The Online Journal on Electronics and Electrical Engineering (OJEEE)

Vol. (3) No. (3)

An Application For Upgrading The Reliability of Electrical System in An Industrial Plant

H. Can Tupras Izmit Refinery, Project Department, Kocaeli, Turkey Dr. C. Perdahci Department of Electrical Engineering, Kocaeli University, Kocaeli, Turkey
Abstract-In this paper, respectively, the requirement for digital protection relays, current status of the industrial plants, protective functions of digital protection relays, relay types, electrical equipments and remote monitoring relays were examined in an industrial plants. A large-scale industrial plants must be robust to operate efficiently and without interruption of power network. Unreliable electrical network can cause unexpected power interruptions. Interruptions will damage to operate the plants and these may also cause significant financial loses. To make reliable electrical system of the plants, provides important advantages in terms of operation and maintenance. In industrial plants examined for this purpose to establish the digital protection relays and power relays with the method of monitoring via SCADA system to increase the reliability of an application is examined. Keywords-Protection relays, reliability I. INTRODUCTION Today one of the most important factors which ensure that industrial plants have sustainable production is uninterrupted and high-quality provision of power to the plant. Ill-timed power failures due to the own structure of the facility and national network of which it is a part have significant impact on the production of facility. The power failures also have significant financial losses. Therefore the less power failures, the less financial losses there will be. Another reason of the significant of power failures is that the interruption experienced during operation can damage equipment and due to this damage they can be completely non-operable and in need of repair. If there is no replacement for the equipment at the facility, the damage can be multiplied. Parallel to the experienced technological developments, large industrial facilities renew their infrastructures so as to improve the reliability of their electrical systems (1). One of the best-known methods is to install digital protective relays on engines, transformers and entry-exit coupling cells and corrections of failures at minimum location at minimum time. At large industrial facilities which have protective functions assigned to digital protective relays, as well as different voltage levels and a widespread distribution infrastructure, high-level of protection can be provided with proper selectivity efforts; however, failure and measurement data of these equipment are transferred to SCADA system at main focus and they can be used in an effective manner; it also helps optimize the reliability of the facility. In addition, with the failure record data obtained from relays, the failure characteristic of the equipment can be generated and potential failure risks can be estimated for the future [2]. In the industrial facility, which is the reference of this study, protective equipment have been used since its foundation which have the highest technology. However, there are no digital protective relays in several engines, transformers, entry-exit and coupling cells of the facility. This application covers replacement of current mechanical relays with digital protective relays and installation of digital protective relays to those which had no relays on. II ELECTRICAL SYSTEM of THE FACILITY Electricity production capacity of the plant is 85MW and maximum consumption is 57MW; it also has an auto-producer license. The facility can satisfy all or part of its own electrical power need from its production; it can also provide the electrical power needed from outside as it is connected to the interconnected network. The purpose of the facility in producing its own electricity is to create alternatives for meetings its electricity need rather than selling it to third parties. As can be understood from the single line graphic of the facility, all busbars have two supplies. The power is being distributed to three secondary distribution stations at 11kV and 3.3kV voltage levels from closed switch station. These 6 secondary distribution stations distribute to 14 secondary stations. The voltage levels of secondary distribution stations are 11kV or 3.3kV. There are digital protective relays at engine, transformer, entry-exit or coupling cells; however these relays have been established at different times and with different models since the foundation of the facility [3]. 1. Current busbars and protective relays 34,5kV, 11kV and 3,3kV distribution stations which constitute the distribution infrastructure of the facility are given in Table 1.

Reference Number: W11-0068

443

The Online Journal on Electronics and Electrical Engineering (OJEEE)

Vol. (3) No. (3)

Distribution Stations 1 2 3 4 5 6 7 8 9 9HS-1 9MMS-1 9MMS-2 9MMS-3 10R-102A 10R-6A 10R-18A PLANT-5-6-7-8 PLANT-21-25-36

Voltage Level 34,5kV 11kV 11kV 11kV 3,3kV 3,3kV 3,3kV 3,3kV 3,3kV 3,3kV 3,3kV 3,3kV 3,3kV 3,3kV 3,3kV 3,3kV 11kV 3,3kV 3,3kV 11kV 3,3kV

Supplying Busbar TEK-2 9HS-1 9HS-1 9HS-1 9HS-1 9HS-1 9HS-1 9MMS-1 9MMS-1 9MMS-1 9MS-1 10R-102A 10R-102A 10R-102A 10R-6A 10R-18A 9MMS-2 47MMS-1 9MMS-3 9MMS-3 63MMS-1

10 9MS-1 11 PLANT-6 12 PLANT-73-74 13 10R-102 14 PLANT-33 15 10R-6 16 10R-8 17 47MMS-1 18 47MS-1 19 10MS-1 20 63MMS-1 21 63MS-1

Table 1 : Distribution Stations 2. System equipment with digital protective relays installed Digital protective relays will be used for the purpose of protecting several equipment in the facility and improving the reliability of electrical system. These relays will be installed on engine feeders, transformer feeders, entry-exit and coupling cells [3]. Digital protective relays will be installed on 10R-6 and 10R-6A power switch building, 10R-102A power switch building, Plant 25-36 , Plant 5-6-7-8 , Plant 47-48 , Plant 26, Plant-33, Plt 9 and 34,5kV switch facility engine feeders, transformer feeders, entry-exit and coupling cells shown in Table 1 [2]. Digital protective relays have been applied on more than 200 medium-voltage system equipment; those installed on 4748 unit are given in Table 2 [3]. 47-48 (Hydrocracker) unit constitutes one of the most important processes of the facility.

PLANT 47/48 UNIT SWITCH ROOM Cell Name Of The No Equpment Description of Equipment 11 kV BUSBAR 47 MMS-1 5L 9GM-601A 11kV 1200kW Pump Motor 4L 47GM-2A 11kV 1550kW Pump Motor 11kV 3500kW Compressor 3L 47KM-2A Motor 47TMM-1A 2L Trafosu Fideri 11kV to 3,5kV 6,3MVA 1L Incoming L INCOMING LEFT 0 BUS TIE 0 BUS RISER 1R Incoming R INCOMING RIGHT 47TMM-1B Transformer 2R Feeder 11kV to 3,5kV 6,3MVA 11kV 3500kW Compressor 3R 47KM-2B Motor 11kV 3500kW Compressor 4R 47KM-2C Motor 5R 47GM-2B 11kV 1550kW Pump Motor 6R 9GM-601B 11kV 1200kW Pump Motor 3,3 kV BUSBAR 11L 47GM-4C 3,3kV 153kW Pump Motor 3,3kV 120kW Compressor 9L 9KM-601E Motor 3,3kV 120kW Compressor 8L 9KM-601C Motor 3,3kV 120kW Compressor 7L 9KM-601A Motor 6L 47GM-302A 3,3kV 120kW Pump Motor 3,3kV 315kW Compressor 5L 48KM-1A Motor 47TML-1C Transformer 4L Feeder 3,3kV to 0,4kV 2MVA 3L EMPTY 47TML-1A Transformer 2L Feeder 3,3kV to 0,4kV 2MVA 1L Incoming L INCOMING LEFT 0 BUS TIE 0 BUS RISER 1R Incoming R INCOMING RIGHT 47TML-1B Transformer 2R Feeder 3,3kV to 0,4kV 2MVA 47TML-1D Transformer 3R Feeder 3,3kV to 0,4kV 2MVA

Reference Number: W11-0068

444

The Online Journal on Electronics and Electrical Engineering (OJEEE)

Vol. (3) No. (3)

160kW Yedek Motor 33kV 315kW Compressor 6R 48KM-1B Motor 7R 47GM-201B 33kV 200kW Pump Motor 8R 47GM-302B 33kV 120kW Pump Motor 33kV 120kW Compressor 9R 9KM-601B Motor 33kV 120kW Compressor 10R 9KM-601D Motor 12R 47GM-4D 33kV 153kW Pump Motor GM/KM/G/K represent Pumps and Compressors TML/THM/TMM represent Transformers Table 2: Equipment on which digital protective relays are installed III. DETERMINATION of THE FUNCTIONS of DIGITAL PROTECTION RELAYS Digital protective relays can be equipped with several protective functions. However, as using all of the functions provided will not yield the optimum results for the business and in terms of cost, first the equipment to be protected by digital protective relay must be determined and then it must be determined the equipment equipped with which protective functions will provide protection. Digital relays to be used in engine feeders, transformer feeders, entry-exit and coupling cells will have the following protective functions (4). ANSI 50-50N: Instantaneous overcurrent ANSI 51-51N: AC Time Overcurrent ANSI 67-67N: Directional time-overcurrent protection ANSI 46: Reverse phase or phase-balance current (protection which is enabled when, at multi-phase circuits, phase flows have inverse phase components or when phase flows are imbalanced or negative phase component flows exceed the preset values) ANSI 66: Notching or jogging device (Motor restart inhibit) it is defined as the function which allows for operation at a certain number for a certain part of a given device or equipment or for a certain number of sequential operations in a given time. In addition, this device can make sure that a circuit is powered periodically or in certain time intervals, or accelerated intermittently or fast for mechanical positioning at low speeds. ANSI 48: Incomplete sequence relay (starting time supervision: regular working, operation or stoppage process, protection which turns to its regular position or closed position and locks a device that cannot be defined correctly in preset time period). ANSI 87: Differential protective Generator, Motor, Transformer, Line (the protection which is enabled when there are angular, proportional or other quantitative

4R 5R

EMPTY SPARE

differences between two or more voltages, or between other electrical components) ANSI 27: Under voltage (the protection that works when entry voltage falls below a preset value) ANSI 59: Over voltage (the protection that works when entry voltage exceeds a preset value ANSI64-59N: Ground detector (Displacement voltagezero sequence voltage: it defines the device which is enabled when a machine or a device apparatus suffers from ground isolation problems. This function cannot be used for devices connected to the secondary circuits of current transformers in a regularly grounded power system. Other overcurrent devices marked with letters G and N must be used instead, i.e. 51N.) ANSI 49: Machine or transformer thermal (the protection which is enabled when the temperature of the rotor (armature) coil of a machine or other load carrier coil of a machine or transformer rises above the preset level). ANSI 81: Frequency (defined as the protection which reacts to the frequency of an electrical quantity. It is enabled when frequency or the change in frequency falls below or rises above a preset value). ANSI 74: Alarm (the component which operates with an audio or visual device or which operates this device) ANSI 86: Lockout (the protection which leaves the devices or systems that conduct opening without function until they are reset by operator from remote or nearby). Inrush Restraint in ANSI 50-50N-51-51N-67-67N functions: during powering on the transformers, magnetizing currents can occur which can increase up to several times of the nominal current and which can continue from a few milliseconds to several seconds depending on its size. Inrush current includes high levels of secondary harmonic (twice of the regular current); in case of a failure second harmonic is almost nonexistent. Inrush limitation function operates by determination of this harmonic which can be found in powering on current. Digital filters are used for frequency analysis, as well as Fourier analysis of triphase and ground currents, so that when second harmonic is detected, system opening can be blocked at directional and non-directional relays. Cold Load Pickup for Overcurrent Protection: it can be called as cold load opening. Opening and delay times can be dynamically adjusted with this function.

Protection functions employed on engines:

27: Low voltage 46: negative component phase balance current protection 48: engine start-up time monitoring 49: engine thermal protection 50, 50N: instant opening 51, 51N(51G): opening in overflow 66: Engine Restart nhibit 74: Alarm 74TC: Trip Circuit Supervision

Reference Number: W11-0068

445

The Online Journal on Electronics and Electrical Engineering (OJEEE)

Vol. (3) No. (3)

87M: Engine differential protection*

*Engine differential protection is not compulsory; nevertheless, differential protection is recommended on engines higher than IMW power. Differential protections at powerful engines bigger than IMW at this facility have been enabled. Protection functions employed on transformers:
49: Motor Thermal protection 50, 50N: Instant opening 51, 51N: Opening at overflow Inrush restraint (valid for 50,50N, 51, 51N, 67, 67N functions) 74: Alarm 74TC: Trip Circuit Supervision 87T: Transformer Differential Protection*

Component values with symetry for voltages Voltages (VL1,VL2,VL3,VL1L2,VLL1L3,VL2L3) Current power, Reactive power, Visible power (Each phase seperately and totally) Aktive and Reactive Energy Power Factor and Frequency Working hour gauge, breaker opener gauge Measuring of average operating temperature in case of overload IV. DIGITAL PROTECTION RELAYS USED A. Local-control multi-functional protective relay 7SJ64 Digital, multi-functional SIPROTEC 4 7SJ64 relays are multi-faceted devices designed for protection, control and monitoring of busbar relays. These devices can be used as line protection in grounded, low-resistant grounded, non-rounded or compensated neutral point-structured networks. Devices are proper for radial, eyed or interconnected networks and single or multi-edged fed lines. 7SJ64 has been equipped with engine protection function which can be adjusted for every size of non-synchronize engines. 7SJ64 has necessary functions for command of breakers at1 breaker busbars or monitoring of protective, breaker positions and flat busbar applications. Therefore the device can be used universally. 7SJ64 provides after-effect protective features for differential protective arrangements of the lines, transformers, generators, engines and busbars in all voltage levels. Protection of non-directional overflow is the basic function of the device. There are three fixed-time overflow protective elements and one inverse time overflow protective component for phase currents and ground current. Several curves at different standards are provided for inverse-time overflow protective elements.[5] B. Differential protective relay 7UT613 SIPROTEC 4 7UT613 digital differential protection provides a fast and selective short circuit protection for transformers at all voltage levels, rotary machines, serial and shunt reactors or short lines and mini busbars consisting of 2 to 5 feeders. In addition, it can also be used as a single-phase protection for busbars up to 9 or 12 feeders (depending on the version). Specific application can be customized which will ensure the most appropriate adaptation to the protected object. The major advantage of differential protection principle is that it can perform instant turn-on at a short circuit failure at any point within the protected area. The current transformers at the edges of protected object limits the protected area towards the network. This certain limit is the main reason for which the differential protection mechanism shows such an ideal selectivity. [6]. 1. Remote Monitoring of Digital Protective Relays All established protective relays will be monitored from Power CC SCADA system which is installed in Plant-9. All trips, alarms, external data and analogue value signals will be

*at transformers of 5MVA and higher at the facility

49: used in relays at primary sides of thermal protection transformers; not enabled on relays at secondary side.

The protection functions defined in digital protection relays installed on transformer feeders have been enabled and adjustment values have been given. 67, 67N: Directional Overflow Protections have been enabled as these generators exist at 11kV outlets of 34,5/ 11kV transformers in the facility; which means at facility entrances, and as it is not possible to feed from TEA and generators alike. In addition, 32G, 32P: Inverse Power Protections are also enabled. Protection Functions used in the Generators:
27 : Low Voltage Protection 32R: Diverse Power Protection 46 : Current Protection for Negative Component Phase Balance 49 : Thermal Protection 50, 50N : Instant turn-on protection (Short circuit protection) 51, 51N(51G) : Over-current protection (reverse time protection) 59 : Over-Voltage Protection 81 : Low / Excessive Frequency protection 87G : Generator Differantial Protection (G Generator)

3.1 Measurement with Digital Protection Relays As the digital protection relays to be used also have measurement functions, the demanded cells will also be measured. In addition to protection, which is their main function, digital protective relays are able to measure the current, voltage and frequency values of the cells on which they are installed this cell can be an engine feeder, transformer feeder or entry-exit and coupling feeder. In addition, they can transmit these measured values to SCADA system, just like they transmit protection functions to SCADA system. As a result, in addition to their major function which is protection, these relays used within the Refinery Plant will transfer such values as the current voltage frequency of the equipment to which they are installed to the SCADA system to make the electrical system of the plant more traceable and reliable, as electrical systems which can be monitored are always more reliable. Measurements which will be made by relays are as follows: [2]

Reference Number: W11-0068

446

The Online Journal on Electronics and Electrical Engineering (OJEEE)

Vol. (3) No. (3)

sent to Power CC scada system from these relays. Only the Power CC in Plant-9 will be controlled by SCADA system and switch will be opened and closed from there [2]. V. CONCLUSION As a result of this paper which aimed at improving the reliability of current electrical system, the system has been made more reliable with the protection functions from which digital protective relays are entered. Protective functions have been parametered as required according to the type and importance of the equipment to which the relays are connected, and it has been ensured that the system makes less trips. In addition, remote monitoring of the system has allowed for receiving instant information from relays which turn on or give alarm and thus faster intervention. In this study, not only the electrical system of the plant has been made more reliable, but the plant also enjoyed several advantages such as costing, operation and maintenance.

REFERENCES [1] Xiaoqiang, Z., "Energy&Utilities Control System of Refinery",2009 third International Symposium on Intelligent Information Technology Application, 2009, 408-411 [2] etinkaya, B, Akduman, B, Tpra Izmit Role Koordinasyon Raporu, Siemens A.S., Kocaeli, 2009 [3] TUPRA General Project Design Specification P1, TUPRA, Kocaeli, 2006 [4] Koruma Rolelerinin Fonksiyon Acklamalar, Siemens E E&C PTI, Istanbul, 2008 [5] SIPROTEC 7SJ62/64 Kullanm Klavuzu C53000G115A-C207-1, SIEMENS AG, Istanbul, 2009 [6] SIPROTEC 7UT613/63x Kullanm Klavuzu V4.60, SIEMENS AG, Istanbul, 2006

Reference Number: W11-0068

447