Chapter 10

Protection of industrial systems

With the increase in size of industrial plant electrical systems, and the high
short-circuit levels encountered on electricity power systems, it is essential that the
electrical protection arrangements in any industrial installation are correctly designed
and have the appropriate settings applied to ensure the correct functioning of the plant
and continuity of supply within the installation. The importance of maintaining con-
tinuity of supply to industrial installations cannot be over emphasised and, in this
respect, the interconnectors to the public supply system play a vital role. It is crucial
that correct co-ordination is maintained between the protection on the main industrial
supply infeeds and the power system supply feeders.

10.1 Protection devices

In addition to the overcurrent relay, which has been covered in Chapter 5, moulded-
case circuit breakers (MCCBs) and thermal relay-contactor and fuse devices are
frequently used to protect elements of the industrial electrical system and these will
be covered in more detail in this chapter.

10.1.1 Overcurrent relays

This type of relay is usually equipped with an instantaneous and/or time-delay unit.
This latter unit can be inverse, very inverse or extremely inverse, and when it is
necessary to prevent the relay from operating in one direction it should be provided
with a directional element. This is required for ring systems or networks with several
infeed sources, the latter being very common in industrial systems.

10.1.2 Direct acting devices in power and moulded-case circuit breakers

As their name indicates, these are devices that act directly on power breakers and
therefore do not require AC or DC coils for tripping. They are especially common
226 Protection of electricity distribution networks

for operating breakers up to 600 V, but are sometimes used on breakers of a higher
voltage and, in these cases, are generally fed by current transformers.
These devices can be operated by:
1. An armature attracted by the electromagnetic force that is produced by the fault
current which flows through a trip coil.
2. A bimetallic strip that is actuated by the heat produced by the fault current.
The characteristic curves of these mechanisms are generally the result of com-
bining the curves of instantaneous relays with long or short time-delay relays. The
starting current of the long delay units can normally be set to 80, 100, 120, 140 and
160 per cent of the nominal value. The calibrations of short time-delay relays are
typically 5, 7.5 and 10 times the nominal value.
It is common to use breakers to protect circuits of low current capacity with
a combination of a single time-delay element plus an instantaneous unit normally
having a bimetallic or magnetic element. In this case, the curves are normally set in
the factory based on the nominal values.

10.1.3 Combined thermal relay contactor and fuse

The combined thermal relay contactor and fuse is used extensively for protection,
mainly in low power systems. In this case the fuse provides protection against short-
circuits and the thermal relay gives protection against overloads. Given that the ther-
mal relay acts directly on the contactor, special care should be taken to prevent a relay
operation for values of fault current that exceed the capacity of the contactor. If this
should be the case, a more rapidly acting fuse should be selected in order to guarantee
that it will operate for any current greater than the breaking capacity of the contactor.

10.2 Criteria for setting overcurrent protection devices associated

with motors

The criteria normally used for the selection of the nominal values and the range of
settings of low voltage overcurrent devices such as thermal relays and moulded-case
breakers that are used frequently in industrial plants are similar to those for overcurrent
protection included in Chapter 5. An important consideration for these devices is that,
as for overcurrent relays, the selected settings can vary depending upon the criteria
adopted by the particular utility or plant operators, providing that the resultant settings
guarantee appropriate protection to the machines and the elements of the system under
analysis. Thus, the settings should be higher than the motor-locked rotor current and
below the motor thermal limit.

10.2.1 Thermal relays

A thermal relay basically has three parameters that can be adjusted: the rating of the
coil, the range of taps in the thermal element, and the range of the instantaneous
element.
 Protection of industrial systems 227

Coil rating
In order to determine the coil rating, manufacturers provide a range of maximum and
minimum current values for which the thermal relay has been designed. The rating of
the coil is somewhat above the maximum value of the motor secondary rated current.
The range of a thermal relay for a motor should overlap the motor manufacturer's
value of the motor nominal secondary current, in amperes. Using a thermal relay that
has a maximum current rating very close to the motor nominal secondary current (in
amperes) is not recommended; in this case it is better to use the next highest range
available.

Example 10.1
Consider a motor with the following characteristics:
power: 100 HP, p.f. = 0 . 8
voltage: 440 V
efficiency: 100 per cent
The thermal protection consists of three single-phase relays, fed from a set of
current transformers with 200/5 ratios. The setting range of the relays is given in
Table 10. l, and the operating characteristics are shown in Figure 10.1.
Inom = 122.36A, and Inom(sec) = 122.36 x 5 / 2 0 0 = 3.06A. In accordance with
the data in Table 10.1, a thermal coil with a rating of 3.87A, which has a current
range of 3.10 to 3.39 A, can be selected. A relay with a range of 2.82-3.09 A should
not be used since the maximum value is very close to the Inom(sec) of the motor.

Range of taps in the thermal element

The tripping current of the thermal element of the relay is normally specified with
a range of 90/95/100/105/110 per cent of the current rating of the coil.

Range of instantaneous elements

The instantaneous elements are specified at ten times the nominal current of the motor.
Typically this range is 6-150 A. For this example:
Iinst = 10 X /nora = 10 × 122.36 x 5/200 = 30.59A (secondary)
This confirms that the 6-150 A range is appropriate.

10.2.2 Low voltage breakers

The low voltage breakers used to protect motors usually have two elements: a time-
delay unit for long-time overloads and an instantaneous element for short-circuits.
The short-time element is optional and recommended only for the more powerful
motors, or when the possibility exists of losing co-ordination with other breakers
located nearer to the source.
The values that should be specified for a breaker are as follows: the nominal
current, and the setting ranges for the time-delay unit, the instantaneous unit, and
also the short-time unit if this is fitted.
228 Protection o f electricity distribution networks
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 Protection of industrial systems 229

(a) 800

700
\
\
600
<
500
~ 6 0 Hz
400

300

200

100

Time (s)
(b) 800

700

600

<
500
,fi
e.
400

300

200

100

Time (s)

Figure 10.1 Range of settings and operating characteristics of GE thermal relays

TMC. (a) Typical time/current characteristic curve for type TMC 23B
relays. (b) Average time/current curves based on 40 degrees ambient for
relays type TMC21B, 24B and 24D. Source: Protection of electricity
distribution systems. Reproduced by permission of General Electric
Company
230 Protection of electricity distribution networks

Nominal current
The nominal value of the breaker is selected using the next higher available setting
to the value obtained from the following expression:
/breaker = 1.05 x SF x Inom.motor
where SF is the so-called service factor, which is an overload margin permitted by
the manufacturer.
In the case of breakers associated with motor control centres (MCCs), the nominal
current is selected using the following expression:
Inom = 1.2 x 1FL
where IFL is the full-load current taking into account the nominal power of all the
motors plus the other loads that are supplied by the feeder. To calculate this, the
nominal current of the largest motor, and the current for the rest of the load multiplied
by the demand factor, are added together.

Setting of the time band

When selecting the time band there should be a co-ordination margin of 0.2 s between
one breaker and the breaker acting as back up. In those breakers associated with MCC
feeders, the time setting should be checked to confirm that the largest motor can be
started satisfactorily while the rest of the load is taking nominal power.
The current of a locked-rotor motor should be estimated in accordance with a stan-
dard code of practice such as the National Electric Code of USA (NEC) Article 430-7
using the code letter in those cases where this information is available. Where this is
not the case, then the current should be taken as being six times the full load current
in accordance with Table 430-151 of NEC Article 430-7. Starting from the value of
current with a locked rotor, the starting current for each motor should be calculated
taking into account the particular method of starting, and the starting time should be
based on manufacturer's data for the motor. In addition, the operating characteristic
of the breaker should be checked to ensure that it provides complete cover over the
thermal-capacity characteristic of the associated conductors. Table 10.2 compares
some of the factors associated with motor starting.

Range of short-time unit

The short-time element is specified taking into account the fact that the operating
current includes the motor locked-rotor current. This current is normally of the order
of six or seven times the motor nominal current. The range of settings of this element
is usually expressed as a multiple of the starting current selected for the long time-
delay unit.

Setting of instantaneous element

The instantaneous element provides protection against short-circuits, cutting down
the tripping time of a breaker when there are severe faults on the associated circuit. The
setting of the instantaneous element is calculated using the expression linst ~--- 10 x IFL,
where/EL is the full load current of the associated feeder.
 Protection of industrial systems 231

Table 10.2 Comparison of motor starting methods (from Industrial Power

Systems Handbook, by D. Beeman, 1985; reproduced by
permission of McGraw-Hill Publishing Company)

Type of starter* Motor voltage Starting torque Line current

Line voltage Full voltage Full voltage

starting torque starting current

Full-voltage starter 1.0 1.0 1.0

Autotransformer
80% tap 0.80 0.64 0.68
65% tap 0.65 0.42 0.46
50% 0.50 0.25 0.30
Resistor starter, single step 0.80 0.64 0.80
(adjusted for motor voltage
to be 80% of line voltage)
Reactor
50% tap 0.50 0.25 0.50
45% tap 0.45 0.20 0.45
37.5% tap 0.375 0.14 0.375
Part-winding starter (low
speed motors only)
75% tap 1.0 0.75 0.75
50% tap 1.0 0.50 0.50

line voltage = motor rated voltage

* The settings given are the more common for each type.

E x a m p l e 10.2
Determine the settings for the thermal relay and the 200 and 600 A breakers, which
protect the system indicated in Figure 10.2, using the information given.

Induction motor
500 HP, 2400 V, power factor = 0.8
Service factor: 1.0
Code letter: G; thermal limit with locked rotor: 5.5 s
Direct start, duration: 1.0 s

Thermal relay
(See Figure 10.1.)
Coil: 3.87 A
Taps: 90-110 per cent o f coil rating
CT ratio: 150/5
232 Protection of electricity distribution networks

~ 1500kVA
13.8/2.4 kV

Thermo-magnetic N
/ 600 A
interrupter J

) 4kV

Thermo-magnetic 200 A
interrupter

Contactor : ' - - -- -- I
I
I
I
I
150/5 .2.____..__@

500 HP

Figure 10.2 System for Example 10.2

Breakers
The setting values and characteristic curve are shown in Table 10.3 and Figure 10.3
respectively.

Solution
Nominal motor current
500 x 0.746 k W
1N= =112.16A
v/3 x 0.8 x 2 . 4 k V

Locked rotor current

From NEC Table 430-7(b), a motor with code G is assessed at 6.29 kVA/HP, and so:

500 x 6.29 kVA

ILR = = 756.57 A
~/3 x 2.4 kV
 Protection of industrial systems 233
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tt')
tt~
c'-I
.<
.<
,<
. ~ X
234 Protection of electricity distribution networks

1000
800
600

400

200

100
80
60

40

20

1
0.8
0.6

0.4

0.2

0.1
0.08
0.06

0.04

0.02

0.01
10 20 30 50 70 lO0 1 2 3 5 7 lO 20 30 50 70 100
Earth fault current in percent Current in multiples of pick-up
of tripping XFMR rating

Figure 10.3 Characteristic operating curves for Siemens-Allis Interrupter

Setting of thermal relay

/start = 1.05 x 1.0 x 1 1 2 . 1 6 A = 117.8A

5 1
Setting---- 117.8 x - - x -- x 100%= 101.46%
150 3.87
With a setting o f 100 per cent,

/start = 1.0 x 3 . 8 7 A × ( 1 5 0 / 5 ) = l 1 6 . 1 0 A (3.5% overload)

 Protection of industrial systems 235

Setting of 2OOA breaker

(i) Long-time element
Range: 100/125/150/175/200/250 A

/start = 1.05 × 1.0 x 112.16A---- 117.8A

Set at 125 A (11.45 per cent, overload)

Selection o f time band:
The long-time element should permit the motor to start:
Start point: I = 756.57 A locked rotor current, and t = 1.0 s
Operation o f breaker at the start:
I/lstart = 756.7 A/125 A = 6.05 times.
Require 1.4 s tripping time. From Figure 10.3, the intersection of 1.4 s and 6.05 times
lies above the lower curve o f Band 1. Therefore, Band 2 is chosen in this case to
guarantee the required discrimination margin o f 0.4 s.
(ii) Short-time element
Range: 3/5/8/12 times long-time pick-up current

lstartl = 6 x ( 1 1 2 . 1 6 A ) = 672.96A

Given that this value is less than the motor starting current, it is necessary to increase
the setting value. Try eight times, then

Istart2 = 8 × ( 1 1 2 . 1 6 A) = 897.28 A and setting = 897.28 A / 1 2 5 A = 7.18

Setting selected: 8 x/pickup = 8 x 125 A = I000 A

Time band: in this case the intermediate band was chosen to provide the necessary
discrimination margin with the instantaneous unit (see Figure 10.3).
(iii) Instantaneous element
Range: 3/5/8/12 times long-time pick-up current
/start = 12 x (112.16A) = 1345.92 A
Setting = 1345.92 A/125 A = 10.77
Setting selected: 11 x / p i c k u p (1375 A)

Setting of 6OOA breaker

(i) Long-time element
Range: 300/375/400/525/600/750 A
1500 kVA
Nominal current of transformer, In -- -- 360.84 A
v/3 x 2.4 kV
With a setting of 400 A, the overload = 400/360.84 = 1.108, i.e. 10.8 per cent, which
is acceptable.

/start ~-- 1.10 X (360.84 A) = 396.92 A

Selection o f time band:

Operation of motor breaker within the limit of the long-time element:
I/Istart = 1000A/125 A = 8.0 times. At eight times, and with Band 2, =~ t = 1.5 s
236 Protection of electricity distribution networks

Operation of transformer breaker:

I/Istart = 1000 A / 4 0 0 A = 2.5 times. At 2.5 times, and with t = 1.7 s, Band 1 is chosen
since this is the lowest available. Notice that a margin o f 0.2 s has been applied here
since the co-ordination is between two low voltage breakers where the curves include
the opening time.

(ii) Short-time element

/start = 6 × (360.84 A) = 2165.04 A

Setting = 2165.04 A / 4 0 0 A = 5.41 => 6 times

Current (A) (×10) 2. 4kV busbar

1000
800
600

400

200

100
80
60

40

20

10
8
6

~ 2

1
0.8
0.6

0.4

0.2

0.1
0.08
0.06

0.04

0.02

0.01

A C B

Figure 10.4 Co-ordination curves for Example 10.2

 Protection of industrial systems 237

Since there is no overlap with the short-time element of the motor, the intermediate
band is also selected.
(iii) Instantaneous element
The instantaneous element is cancelled in order to maintain co-ordination. The
co-ordination curves are shown in Figure 10.4.
It should be emphasised that, although the values selected for the protective
devices in this example ensure proper co-ordination, they are not unique. Other
settings could be chosen provided that the curves so obtained guarantee adequate
reliability and good selectivity.