Preface

In this report the reader will have the privilege to get an overview about protection relays in electrical equipment, especially for motors and capacitor banks. As well as knowing some of the different types of protection relays used at the refinery, such as : SEL 749M, SPAM 150C, THERMAL OVERLOAD RELAY, ARGUS RAYROLLE, CAPACITOR/FILTER PROTECTION ( CAPGUARD) , SPAJ 142 and DIFFERENTIAL RELAY. You will also have an overview about the different types of test, to be performed in a motor protection relay such as: Over current test, Overload, Earth Fault, Unbalanced, under current test, etc. All this tests can be achieved by the aid of an Omicron. OMICRON Test Universe Hardware and Software were designed to fulfil all testing requirements and have set the standard for testing Protection Relays. In this report also contains information regarding to power factor correction. Now Id like to invite you to start reading through this report, and I hope you will enjoy it.

By: Claudio Vunda (Big-C)

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Introduction
Power system protection is a branch of electrical power Engineering that deals with the protection of electrical power systems from faults through the isolation of faulted parts from the rest of the electrical network .The objective of a protection scheme is to keep the power system stable by isolating only the components that are under fault, whilst leaving as much of the network as possible still in operation. Protection plays an important role in any electrical system. Relays to sense the fault and initiate a trip, or disconnection the power system, the protection relays are intended to prevent damage to the plant and electrical equipment in case of abnormal conditions of operation, due to internal failures, as well as insulating failures or regulation malfunctions.

By: Claudio Vunda (Big-C)

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OMICRON SETTING

Summary
Before the test can be performed, the technician and I , identify the potential hazards and conduct the RAP. The permit to be obtained in the control room, Once obtained the Permit the technician isolate the panel where the job is going to be performed, and affix the danger card on the panel. Once making the area safe, then we can start setting the hardware part of the Omicron, by connecting the power supply cable, the currents and voltages cable, the communication cable which allow the omicron to communicate with the software through a computer, the binary/ analog input cable ( for the tripping), and then we bridge the currents output A and current output B , to get the 25A which is the maximum current that the omicron can give.

Now by the aid of the relay manual and looking at the panel drawing we identify the red phase, white , blue phase and the neutral, in order to connect the currents, I1 in red phase, current I2 in white , I3 in blue, and the IN in neutral. And also identify the tripping pins to connect the tripping cable, then we can switch on the omicron, and the computer too. Remember when connecting the currents, the phases must be disconnected from the relay, e.g. C11, C31, and C51. Now we can start setting the software part, by checking if it communicates with the hardware, by looking at the associate button at the back of the omicron , and also check if the bridging currents are done correctly. Once this has been achieved, we can start filling the information regarding, the relay type, e.g. SEL 749M, the serial no. of the relay, the panel no., the substation name, date of the test, as well as the name of the person responsible for job, etc.

By: Claudio Vunda (Big-C)

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Calculations

With the full load current (FLC) of the motor and the CT ratio, we need to do some calculation in order to find the FLC at the secondary side of the CT, the current which is going to be injected into the relay. Example: FLC= 23,5A CT ratio = 30/5 Then 23, 5/30 = 0, 75*5 FLC = 3.75 A Once obtaining the new FLC we also have to find the simulating currents, when the motor starts. In this case times the new current by six and then by four, as below. 3, 75* 6 = 22,5A 3, 75*4 = 15A

By: Claudio Vunda (Big-C)

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Testing summary

Thermal Lockout:
In this test as well as the others, we mainly focus in the last state, So we simulate a current of 15A in all the phases in the state 2, and the test was set to 20seconds, with a diverging of +/-5 seconds then we start the test, the timer starts counting and a red light comes on indicated the motor run. When the test is finished the fault type in this case (Thermal Lockout ) will appear on the relay display and also a red light will indicate the fault and the trip. Now to determine whether the relay passed or not, we check on the time assessment to see if the relay tripped within the time set, if the relay passed a green positive sign would come up, if failed a red cross will appear and if not assessed a zero will come up and there we have to find out why not assessed. Maybe checked the connection, the right currents set, the time assessment, etc. For our case the relay passed on the Thermal Lockout test because the relay tripped 22.43s, within the time set. Before another test can commence we need to reset the relay, to be ready for the next test

By: Claudio Vunda (Big-C)

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Ground fault test:

In this test and as well as the others the approach is always the same as above in determining whether the relay passed or failed. So we simulate in the last state that one of the phases is down to earth in this case L1, with a current of 0A, and the other phases we gave 3,75A for each, and the time set was 250ms within +/-30ms tolerance. Then we start the test , the timer starts counting a red light comes up , in the relay indicated the motor running and when the test finishes the fault is viewed on the relay display( Ground fault ). By looking at the time assessment and level assessment we found that that relay passed, because the tripping occurred within the time set, and the reading was 224.3ms.

Loss Trip test (Under Current Test)

Once the relay is reset we can start our next test , so we simulated a current of 100mA in all the phases, in the last state. And the time was set for 8s , with a tolerance of +/4s. The test is started, the timer starts counting and the red light indicated the motor running comes on. After a certain time the fault will be displayed on the relay .Also by looking at the time assessment and the level assessment , we could determine that the relay passed on this test, due to the fact that the tripping occurred within the time simulated, the reading was 5.043s

By: Claudio Vunda (Big-C)

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Ground Fault Start:

With the relay already reset we start filling the test setting by simulating that phase 2 is down to earth 0A and the other lines we gave 20A. The time setting was 400ms, with +/- 50ms tolerance. So we start the test, after some time the tripping will be displayed on the relay. In this type of test the motor must not even run, so the red light indicated motor run in the relay must not even come up, the relay must trip the motor for not running. For our case it did happen, so the relay passed the test and also by looking at the time assessment and level assessment the trip occurred within the time setting, the reading was 440.1ms.

Over Current Trip Test:

With the relay already reset, we start filling the test setting and we simulated that the relay is set 6* FLC, which gives a current of 22.5A . This current we gave for all the phases, the time set was 40ms, with a tolerance of +/-20ms. Then we start the test , and the timer starts counting and the red light comes on indicated the motor running. Once the test finishes , the fault type will be displayed in the relay, and by looking at the time assessment and the level assessment , we could see that the relay passed, the tripping occurred within the time setting, in this case 23.20ms.

By: Claudio Vunda (Big-C)

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Fault Start Over Current Test

With the relay already reset, we start filling the test setting and we simulated that the relay is set 6* FLC, which gives a current of 22.5A . But we simulated a current 25A for all the phases, the time set was 40ms, with a tolerance of +-20ms. Then we start the test , but the red light does not comes on due to the fact that in this type of fault the motor does not run, once the test finishes , the fault type will be displayed in the relay, and by looking at the time assessment and the level assessment , we could see that the relay passed, the tripping occurred within the time setting, in this case 26.90ms.

Once the tests have been accomplished, we save the data for report, and evidence purposes, and then reset the relay to where it was set. Then we reconnect the currents cable ( C11, C32, C52) in the right pin( A1, A3, A5 ) connection at the relay terminal and tightened nicely, to avoid relay malfunction which could cause fault and damage in the equipment. Then we close the panel and Technician to remove the hold tag on the panel and energise the drive if found energised. The event is then logged in the substation logbook and clearance/ permit to be signed off as the job complete.

By: Claudio Vunda (Big-C)

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Power Factor Correction

Power factor is the ratio between, Active (Real) power in kWatts, and the apparent power in KVA. Or is a measure of how efficiently electrical power is consumed. What cause a lower power factor? Inductive loads cause a lagging power factor , or cause the current to lag behind the voltage, therefore the wave form of current and voltage are then out of phase with each other. So the more out of phase they become the lower the power factor. How to correct the power factor? Power factor is enhanced by using statics capacitors in a bank or synchronous motor, but for us at Sapref we are using capacitor banks. Capacitors will produce reactive capacitance( Xc) and the Reactive power ( Q ) is directly proportional to the square of the voltage ( V2 ) and inversely proportional to the reactive capacitance ( Xc ). Hence the greater the ( Xc ) , smaller the Reactive power, and smaller the Q smaller will be the phase shift angle between the current and the voltage, and the better will be the power factor (Cos ). Power factor importance The significance of power factor lies in the fact that utility companies supply customers with VA, but bill them for Watts. Power factors below 1.0 require a utility to generate more than the minimum volt-amperes necessary to supply the real power (watts). This increases generation and transmission costs. For example, if the load power factor were as low as 0.7, the apparent power would be 1.4 times the real power used by the load. Line current in the circuit would also be 1.4 times the current required at 1.0 power factor, so the losses in the circuit would be doubled (since they are proportional to the square of the current). Alternatively all components of the system such as generators, conductors, transformers, and switchgear would be increased in size (and cost) to carry the extra current. Demonstrations P= 160kw V= 6,6 KV Cos = 0,7 I = P/1,73*V* Cos I = 20,02A So : 20/14 equal 1,4 P= 160kw V= 6,6KV Cos = 1 I = P/1,73*V* Cos I = 14,01A

By: Claudio Vunda (Big-C)

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Capacitor Banks Protections Relays

The overall protection for this installation minimizes fault damage, provides high bank availability, and reduces installation and maintenance costs. Multifunction numerical relays provide the following functions for system protection: Over current protection for phase and ground faults between the breaker and the capacitor Bank using redundant numerical relays. Overvoltage function to protect for sustained system overvoltage that may cause capacitor Can failures. Breaker failure protection function to allow fault clearing in the event of a failure in one of the capacitor bank breakers.

Monitoring and Control of Capacitor Banks

By: Claudio Vunda (Big-C) Page 10

A programmable logic controller (PLC) and digital relays to provide the monitoring and control of capacitor bank installation. Individual capacitor step circuit breakers provide capacitor bank switching. There are two modes of operation: Manual and automatic.
Manual mode

In the manual mode, operators switch capacitor banks from substation through step control switches installed on the switchboards. The following permissive conditions must be met before a capacitor step can be switched on or off by the manual control switches. The capacitor step must be in manual mode. The circuit breaker must be open for at least five minutes before it can be reclosed. This allows the capacitors to be discharged to a safe voltage level through their internal discharge device. If the breaker is not open for five minutes, the programmable logic controller blocks the close circuit and prevents the operator from closing the breaker.
Automatic Mode

In the automatic mode, the PLC controls the switching of the capacitor steps. The PLC is programmed to perform voltage control and event recording, record step operations, balance switching operations, and communicate with a programmable graphics interface (PGI) located in the control room. The PGI is used to adjust voltage set points, and to view the status of capacitor step devices and bank alarms.

Differential Protection Relay

By: Claudio Vunda (Big-C) Page 11

A differential Relay is the one which operates when the vector difference of two or more similar electrical quantities exceeds a predetermined amount. This type of relay look after the cable at both ends, lets study the example. As an example a power line from one substation to another will have a current diff relay at both substations which communicate with each other. In a healthy condition relay at substation A (UTILITIES SUBSTATION) may read 200 amps (power exporting) and substation B (CDU 2 ) will read 200 amps (power importing). If a path to earth or ground develops there will be a surge of current. As supply grids are generally well interconnected the fault in the previous example will be fed from both ends of the power line. The relay at substation A will see a massive increase in current and will continue to export. Substation B will also see a massive increase in current however it will now start to export as well. In turn the protection relay will see the currents travelling in opposite directions (180 degrees phase shift) and instead of cancelling each other out to give a summation of zero it will see a large value of current. The relays will trip the associated circuit breakers.

By: Claudio Vunda (Big-C)

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Thanks
First and foremost thabks to God , without his help and blessing I would not have been able to finish this report. Then, I would like to thank The Electrical Leader Booysen, for accepting me in the Technician department and giving me supports. Thanks to Mabutho, Bruce and Selva for allowing me to share knowledge , and giving me a lot of information. And last but not least I am so thankful for my mentor Dumisni Gumede for his encouragement and unlimited support, I have learnt a lot with you.Well done you all, I am so proud of you.

By: Claudio Vunda (Big-C)

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