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FOR
REV.NO R1 ISSUE
DATE 97-04-14
CONTENTS
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1. SCOPE
This design guide presents preferred practices for relay settings and protection
co-ordination to achieve selective tripping in the electrical auxiliaries of
industrial and power plants. Part-I of this guide details relay co-ordination
procedures while Part-II indicates methods of setting different types of relays
for various protections.
1.1 The co-ordination starts from the extreme downstream protection, which may
be a fuse.
1.2 The co-ordination interval for the relay immediately above the fuse is decided
by the fuse positive tolerance, relay negative tolerance, relay overshoot and a
safety margin. A minimum co-ordination interval of 0.2 sec. is to be
maintained between the relay and the fuse.
1.4 For industrial plants, the operating time of the extreme upstream relay in the
plant, considered along with its breaker opening time, at the incoming power
supply fault level, is governed by the maximum time permitted by the
Electricity Board and equipment ratings at that fault level. The co-ordination
starting from the extreme downstream relays shall ensure that this requirement
is met.
1.5 For power plants the operating time of the extreme upstream relay is
determined by the switchgear rating. Since the switchgear normally has a 1.0
sec. rating, the maximum relay operating time should not exceed 0.9 sec. at the
rated fault level.
1.6 The following procedures can also be considered to simplify relay coordination
:
1.6.1 Use of very inverse and extremely inverse time relays on downstream feeders.
1.6.2 Reduction of the co-ordination interval to 0.35 sec although this reduces the
safety margin.
1.6.3 Elimination of the co-ordination interval between two relays which will not
cause power interruption to other loads. For example, in co-ordination of relays
on the primary and secondary of transformers and co-ordination of relays on the
breakers at the sending and receiving end of a tie/radial feeder.
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1.6.4 The co-ordination interval between relays provided on incoming feeders and the
bus coupler can be eliminated, in cases where the bus coupler is normally kept
open.
1.7 On any particular bus, amongst relays on various outgoing feeders, the relay
with the highest operating time is to be considered for co-ordination with the
relay on the incoming feeder. It shall also be ensured that the relay on the
incoming feeder does not operate for the starting condition of the largest motor
when feeding all other normal loads.
1.8 The instantaneous relays on the primary side of the transformer feeder shall be
set above the through fault level on the secondary side to prevent the relay from
operating for a secondary side fault. Generally, the setting adopted is 1.3 times
the through fault current in cases where relays with low transient over-reach are
used, if not a setting of 2.7 shall be adopted. This value covers the CT error,
the relay error as well as the over-reach of the instantaneous relay.
1.9 Where inverse time relays with high-set instantaneous units are provided on
outgoing transformer/motor feeders, the IDMT relay on the incoming feeder
shall be co-ordinated with the operating time of the instantaneous relay to bring
down the bus fault clearing time. However, with the IDMT relay characteristic
selected in this manner, for the incoming feeder, it should be ensured that
grading is obtained with the outgoing feeder IDMT characteristic as well. This
aspect has been further elaborated under item 2.1.3 of Part-II of this guide.
1.10 The operating time of the relay on an incoming feeder at that respective
switchgear fault level shall be such that the operating time of the immediate
back up relay, considered together with its breaker opening time, shall not
exceed the short time rating of the switchgear, which is normally 1.0 second.
Whenever there is a substantial difference between the system fault level and
the switchgear rating, the incoming feeder relay and the immediate back up
relay operating times, at the system fault level, are permitted to increase, based
on "I2T" criterion as may be necessary for co-ordination with downstream
relays, for example, if the fault current at the switchgear bus is 'X' which is
much lower than the switchgear 1.0 sec, rating, 'Y', then the relay operating
time at the bus fault level 'X' can be increased to (Y)2 x 1.0 second.
x
1.11 Current settings on directional relays when used for duplicate incoming feeders
are to be set at 50% of the normal full load of the protected circuit and the time
multiplier set at 0.1, i.e., as low as possible. Care shall be taken to ensure that
the continuous thermal rating of the coil is not preceded during power flow in
the reverse, i.e., non-operating direction.
2.1 An impedance diagram of the Plant System is to be prepared showing the per
unit impedance (considered with negative tolerances as per relevant standards)
of all the circuit elements. Using network reduction techniques, the short
circuit levels at various voltages of the system can be calculated. Design Guide
for Electrical Auxiliary System for Thermal Power Plants - TCE.M6-EL-Au-G-
710-6009 may also be referred in this regard.
OR
* The factor 1.2 relates t the 20% negative tolerance on the impedance.
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1.0 GENERAL
1.2 Motors Feeders : Which are meant solely for the switching and protection of
motors - either HV or LV.
1.3 Tie Feeders : Which couple two switchboards at the same voltage level with
circuit breakers at both the sending and receiving ends or with a breaker at the
sending end and a switch at the receiving end. Power flow through these
feeders is normally uni-directional, though under certain circumstances, bi-
directional power flow may be permitted.
The various criteria to be kept in view while setting the individual relays for
different protections have been detailed under each type of feeder protection.
Procedure for setting certain miscellaneous relays, common to a switchboard
(like neutral displacement and under voltage relays on Bus voltage transformer
modules) have also been indicated.
Whether all the above, or a few selected protections are applied, depends on the
transformer rating and the system earthing. Application of these protections
have been detailed in guide No. TCE.M6-PI-G-TF-6508, - "Protection of
Transformers".
2.1 Overcurrent Protection (50/51) :
2.1.1 Purpose :
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An instantaneous over current relay (50) having a low transient over reach is
used to provide the instanta-neous protection whereas a definite minimum time
relay having inverse characteristics (51) is used to provide time delayed back-
up protection. Both the above relays may be mounted in a single unit or
supplied in different cases.
The instantaneous element is used on the primary side of the transformer only,
as use of this relay on the secondary side would make co-ordination ineffective.
Directional relays, both on the HV & LV sides, are used in case of Tie
transformers where bi-directional power flow occurs.
The method of setting the relay would therefore be to chose a higher current
setting to avoid the motor starting inrush current and to choose a time multiplier
setting to grade with the instantaneous over current element of the downstream
transformer feeder. It may be noted that with this philosophy in setting,
overload protection is not afforded by this relay,but much faster fault clearing
times are achievable. Overload protection to the transformer is basically
provided by the over-temperature protection devices which sense the
transformer winding and oil temperatures. Relay characteristics illustrating the
above have been shown in Fig. 1.
While the current setting i.e., the plug setting multiplier (PSM) preferred on the
primary side would be just above the transformer full load current, it is usually
not practical to choose such a low setting, as both the current (PSM) as well as
time (TMS) settings have to be necessarily co-ordinated with the IDMT relay
(51) on the transformer secondary. For reasons detailed above, the current
setting may be quite high and as such this protection is considered as a back up
and is expected to operate on both transformer internal faults as well as through
(external) faults on the downstream side (Ref. Fig. 1).
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It should be ensured, that in order to maintain co-ordination, this relay does not
operate for any fault on the secondary side of the transformer. The setting
should therefore be chosen so as to be above the secondary side short circuit
current (reflected on the primary side) but definitely well below the primary
side fault current. Also, in order to avoid spurious operation of this relay on
offset fault currents on the transformer secondary and magnetic inrush currents,
an instantaneous over current relay with a low transient over-reach (5% or less)
is recommended.
Procedures defined in clause 2.1.3 for over current relays are generally
applicable to this protection as well. However, for setting IDMT earth fault
relays, in the absence of any other constraint, the lowest current setting
available may be generally chosen, keeping in view the co-ordination
requirements detailed in 2.1.3 above and in Part-I of this guide.
2.3.1 Purpose :
This relay provides instantaneous earth fault protection to all internal faults on
the transformer winding to which it is applied. As it is a unit protection, the
setting of this relay does not require co-ordination with other protection
systems. In low resistance earthed system, this protection also supplements the
normal differential protection, since it offers protection to a larger percentage of
the transformer winding. This protection cannot be applied to high resistance
earthed (i.e., non-effectively earthed) systems.
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This relay is normally set at the lowest current tap available, viz. 10%.
However, to ensure that the relay does not maloperate on through faults, an
additional stabilizing resistor is connected in series with the relay. The
resistance ensures that the current in the relay circuit does not reach the
operating value even when the maximum voltage VR appears across the relay
circuit under through fault conditions. The procedure for calculating the value
of the stabilizing resistor is as follows :
(i) The maximum voltage that is likely to appear across the relay i.e., VR
during external faults is first calculated assuming the worst condition of
imbalance, i.e., the CT on one side saturating
(ii) Next, the total relay circuit impedance - RT is calculated at the relay tap
selected (IR).
RT = VR
IR
(iii) The relay coil impedance RR at the chosen tap should be obtained from
the manufacturers' catalogues.
(iv) The value of the additional stabilising resistor (RS) required would then
be the total circuit impedance (RT) minus the relay coil impedance at
the selected tap (RR)
RS = RT - RR
As the current transformers designed for this protection would have a knee
point voltage equal to at least 2 VR, they would develop an adequate voltage,
higher than VR, to operate the relay in case of internal faults.
2.4.1 Purpose :
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The current and time settings on this relay should protect the short-time rated
earthing resistor from damage. The current setting chosen should be less than
the resistor continuous withstand value. The operating time of the relay should
be less than the withstand time of the resistor at the maximum system E/F
current. In addition to matching the short-time rating of the resistor, the setting
should also co-ordinate with all downstream E/F relays. In effectively earthed
systems, the minimum current setting available on the relay may be chosen with
a time setting adequate to co-ordinate with all downstream earth fault relays.
This unit type protection is provided against phase to phase as well as phase to
earth faults in both the transformer windings or at the transformer terminals.
However, earth faults on the LV winding in high resistance earthed systems
would not be detected by this protection.
These relays are normally provided with a fixed operating value. However, in
case relays with different settings of operating value are used, the lowest setting
available may be adopted. A biased relay is used to prevent operation under
through faults, as even under normal external fault conditions a certain
differential current can flow through the operating winding of the relay due to
the following reasons :
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2.6.1 Purpose
This relay provides protection against low oil level and transformer internal
faults, including incipient faults.
No setting is required to be carried out at site. The oil/gas surge rate and the
accumulated gas volume setting required to actuate the trip and alarm circuits
respectively are preset at the factory depending on the capacity of the
transformer.
The over temperature protection for both the windings and oil is to be set as per
the manufacturers' recommendation. This is normally preset at the factory.
3.1.1 Purpose
The operating value of this relay shall be set at the motor full load current.
3.2.1 Purpose
These relays, provided for all motors above 100 kW, offer back up protection to
motors under stalling conditions. Thermal overload relays may also provide
protection under stalling conditions. In cases where the thermal protection is
not effective under stall conditions (i.e., where the thermal withstand charac-
teristic of the motor lies below the relay operating characteristic) in either the
cold or hot condition, this relay becomes the only protection under stalling
conditions.
(a) The current setting chosen on each inst. O/C relay shall normally equal
twice the full load current of the motor. The common timer setting shall
be 1 to 2 secs. more than the starting time of the motor at the minimum
permissible voltage during starting, i.e., 80%.
(b) If however, on carrying out the relay application check, the relay hot or
cold characteristic is found to cut the corresponding motor withstand
curve, at any point, which is say "X" times the full load current then the
current setting adopted shall be twice the full load current of the motor,
or, (X x IFL) x 0.9 whichever is lower. The time setting chosen shall be
as detailed under (a) above.
(c) In cases, where the locked rotor withstand time at 110% of rated voltage
under hot conditions is less than or nearly equal to the starting time of
the motor, at 80%, of the rated voltage an arrangement shown in Fig. 2
with a speed switch on the motor and an additional on-delay timer is to
be utilised.
The normally closed contact of the speed switch provided shall open out at the
set speed during starting.
(i) Timer TR2 shall be set as usual, i.e., more than the starting time of the
motor.
(ii) Timer TR1 shall be set 1-2 secs. below the locked rotor withstand time
under hot condition.
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(iii) The speed switch on the motor shall be set to operate at a speed attained
by the motor under normal starting conditions in a time less than the
setting of timer TR1.
With this arrangement, if the motor starts normally, the speed switch N/C
contact provided in series with timer TR1 would de-energise it before it could
operate. If however, the motor stalls, the speed switch remaining in the closed
condition, timer TR1 would operate and trip the motor before the locked rotor
hot withstand time is reached. Timers TR1 and TR2 may either be integral with
the stalling protection relay or mounted separately.
3.3.1 Purpose
This relay provides protection to the motor against overheating due to either
overloading or presence of negative sequence currents under both hot and cold
conditions.
A. Current Setting
IRel = IFL x IS x R
Ip P
In case the relay has current settings available in steps the next higher
setting (with respect to the calculated setting) shall be chosen. The
procedure indicated above is general in nature. Manufacturers'
catalogues shall also be referred for particular recommendations, if any.
The time constant of the relay chosen shall be less than the time
constant of the motor being protected. However, this shall be chosen
after carrying out the relay application check as described below.
Relay application checks are to be carried out on all motors rated above
125 kW. This check consists of plotting the motor withstand curves and
relay operating characteristics under both hot and cold conditions
together with the motor starting current Vs time characteristics on the
same graph.
(iii) The relay hot operating characteristic lies above the motor
starting current Vs time characteristic.
If the above conditions are met then the stall protection is backed
up by the thermal protection.
In this case either or both the relay characteristics, i.e., hot and
cold, intersect with the corresponding motor withstand curves
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In this case the DC supply to the relay shall be wired to the relay
thro' a 52A contact as shown in Fig. 5. With this arrangement,
which is applicable to static relays only, it would be ensured that
the relay cold characteristic would be applicable even in case of
a hot restart. In this case, it is preferable to have relay cold curve
below motor hot curve. Even if it is not so a certain degree of
overload protection will be offered and stall protection would
still be available in this condition, this is acceptable since this
condition lasts only for a short duration until the relay reaches
thermal equilibrium once again. However, acceptability of this
scheme shall be checked out for each make of relay.
This relay provides protection against interphase winding short circuits and
terminal/cable faults.
Instantaneous overcurrent relays, one on each phase having low transient over-
reach (less than 5%) to prevent pick up during transient inrush currents when
starting the motor.
The relay shall be set at 1.5 times the starting current. The additional factor for
0.5 takes care of the CT & relay errors, transient over-reach of the relay and
tolerance on the starting current.
3.5.1 Purpose
This relay provides protection to the motor against leakage current to ground.
The relay shall be set at 20% of the rated value in case of solidly earthed
systems and at 10% in case of system grounded through a low
resistance.
The maximum Earth fault current likely to flow due to the system
capacitance is calculated. The relay is set at a value lower than 50% of
the secondary equivalent of the fault current. The setting shall however,
be higher than the fault current contributed by the capacitance of the
largest motor on the bus to prevent the core balance relay on that
particular feeder from operating. The CBCT manufacture shall be
informed of the relay setting and total circuit burden. The performance
of the CBCT shall be guaranteed by the CBCT manufacturer at the
minimum operating current.
This relay, used for motors having a rating above 1500 kW provides fast acting,
unitised protection to the motor against internal phase faults and ground faults
for motors connected to solid by earthed or low resistance earthed systems. For
high resistance earthed system this protection will not sense earth faults.
Three single pole, high impedance voltage operated, instantaneous over current
relays are used with a stabilising resistor in series with each relay.
The relay shall normally be set at 20% of the full load current. The stabilising
resistor shall be set in a manner identical to that detailed under Clause 2.3.3.
However, in this case the maximum starting current should be considered
instead of the system fault current.
3.7.1 Purpose
Single pole instantaneous overcurrent relay with a high drop off to pick up ratio
(of the order of 9% or more) together with a on-delay timer. This relay shall
have a range of 70-130%, preferably continuously adjustable or adjustable in
steps of 5%.
The current setting adopted should lie in the region of 110 to 120% of the motor
full load current. The timer should be set to operate at a value larger than the
starting time at the minimum permissible voltage (80%).
As items (a), (b) and (c) above do not require any setting as such, these are not
discussed in this guide.
In case where RTD's for winding temperature monitoring are used with remote
sensing/monitoring devices which require to be set, th trip temperature setting
shall be bout 10°C less than the withstand temperature of the class of insulation
used in the motor.
(b) Inverse definite minimum time earth fault relay (only in case of
effectively earthed or low resistance earthed systems).
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The type and procedure for setting these relays are identical to that detailed
under the corresponding protections for transformers under Clause 2.0.
5.1.1 Purpose
This relay is used to sense earth faults in systems earthed through a high
resistance. As this protection may be sensitive to earth faults throughout the
system, it cannot be used for tripping any feeder in particular but is connected
to give an alarm only.
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Sl. Motor Motor Type of ___________________Type of Protection Provided_______________________
No Rating Vol- Switch- HRC Bimet- Locked Thermal Short Earth Under Differ- Over-
(kW) tage ing Fuses allic Rotor Over- Circuit Fault Voltage ential load
(V) Device Thermal Relays load Protec- Relays Protec- Relays Alarm
Relays Relays tion tion Relay
Relays
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1 2 3 4 5 6 7 8 9 10 11 12 13
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6. Above 6600/ Circuit - - 2 Nos. 1 No.* 3 Nos. 1 No. Provided 3 Nos. 1 No.
1500 11000 Breaker (1 per (from bus (1 per
Phase) u/v relay) Phase)
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NOTES : (TABLE - 1)
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4. Two numbers Locked Rotor and Thermal Relays indicated shall be connected
to the R & B phases.
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