed on the LV side.

The Design Task


The design task is as follows. Analyse the system and recommend:-
Confirm transformer impedances and transformer voltage regulations;
The circuit-breaker ratings on all shown circuit breaker positions (at R1-R6);
The differential protection settings on relays D1 and D2 and the associated CT sizes on
the 33/6.6kV transformers;
The overcurrent relay settings on all transformers, generator and synchronous motor (R1
– R6);
The DC fuse ratings and types (current and voltage) on the DC motor drives (F7);
The fusing arrangement and fuse sizes on the rectifier installation (AC and DC sides) (F5
and F6 plus any other fuses you consider necessary);
All AC fuse ratings and types (F1-F4);

ELEC 5204 Mid-semester Assignment B, 2009 P 1 of 6


If it is not possible to obtain a suitably large fuse on the DC or AC sides, recommend a
circuit breaker-relay alternative;
If grading requirements result in very slow tripping times on some upstream relays,
recommend some possible system redesign options (in particular consider the DC supply
arrangements);
6.6 kV cables will be run from the 6.6 kV main bus, to the transformer HV terminals on
the local distribution and VSD substations. Recommend a suitable cable size. Confirm
that the fault levels do not exceed the short-circuit rating of the cables. Amend the
transformer impedances and/or take other corrective action, if need be.

There are both differential and overcurrent relays on each side of the main 33/6.6kV substation
transformers, with overcurrent relays on the local generator, synchronous motor and the 6.6kV
and LV sides of each distribution substation. The differential and overcurrent relays each have
their own CT. Available CT sizes are 60:5, 80:5, 100:5, 150:5, 200:5, 400:5, 500:5, 800:5,
1000:5, 1200:5, 1500:5, 1800:5, 2000:5, 2500:5 and 3000:5 at all voltages. Available circuit
breaker ratings are 315, 630, 1000, 1500, and 2000 Amps with current breaking ratings of 13.1,
17 or 25 kA at 33kV and 6.6kV and up to 35 kA at 415 V and 690 V. The primary current rating
of CTs on the 6.6 kV side of the 33/6.6kV substation transformers will be chosen to suit the
differential protection and the overcurrent relays will have the same CT ratio. All CT
secondaries (and hence also all overcurrent relays) will be 5 amps. You will have to specify the
secondary current rating on the 6.6 kV side of the differential relays on each 33/6.6 kV
substation transformer.

Available fuse ratings are 20, 31.5, 50, 63, 100, 150, 200, 400, 630, 800, 1000, 1500, 2000 or
2500 Amps for both AC and DC. Available 6.6 kV (underground) 3-phase cable sizes are 185
mm2, 240 mm2 and 300 mm2 aluminium. Cable impedances and ratings (in Amps) are shown
below:

CABLE FAULT
DATA R1 X1 RO XO RATING CAPABILITY
185 mm2 0.211 0.102 2.24 0.096 335 15
240 mm2 0.161 0.0983 0.33 0.05 385 15
300 mm2 0.13 0.0958 0.266 0.0487 435 15
ohms per km ohms per km Amps/ph kA for 1 sec

Other Tasks Are:

What are the minimum operating arrangements that will meet maximum loading
conditions, i.e. how many transformers in main 33/6.6kV substation with the local
generator in or our of service;
Confirm that for the transformer impedances suggested, the maximum permissible fault
level of 250 MVA on the 6.6 kV bus and the cable fault capability is not exceeded;
Check that the maximum fault level on the local distribution substation 415 volt bus and
the 690 volt bus of the VS drives substation does not exceed 23 kA;
The DC fault level must not exceed 50 kA;
If necessary, recommend alternative transformer impedances to ensure the specifications
are met (up to 15% on own base); alternatively recommend transformer operating
restrictions in the main 33/6.6kV substation (i.e. can 2 transformers run in parallel at any
time);
If fault currents anywhere exceed maximum fuse availability recommend alternative
actions;

ELEC 5204 Mid-semester Assignment B, 2009 P 2 of 6


Confirm that the maximum voltage regulation on the 33/6.6 kV substation does not
exceed 7.5% (assume purely inductive impedance, on 0.9 lagging PF load), and 3.5% on
both the distribution substation transformers;
Suggest a simplified switchgear/fuse arrangement on the 690 V busbar of the VSD
6.6kV/690V substation.

Standard Relay Characteristics

When choosing the differential relay settings, allow for up to 15% mismatch from the nominal
turns ratio of the 33/6.6kV transformers, due to tap-changer operation. For the overcurrent relays
choose both the current pick-up and time dial settings. The current pick-up must be at least
150% of normal maximum feeder load for transformers, motors and generators to allow for
temporary overloads for up to 2 hours. In addition the setting on the transformer relays must
allow for transformer inrush current (12 times full load for 0.01 second and 6 times for 0.1
second). The distribution transformer HV settings must act as back-up for the low voltage side
and be able to detect LV arcing faults of 4000 Amps phase-neutral. The earth fault pick-up
settings are normally about 20% of the overcurrent, but again relays must grade correctly. Note
carefully the impact of the delta-earthed star winding arrangement on all transformers, and the
impact that will have on single phase to earth faults on the LV side of transformers when
reflected to the HV side.

The standard IEC formula for the operating time of overcurrent relays is:-

“Standard inverse” Time = 0.14 * TL /(I 0.02 –1),


“Very inverse” Time = 13.5 * TL /(I –1),
“Extremely inverse” Time = 80 * TL /(I 2 –1),

Where : Time = the operating time, in seconds


TL = the relay time dial (“time lever”) setting,
I = the relay current, in multiples (per unit) of the relay nominal current (in this
case, the latter will be 5 amps).

A copy of the curves is attached in Fig B.1 (from the lecture notes). An Excel spreadsheet to
calculate the relay and fuse times and draw curves is also available. A copy of the different fuse
time-current curves is shown in Fig B.2.

As part of the analysis, you will have to consider faults at all points on the network, for both
maximum and minimum fault conditions. The overcurrent relays must grade properly between
themselves and all fuses under all fault conditions. Normally, you would use “standard inverse”
on the overcurrent relays on the 33/6.6kV transformers and on the 6.6kV side of both distribution
substation transformers, but you may wish to consider the ”extremely inverse” curve type for the
low voltage sides of the distribution substations, to improve grading with the downstream fuses.
When calculating faults, assume the transformers generator and motors are purely inductive.

In particular, the following grading must occur-

Between the 6.6 kV overcurrent and 33kV overcurrent on the main supply substation
transformers, for faults on the main 6.6 kV busbar, for both one and two transformers in
service and with or without the local generator in service or the synchronous motor (i.e.
between relays „R1‟ and „R2‟),

ELEC 5204 Mid-semester Assignment B, 2009 P 3 of 6


Between the 6.6 kV overcurrent and LV overcurrent on both the local distribution and
VSD substation transformers (i.e. between relays „R4‟ and „R7‟ and relays R6 and R8 ),
for faults anywhere on the low voltage systems (AC or DC sections),

Between the LV substation overcurrent and the outgoing low voltage lines, on both
distribution substations (i.e. between relays „R7‟ and fuses „F2,3 and4‟; and relay „R8‟
and fuses „F5‟) for faults on the low voltage lines,

Between the AC fuse and DC fuse(s) on the VSDs system (i.e. fuse „F5‟ and DC fuses
„F6‟ and „F7‟) for faults on the DC systems.

System Single-Line (Schematic) Diagram

Refer to file “Model Industrial Network”.

ELEC 5204 Mid-semester Assignment B, 2009 P 4 of 6


Fig B.1 - Standard Inverse, Very Inverse and Extremely Inverse Overcurrent Time-Current
Characteristics for 1.0 Time Settings and 100 A current pick-ups.

NB: At a given current multiple, operating time is proportional to the Time Lever setting

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Time Grading Curves
HV Fuse gG Fuse gR Fuse aM Fuse

10000

1000
Op Time, Sec

100

10

0.1

0.01
100 1000 10000
Primary Current, A

Fig B.2 - Standard Fuse Time-Current Characteristics for Common Fuse types and 100 A Fuses.

NB: For fuses other than 100 A, operating time is proportional to the fuse rating/100

System single-line diagram and details of transformers, motors, etc are shown in Attachment.

ELEC 5204 Mid-semester Assignment B, 2009 P 6 of 6

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