Commissioning & Maintenance of Protective Relays: Technical Institute

Commissioning & Maintenance
of Protective Relays
GRID
Technical Institute
This document is the exclusive property of Alstom Grid and shall not be
transmitted by any means, copied, reproduced or modified without the prior
written consent of Alstom Grid Technical Institute. All rights reserved.
Test Options (1)
1. Primary injection sensitivity tests only
 Minimum of time consumed

 If results incorrect, secondary injection and CT tests
required
 Unable to check :-
a. Adequate timing curves
b. Directional properties
c. Power and impedance relays
 Not suitable for maintenance tests
> Commissioning & Maintenance of Protective Relays

Test Options (2)
2. Secondary injection tests

(But with C.T.’s still connected)
 True primary sensitivity easily equated

 If results incorrect isolated relay and CT mag.
curve checks necessary
 Ref. for maint., but system outage required
 Primary tests on C.T. ratio and polarity still
required on commissioning

Test Options (3)
3. Secondary injection tests

(But with relays isolated by test facility)
 Proof of isolated relay characteristic obtained

 Ref. for maintenance obtained
(relay if necessary tested with system on load)
 Full primary injection/on load tests done on initial
commissioning only

Test Options (4)
4. On load tests
 Checks that expected C.T. / V.T. quantities present at test

facility
 Scheme stability for external faults
 Proof of correct directional characteristics

Summary
ALSTOM’s preference:-
1. Secondary injection (isolated relay)
2. Primary injection
(incl. C.T. ratio, phasing and mag. curve)
3. On load tests

Site Testing and Commissioning
of Protection Equipment
 To assure ourselves, and the interested authorities,

that the overall protective system functions
correctly
 Resist pressures to take risks
 Study wiring diagrams and protection requirements

 Key diagram
 Delegate responsibilities
 Observe safety of self and others

Commissioning Flow Chart
Summary (1)
To assure ourselves, and the interested

authorities, that the overall protective
system functions correctly.

Study of wiring diagrams and protection
requirements.

Careful delegation of responsibilities to
reduce the duplication of effort and to
ensure that all the following aspects are
covered :-

Summary (2)

Insulation Tests

Secondary Injection Tests (Relay Tests)
 Ensure clean dust free area
 Mechanical inspection
 Out-going contact wiring
 External resistors
 C.T. shorting and isolating switches
 Contact follow-through and pressures
 Electrical checks on each basic electrical function
to prove satisfactory operation
 Prove trip and alarm circuits
 Test results (record and maintenance purposes)


Summary (3)

Primary injection tests
 D.C. flick tests on C.T.’s
 C.T. mag curve tests
 C.T. ratio and polarity tests
 Primary sensitivity tests
 Stability tests
 Test results
0 > Commissioning & Maintenance of Protective Relays

Summary (4)
 Line / Transformer / Generator energisation

 V.T. ratio and phasing tests
 On load tests
 Stability tests
 Directional properties
At the end of each stage ask yourself :-

Is there anything wrong, wiring or otherwise, that I
have not checked that may prevent correct operation
If so, CHECK IT OUT !

 Measuring instruments
 D.C. auxiliary supplies
Peak 1.6 x AV.
Average D.C.
0V.
Mean D.C. Peak to Peak V
<12% of mean D.C. comp.

0V.
 Faulty relays

Maintenance of
Protective Relays (1)
Frequency of Maintenance
Dictated by :-
a) The site condition
b) The availability of maintenance staff and
resources
c) The availability of plant outage times
d) The risks involved if the protection should fail
e) The type of relay construction

Maintenance of
Frequency of Maintenance (continued)
f) The proven reliability of devices under

identical site conditions
g) The availability of built-in self-check features
or semi-automatic test facilities, and the
difficulties of alternative tests
h) The interval of time an unexpected catastrophic
failure, component or otherwise, that may go
undetected and leave the system unprotected

Maintenance of
Onerous site conditions :-

1. Dusty or dirty environments
2. Corrosive chemical atmospheres
3. Frequent or continuous vibration
4. High humidity
5. High or cycling temperatures
6. Consistently high levels of energising or auxiliary
quantities
Typically maintain every 12-18 months under ideal
conditions and decrease frequency

Maintenance of
 Visual inspections
 The commissioning test stage
 At each maintenance test
 After heavy fault clearance
 More regularly if onerous site conditions

 Calibration tests
 Trip testing

Maintenance of
Recommended maintenance tests
 Instruction manuals
 Record relay settings
 Visual inspection
 Secondary injection tests
 Contact integrity
 Return to ‘in-service’ settings
 Check energising quantities

Maintenance of
 Relays involving static (electronic) components
 Electro-static discharge (ESD)
 Wrist straps
 Modern static relays (K-SERIES, MiCOM etc.)
 Fault find to board level only
 Protect boards

Corrective Maintenance of
 Cleaning solvents
 Trichlortrifluorethane (Ozone damaging)
(Arklone, Freon, Flourisol and Supersolve)
PROZONE
 Contact lubricants and other lubricants
 Contact cleaning burnishers
 Contact pressures and settings
 Dust removal
 Relay recalibration (Why?)

Contents of Section 23 of ‘PRAG’ (1)
(Protective Relay Application Guide)
 Insulation tests
 Current transformer tests
 Voltage transformer tests
 Test facilities
 Secondary injection tests
 O.C. and E.F.
 Differential
 Pilot wires
 Negative phase sequence
 Directional Distance
 D.C. operated

 Primary Injection Test (+ on load tests)

 O.C. and E.F. relays
 Directional
 Generator Differential
 Transformer Differential
 Restricted E.F.
 Pilot Wire
 Busbar
 Negative phase sequence

 Tripping and Alarm Annunciation
 Periodic Maintenance
In addition to PRAG :-
Consult instruction manuals

Test Terminal Block
To
Torelay
relaycoils
coils
A B C A B C N A BC N
To CT
To CT test
test To main
To main To
Tomain
mainVTVT
windings current
current
windings
(if any) transformers
(if any) transformers

Test Switch and Sockets
To relay coils
A A
Current B Voltage
test B
test
sockets C C sockets
N N
Test selector switch

Make before break
on CT Circuits
To main current To main VT

transformers

Current Transformer
Polarity Check
P2 P1
- S2 S1 +
Push
button
switch
- +
A
Battery

Current Transformer
Ratio Check
A B C Test plug
insulation
A2
Temporary
short 51
circuit
51
P1
S1
51
64
P2 S2
Relay or test block
A1 contact fingers
Primary injection
test set
250V AC supply

Testing Current Transformer
Magnetizing Curve
A B C Test plug isolating

current transformers
from relay coils
Variable
transformer
250V 8A
A
250V
To relay AC
P1 coils supply
S1 V
S2
P2
Main circuit Step-up transformer
breaker open if required

Voltage Transformer
Phasing Check
A
B
C A
V1
V2 C B
VN
V
VL
V1
V2
A B C Phase rotation
meter

Overcurrent Test Set
Fine control A
Coarse Range
variable control
transformer reactor adjusting CT
K1 I
K2
250V
AC 51
Relay
supply coil
Start Stop
timer timer
Supply Backing Injection

switch transformer Medium transformer Relay short-
10% control control circuiting switch
reactor
Relay current I = Ammeter reading (A) x K1 K2

Basic Current Control Circuit
of CFBA Test-Set
A
60Hz
L1 L2
50Hz
0.1A
10X 5X 2X 1X
220/250V 0.2A
O/V Detector
AC 60Hz 0.5A Output
Circuit
Supply to
Variac V1 50Hz
50/60Hz 1A Relay
2A
5A
Supply Shorting 10A
Switch Timer
Supply T1 Injection
Contractor Start ‘Matching’
(Break to Start) C.T.
Thermal Overload / Overvoltage

Protection

Sensitivity Check on
Biased Differential Relay
B B
OP
Test plug
fingers
To main current
Overcurrent transformers
test set
250V
A.C. supply
OP Relay operating coil
B Relay bias coil

Testing Bias Characteristics
(Using Overcurrent Test Set)
B B
OP
I1+I2 I1 I2
Test plug
fingers
A1 A2
R
To main current
transformers
Overcurrent
test set
250V A.C.
supply

Testing Relay Bias Characteristic
(Using Resistances)
B B
OP
I1+I2 I1 I2
Test plug
fingers
A1 A2
R1 To main current R2
transformers
250V A.C. A1 and A2 Ammeters

supply OP Relay operating coil
B Relay bias coil

Sensitivity Test
Feeder isolated
A
B
C
Test Relay
plug contact
Overcurrent 250V fingers
A.C. supply
test set
B B
OP OP
Pilots

Testing Sensitivity of Negative
Phase Sequence Relay
A
To main
current B
Relay
transformers C 46
250V coil
A.C.
supply N
Overcurrent
test set
Test plug Filter
in test block network

Test Equipment for Directional Relays
Supply switch
A
440V
B
3 phase
C
4 wire supply
N
Variable Choke
transformer
for current Relay
67
control current coil
Range adjusting CT
440/110V
phase shifting A PA
transformer
PA Relay
V 67
voltage coil
Variable transformer
for voltage control
To other voltage coils V Voltmeter
of relay under test A Ammeter
(if required) PA Phase angle meter

Primary Injection Test Set
A
250V A.C.
supply
Variable transformer 40A

Injection transformer
250/10 + 10 + 10V
10kVA

Primary Check on
Main Current Transformers
Temporary three-
phase short circuit
A
Primary 51
injection
test set B
250V 51
A.C. supply
C
51
51 Overcurrent relay
64 Earth fault relay A 64
A Ammeter

Sensitivity Test on Earth Fault Relay
250V
A.C. Primary injection
supply test set
A
51
B
51
C
51
64

Load Test on Directional
Overcurrent Relays
Direction of power flow

A B C for relay operation Load current
A PA
A PA V
A Ammeter B
V Voltmeter
PA Phase angle C
meter Directional overcurrent relays
Test Plug Link Connections to
Reverse Current seen by Relay
To relay
20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7 8 9 10
Test plug
To main VT and CT
Load Test on Directional Earth Fault Relay
ABC P1 P2 Loadcurrent
Load
current
S1 S2
V1
Temporary
IA short circuit V2
connections
A Insulating strips in
51 relay or test block V V
51 51 PA
P contact fingers V
A L N
P
PA
A
AA Ammeter
Ammeter
VV Voltmeter
Voltmeter Directional earth
PA
PA Phase
Phaseangle
anglemeter
meter fault relay

Testing Sensitivity of Generator Differential
Protection Using Primary Injection Test
87 Generator differential relay

Primary injection
250V A.C. supply V Voltmeter
test set A Ammeter
A Isolating links
Generator
A
B
C
87 87 87
V

Testing Sensitivity of Generator Differential Protection
Using Generator to Supply Primary Current
Temporary
short circuit
Isolating
Generator links
A
B
C
87 87 87
V
87 Generator differential relay

V Voltmeter
Checking Stability of Generator
Differential Protection
Temporary
Isolating short circuit
Generator links
A
B
C
A A A
87 87 87
Shorts across relay/

stabilising resistors 87 Generator differential relay
A Ammeter

Earth Fault Sensitivity Check on Transformer
Temporary
short circuit
A A
B
Primary
injection
test set
C
250V
A.C.
supply Bias coils
Operating 87 87 87
coils

Phase Fault Sensitivity Check on Transformer
Temporary
A short circuit
A
Primary
injection
B
test set
C
250V
A.C.
supply
Bias coils
Operating 87 87 87
coils

Stability Check on Transformer
Generator Temporary short circuit
~
Bias coils
A
87 87 87
Operating coils
Instantaneous current distribution for three-phase short
circuit with phase A current at maximum

Sensitivity Check of Restricted
Earth Fault Protection
250V A.C.
supply A
Primary
injection
test set A
B
C
64 Earth Fault Relay 64

A Ammeter
V Voltmeter V
Stability Check of Restricted Earth
Fault Protection
250V A.C. supply

A Temporary short circuit
Primary
injection
test set
A
B
C
64 Earth Fault Relay

A 64
A Ammeter
Sensitivity Check of Negative
Phase Sequence Relay
A B C
Temporary
short circuit
Filter
network 46
Primary injection
test set
250V 46 Negative phase sequence relay

A.C. supply A Ammeter
Test Plug Link Connections for
Load Current Test
To relay
filter network
20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7 8 9 10
A B C N
Earth Fault Sensitivity Check
of Pilot Wire Relay
A A
B
C
Primary
injection
test set
B 250V A.C. supply

OP
Pilots to remote
end relay
B Relay bias coil OP Relay operating coil A Ammeter

Phase Fault Sensitivity Check
of Pilot Wire Relay
A B C
OP
B Relay bias coil

OP Relay operating coil
A Ammeter
Primary
injection Pilots to remote
test set
end relay
250V A.C. supply
Load Current Distribution
A B C A B C
Feeder
Instantaneous current
distribution of three-phase
balanced load with
phase A current at B B
maximum OP OP
Pilots

Short-Circuiting Connections
on Test Plug for Load Test
To relay summation CT
Short circuiting connections
on rear of test plug
20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7 8 9 10
A A B C N
To main current
transformers
Ratio Check of Current Transformers
of Reference Circuit
A1
250V A.C.
supply
Primary injection A2
test set Test
links
A
B Zone
C bus wires
N
A1 and A2 Ammeters
87 Busbar Protection relay
95 Supervision relay 95X
95X Bus wires short-circuiting 95 87 87 87
relay

Polarity Check of Reference
Circuit Current Transformers
A Ammeter A B C
Temporary short circuit
87 Busbar Protection
relay A
95 Supervision relay
95X Bus wires short-
circuiting relay
Test
links
A
250V A.C.
supply A
B Zone
Primary injection C bus wires
N
test set
95X
95 87 87 87

CT Inter-Group Ratio and Polarity Check in
Busbar Protection Scheme
Reference circuit Test circuit
Temporary
short circuit Test
links
A
A A A A
A 1 1 1 1
250V A.C. supply
Primary injection
B
C
N
Zone
test set
A1 Ammeter for ratio check A2 bus

A2 Ammeter for polarity A2
check A2 wires
87 Busbar protection relay 95X
95 Supervision relay 95 87 87 87
95X Bus wires short-
circuiting relay

Sensitivity Check of Busbar
Protection Scheme
A B C
250V A.C.
supply
Primary injection Test
test set links
A
B Zone
C bus wire
N
95X
V 95 87 87 87

Stability Test
A
B
C
Test Test
plug Overcurrent plug
test set
250V
A.C. supply
B B
OP OP
Pilots

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Commissioning & Maintenance

1. Primary injection sensitivity tests only

 Minimum of time consumed

 Not suitable for maintenance tests

> Commissioning & Maintenance of Protective Relays

2. Secondary injection tests

 True primary sensitivity easily equated

> Commissioning & Maintenance of Protective Relays

3. Secondary injection tests

 Proof of isolated relay characteristic obtained

> Commissioning & Maintenance of Protective Relays

 Checks that expected C.T. / V.T. quantities present at test

> Commissioning & Maintenance of Protective Relays

1. Secondary injection (isolated relay)

> Commissioning & Maintenance of Protective Relays

 To assure ourselves, and the interested authorities,

 Resist pressures to take risks

 Study wiring diagrams and protection requirements

 Observe safety of self and others

> Commissioning & Maintenance of Protective Relays

To assure ourselves, and the interested

> Commissioning & Maintenance of Protective Relays

0 > Commissioning & Maintenance of Protective Relays

 Line / Transformer / Generator energisation

At the end of each stage ask yourself :-

1 > Commissioning & Maintenance of Protective Relays

Peak 1.6 x AV.

Mean D.C. Peak to Peak V

<12% of mean D.C. comp.

2 > Commissioning & Maintenance of Protective Relays

3 > Commissioning & Maintenance of Protective Relays

Frequency of Maintenance (continued)

f) The proven reliability of devices under

4 > Commissioning & Maintenance of Protective Relays

Onerous site conditions :-

5 > Commissioning & Maintenance of Protective Relays

 The commissioning test stage

 At each maintenance test

 After heavy fault clearance

 More regularly if onerous site conditions

6 > Commissioning & Maintenance of Protective Relays

Recommended maintenance tests

7 > Commissioning & Maintenance of Protective Relays

 Relays involving static (electronic) components

 Electro-static discharge (ESD)

 Modern static relays (K-SERIES, MiCOM etc.)

 Fault find to board level only

8 > Commissioning & Maintenance of Protective Relays

9 > Commissioning & Maintenance of Protective Relays

0 > Commissioning & Maintenance of Protective Relays

 Primary Injection Test (+ on load tests)

1 > Commissioning & Maintenance of Protective Relays

 Tripping and Alarm Annunciation

2 > Commissioning & Maintenance of Protective Relays

7 > Commissioning & Maintenance of Protective Relays

Test selector switch

To main current To main VT

8 > Commissioning & Maintenance of Protective Relays

9 > Commissioning & Maintenance of Protective Relays

0 > Commissioning & Maintenance of Protective Relays

A B C Test plug isolating

1 > Commissioning & Maintenance of Protective Relays

2 > Commissioning & Maintenance of Protective Relays