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WELCOME
Take a seat where you feel comfortable
Help yourself to coffee or tea Please fill in the attendance register.

Workshop will start at 8:30

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Administrative Details

Workshop program Start.....08.30

Refreshment Lunch....12.30 Refreshment

Break....10.00 to 10.20 to 13.30 approximately Break...15.00 to 15.20

Close... 17.00

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Practical Power Systems Protection For the Electrical Industry

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The Lecturer
Who

am I?

I am Dave Duncan and I am employed by TEST-A-RELAY CONSULTING

What is my background?
I have been in the protection business for 33 years, both industrial and power transmission & distribution

Am I contactable after this workshop?

Yes

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The Workshop

This workshop is for you! Interaction with you is important. Ask any question - dont be intimidated by your peers.

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The Workshop

Relate any relevant experiences you have to other attendees. Time is precious, please keep any unrelated questions/experience to the breaks. Above all enjoy yourself. A good joke is always welcome.
Beep. TRY THAT QUESTION AGAIN.

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Topics for the Day

Introduction Need for Protection Fault Types and their effects Causes of unbalance System Earthing & Faults Application Protection calculations

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Introduction
Workhorse Electrical Squirrel

of industry

energy to rotational energy

cage induction motors (TEFC) very lifetime of up to 40 years

popular
Expected

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Motor Protection Main Functions

1. To safeguard the motor to ensure continuity of use. To minimise damage and repair costs. To ensure safety of personnel.

2. 3.

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Power System Protection Basic Requirements

1.Selectivity: to detect and isolate the faulty item only. 2.Stability: to leave all healthy circuits intact to ensure continuity of supply. 3.Speed: to operate as fast as possible when called upon to do so, thereby minimising damage, production downtime and promoting safety to personnel. 4.Sensitivity: to detect even the smallest value of fault current or system abnormalities and operate correctly at its setting.

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Types of Motor Failures

FAILURES OF MOTORS
% a) OVERLOADS b) POLLUTION (corrosive atmosphere) c) PHASE FAILURE (EARTH FAULTS) d) BEARING FAILURE e) AGEING (ambient temp too high) f) ROTOR FAULTS g) MISCELLANEOUS 30 19 14 13 10 5 9

FIGURE 1
ACKNOWLEDGEMENT TO SCHNEIDER SA

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Main causes of damage

19% 26%

Long time overheating Insulation failure Rotor or bearing fault Faulty Protection

5%

20% 30%

Other causes

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Protective functions needed

Thermal overload 19% 26% Short circuit & Earthfault

5%

Start-up supervision and thermal sensor unit Continuous self testing of protection relay 30% Other protection functions/undertectable faults

20%

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Motor Capability Curve

1000
NORMAL OPERATING AREA FAULT ON CABLE OR IN TERM. BOX

100

10.0

STATOR LIMITATION AREA

ROTOR LIMITATION AREA

1.0

MOTOR START CURVE

0.1

1.0 2.0 3.0 4.0 5.0 6.0 7.0 MOTOR CURRENT IN PER UNIT OF FULL LOAD

8.0

FIGURE 2 - MOTOR CAPABILITY LIMITS

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Temperature rise versus time

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Equivalent Circuit of Squirrel cage

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Protection Philosophy

Selectivity - Stability - Speed - Sensitivity Emphasis on Speed for the following reasons: To minimise damage and repair costs. To reduce production downtime. To prevent undue thermal and magnetic overstressing of healthy equipment on through fault. To keep voltage depressions as short as possible in the interests of plant stability. Above all, to ensure the safety of personnel.

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Power System Protection Qualities

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Dependability It

must trip when called upon to do so

Security It

must NOT trip when it is not supposed to trip.

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Time Constants
PERCENTAGE OF FINAL TEMP RISE

100% 80% 60% 40% 20% 0% 0 63% HEATING

36% COOLING

TIME IN TERMS OF t/Tau (Tau = TIME CONSTANT) FIGURE No 3

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Fused Protection
1000 THERMAL PROTECT FUSE
TIME IN SECONDS

100

CONTACTOR CURRENT BREAKING LIMIT

10

MOTOR 1 MOTOR FULL LOAD 0,1 10 100 FAULT CURRENT IN AMPS FIGURE No 4 1000 10000 START

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Effect of Motor Heating

1000 100 A B

10

C D A - MOTOR CAPABILITY COLD , Tau = 30min B - P&B GOLD COLD, SET TO 105%, 14min

C - P&B GOLD HOT, SET TO 105%, 14min D - MOTOR CAPABILITY HOT, Tau=30min, 10% TIME LEFT

0,1

MULTIPLES OF MOTOR FULL LOAD CURRENT FIGURE No 5

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Motor contribution to a Fault

10
AMPS IN PER UNIT I full load

8 6 4 2 0

10

15

20

25

TIME FROM BEGINNING OF EXTERNAL FAULT - mS CURRENT INFEED FROM AN INDUCTION MOTOR TO AN EXTERNAL FAULT FIGURE No 6

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(A) Phase-to-Earth (B) Phase-to-Phase (C) Phase-to-Phase-to-Earth (D) Three Phase

(E) Three Phase-To-Earth (F) Phase-to-Pilot (G) Pilot-to-Earth

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% OF MOTOR FULL LOAD

Motor Unbalance Capability

100 Z1/Z2 = 4 80

Z1/Z2 = 6 60

40

Z1/Z2 = 8

20

10

12

14

VOLTAGE UNBALANCE (E2/E1 x 100%)

REDUCTION OF MOTOR OUTPUT FOR WITH UNBALANCED SUPPY VOLTAGES

FIGURE 7

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Typical Motor Start

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Motor Current during start

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Blocked Rotor Condition

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Causes
HIGH ROTOR TEMPERATURERS CAUSED BY a) TOO LONG A START TIME b) A LOCKED ROTOR FAULT WITH LOCKED ROTOR TIME BEING EXCEEDED c) TOO MANY STARTS WITH INSUFFICIENT COOLING TIME BETWEEN STARTS

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Effect Of Unbalance
I1 I2 CORRECT ROTATION ANTI CLOCKWISE 1 FOR I
FIGURE No 8

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Positive/Negative/Zero Components
Rotation

Vc1
120

Va1

Vc2

Rotation

Va2 Va0 Vb0 Vc0

120

120

120

120

120

Vb1

Vb2

The Positive, Negative and Zero Components Opposite rotation

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Rotation

Rotation

Vc1
120

Va1

Vb2
120

Va2

Va0 Vb0 Vc0

120

120

120

120

Vb1

Vc2

The Positive, Negative and Zero Components Same rotation

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Maximum Continuous Output vs Voltage unbalance

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Unbalance Measurement
RELAY MEASUREMENT I max - I min I ave I ave `B'

SIGNAL AT POINT `A'

I ripple `C'

TIME TYPICAL CIRCUIT FOR UNBALANCED 'RIPPLE' FIGURE 10

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Ratio of Unbalance to I2
RATIO OF UNBALANCE TO I2
I I 2 1.7 FOR

I=I

-I

MAX

MIN

1.6

1.5

1.4 0 60 120 180 240 300 360

ANGLE OF I WITH2REFERENCE TO I FIGURE 11

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Motor Torques

TORQUE

NORMAL VOLTAGE

1-POS SEQ S=0 S=-1 S=1 1-NEG SEQ FIGURE No 12

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Unbalance Tripping
% OF MOTOR FULL LOAD
100

80

Z1/Z2 = 6 60 60

% OF MOTOR FULL LOAD

100

80

Z1/Z2 = 6

40

20

RELAY RESPONSE (VARIES WITH PHASE ANGLE OF I2 W.R.T. I1 )

40

20

RELAY RESPONSE (DOES NOT VARY WITH PHASE ANGLE OF I2 W.R.T. I1 )

10

12

14

10

12

14

VOLTAGE UNBALANCE (E2/E1 x 100%)

VOLTAGE UNBALANCE (E2/E1 x 100

RESPONSE OF RELAY FOR Imax - I average I average FIGURE 13a

RESPONSE OF RELAY FOR I FROM AN NPS FILTER

FIGURE 13b

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Winding Earth Fault

If X% V fault = Vpn * X/100 NEUTRAL IMPEDANCE - Z

If V fault / Z = X/100 * Vpn / Z FIGURE No 14

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Basic Circuit of High Impedance Current Balance Scheme

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Calculation of stability setting

300/1

9000 A
300/1

Calculate setting of stabilising resistor for the above REF protection. The relay is a type CAG14, rated 1A with 10-40% setting range (burden = 1.0 va)

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Calculation of stability setting

30A

1 (Rl)

3 (Rct)

10v
CAG14

120 v 300/1

relay

300/1
110v

Secondary fault current = 9000 x 1/300 = 30 amps Relay operating current : Choose 10% tap on CAG14 relay rated at 1 amp. Relay operating voltage : VA (burden) = 1.0 = 10 volts I (current) 0.1

Stabilising voltage V = I(Rct + Rl) = 30( 3+1) = 120 volts Resistor = (120 10) / 0.10 = 110/0.10 = 1100 ohms

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Method of Earth Fault Detection

THERMAL ETC

STAB R

E/F

DOTTED LINES SHOW ALTERNATE CT FOR E/F (NO STAB R) NOTE:- CORE BALANCE GIVES NO PROTECTION FOR FAULT F

FIGURE No 15

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Ground Fault Protection

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Useful Data
MOTOR O R U FRAME SIZE (shaft height in mm)

DESIGN 355 400 450 500 560 630 710 800 900 1000 20 30 25 35 28 40 30 45 45 35 50 50 40 55 50 60 60 70 65 80 70 90 -

O - OPEN TYPE R - ENCLOSED WITH FORCED COOLING (DIN IP54) U - COMPLETELY ENCLOSED WITH COOLING RIBS (DIN IP AVERAGE THERMAL TIME CONSTANTS Tau IN MINUTES BBC INDUCTION MOTORS - FRAME SIZE AND DESIGN FIGURE No 16

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Single Phasing
V R

V R1
SINGLE PHASE VOLTAGE

V W-B V R2 V W2 V W1 V W

V B2 V B1 V B

NOTE:- MAGNITUDE V pos = MAGNITUDE V neg = 0.5 V ph-n FOR SINGLE PHASING (NO OTHER LOADS & STARTING) FIGURE No 8a

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Causes
HIGH ROTOR TEMPERATURERS CAUSED BY a) TOO LONG A START TIME b) A LOCKED ROTOR FAULT WITH LOCKED ROTOR TIME BEING EXCEEDED c) TOO MANY STARTS WITH INSUFFICIENT COOLING TIME BETWEEN STARTS

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Protection with Fuses

FUSES
DISADVANTAGES FOR MOTOR PROTECTION

a) CANNOT PROVIDE CLOSE THERMAL PROTECTION

b) DO NOT OPERATE FOR SYSTEM UNBALANCE MAY BE CAUSE OF SINGLE PHASING

c) MUST BE SIZED LARGER FOR MULTIPLE STARTS TO COVER TOTAL TIME

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Bimetallic Strips
BI-METALLIC ELEMENTS
DISADVANTAGES FOR MOTOR PROTECTION

a) TIME CONSTANT NOT FIELD ADJUSTABLE

b) COOLING AND HEATING TIME CONSTANT EQUAL - NO PROTECTION FOR MULTIPLE RESTARTS

c) SINGLE SHAPE CURVE TO COVER THERMAL OVERLOAD AND STARTING

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Starting
MOTOR STARTING PROTECT
METHODS OF DETECTION

a) DEFINITE TIME LAG FOR START CURRENT

b) a) PLUS CUMULATIVE START TIME

c) a) PLUS MAXIMUM HOT/COLD STARTS PER HOUR

d) DEPENDENT TIME LAG FOR STARTING CURRENT (COMBINED WITH MOTOR 2 2 STATOR TEMPERATURE ie I 2+ 6I ) 1

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Relay gives stall protection

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Relay does not give stall protection

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Negative Sequence / Unbalance

MOTOR PROTECTION
NEGATIVE SEQUENCE

a) WEIGHTED COMBINED HEATING EFFECT IN THERMAL MODEL (I 1 + 6I2 ) b) A DEPENDENT I TIME CHARACTERISTIC c) AN INDEPENDENT TIME CHARACTERISTIC d) AN INDEPENDENT TIME CHARACTERISTIC BUT OPERATES FOR I MAX - I AVE TOO LARGE
2 2 2

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SYSTEM UNDERVOLTAGE

Under Voltage Protection

2 MOTOR TORQUE IS PROPORTIONAL TO I

MAX TORQUE @ FULL VOLTAGE USUALLY 200% 100% TORQUE AVAILABLE AT 70% VOLTAGE UNDERVOLTAGE TRIPPING BELOW 70% VOLTA POS SEQ. or 3x SINGLE PHASE RELAYS TRIP BEFORE AN AUTO RECLOSE BUSBAR VOLTAGE DETECTION SUITABLE FOR A GROUP OF MOTORS

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Motor Information
Modern Relays require extra information Manufacturers cannot always supply the required information Information is difficult to obtain for old existing motors Empirical tables may need to be used

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Accuracy of Settings
THE RELAY HAS DEFINED INACCURACY (2%) CTs USUALLY HAVE A NEGATIVE ERROR CLASS 10P10 - 3% CLASS 5P10 - 1% -3% ERROR COULD ALLOW 6% OVERLOAD WHICH WILL REDUCE INSULATION LIFE THERMAL REPLICA FORMULA t = Tau lnH
2

I - (kIB ) where `k' VARIES FROM 1.0 TO 1.05 for different manufacturers

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Additional Options
MICROPROCESSOR RELAYS CAN INCLUDE i) STORAGE OF FAULT DATA ii) COMMUNICATION PORTS TO ALLOW:a) INTERROGATION & SETTING OF RELAY b) CONTROL OF BREAKER/CONTACTOR c) DUAL SETTINGS FOR DIFFERENT SYSTEM CONDITIONS iii) MULTIPLE, MATRIX SELECTED OUTPUTS iv) STARTER FUNCTIONS USED FOR BZone v) SELF SETTING ADAPTION WITH EXTERNAL TEMPERATURE SENSORS

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Motor Bearing Failure

ROLLER / BALL BEARINGS ON SMALL MOTORS i) FAILURE CANNOT BE DETECTED BY I CHANGING ii) COMPLETE FAILURE IS VERY RAPID iii) MOTOR PROTECTED BY STALL PROTECTION ON BEARING FAILURE SLEEVE BEARINGS ON LARGER MOTORS a) FAILURE MODE IS SLOWER THAN BALL BEARINGS b) TEMPERATURE RISE OF BEARING CAN BE USED FOR PROTECTION c) MOTOR PROTECTED BY STALL PROTECTION ON BEARING FAILURE

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Insulation Classes
CLASS OF INSULATION A
AC WINDINGS - >200kW to <5000kW 60 AC WINDINGS - 600W to 200kW

E 75 75

80 105 125 80 105 125

60

PERMANENTLY SHORT CIRCUITED TEMPERATURE RISE SHALL ROTOR WINDINGS NOT BE DETRIMENTAL TO OTHER INSULATION

ALLOWABLE TEMPERATURE RISE OF WINDINGS (MEASURED BY RESISTANCE METHOD)

CLASS OF INSULATION A
ADJUSTMENT DECREASE FACTOR 0.6 ON 1% PER 100m FOR CLASS F

E 0.7

0.8 1.0 1.25

ADJUSTMENT OF TEMPERATURE RISE FOR CLASS F INSULATION IS 1% FOR EVERY 100m ABOVE 1000m. ADJUSTMENT FIGURES FOR OTHER CLASSES IS GIVEN ABOVE. TABLE No 1

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Effect of Height above Sea Level

CLASS OF INSULATION
ALTITUDE

m 1000 1500 2000 2500 3000

35C 40C 35C 40C 35C 40C 35C 40C 35C 40C

1,04 1,00 1,03 1,00 1.03 1,00 1,03 1,00 1.02 1,00 1,03 0,98 1.02 0,98 1,01 0,98 1,00 0,97 0,99 0,97 1,01 0,97 1,00 0,96 0,99 0,96 0,97 0,95 0.96 0,94 1.00 0,95 0,98 0,95 0,97 0,94 0,95 0,92 0,92 0,90 0.98 0,94 0,96 0,93 0,95 0,92 0,92 0,89 0,89 0,87

MOTOR DERATING FACTORS FOR ALTITUDE AND AMBIENT TEMPERATURE

TABLE No 2

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Thank You
We We ...if

hope you benefitted from the workshop. dont stop here... you have any further queries or require

help we would be delighted to assist you.

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Remember...
I

can be contacted at any time (012) 665 0545 (082) 578 2558 OR
E-mail

me at dave@test-a-relay.co.za Alternatively office@test-a-relay.co.za