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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

Close... 17.00

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

Test-A-Relay

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.

Test-A-Relay

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

popular
Expected

lifetime of up to 40 years

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Motor Protection
Main Functions
1.

To safeguard the motor to ensure

continuity of use.

2.

To minimise damage and repair costs.

3.

To ensure safety of personnel.

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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

30

b) POLLUTION (corrosive atmosphere)

19

c) PHASE FAILURE (EARTH FAULTS)

14

d) BEARING FAILURE

13

e) AGEING (ambient temp too high)

10

f) ROTOR FAULTS

g) MISCELLANEOUS

FIGURE 1
ACKNOWLEDGEMENT TO SCHNEIDER SA

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Main causes of damage

19%
26%

Long time
overheating
Insulation failure

5%

Rotor or bearing
fault
Faulty Protection
20%

Other causes
30%

Test-A-Relay

Protective functions needed

Thermal overload
19%

26%

5%

Short circuit & Earthfault

Start-up supervision and

thermal sensor unit
Continuous self testing of
protection relay

20%
30%

Other protection
functions/undertectable
faults

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100

10.0

1.0

0.1

NORMAL OPERATING AREA

1000

STATOR
LIMITATION
AREA

ROTOR LIMITATION AREA

MOTOR START CURVE

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

FAULT ON CABLE OR IN TERM. BOX

Motor Capability Curve

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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PERCENTAGE OF FINAL TEMP RISE

Time Constants
100%
80%

HEATING

60%

63%

40%

36%

20%
0%
0

COOLING

TIME IN TERMS OF t/Tau (Tau = TIME CONSTANT)

FIGURE No 3

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Fused Protection
1000

THERMAL

FUSE

TIME IN SECONDS

PROTECT

CONTACTOR

100

CURRENT
BREAKING
LIMIT

10

MOTOR
1

START
MOTOR
FULL
LOAD

0,1

10

100

1000

10000

FAULT CURRENT IN AMPS

FIGURE No 4

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Effect of Motor Heating

1000

100
A
B

10

D
A - MOTOR CAPABILITY COLD , Tau = 30min
B - P&B GOLD COLD, SET TO 105%, 14min
1

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

AMPS IN PER UNIT I full load

10
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

(E) Three Phase-To-Earth

(B) Phase-to-Phase

(F) Phase-to-Pilot

(C) Phase-to-Phase-to-Earth

(G) Pilot-to-Earth

(D) Three Phase

% OF MOTOR FULL LOAD

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Motor Unbalance Capability

100
Z1/Z2 = 4

80

Z1/Z2 = 6
60

Z1/Z2 = 8

40

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 1FOR I
FIGURE No 8

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Positive/Negative/Zero
Components
Rotation

Va1

Vc1

Rotation

Vc2

120

120

Va2 Va0 Vb0 Vc0

120

120

120

120

Vb2

Vb1

The Positive, Negative and Zero Components

Opposite rotation

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Rotation

Rotation

Vc1

Va1

Vb2

Va2

120

120

120

120

Vb1

120

120

Vc2

The Positive, Negative and Zero Components

Same rotation

Va0 Vb0 Vc0

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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

FOR

I=I

60

120

-I

MIN

MAX

1.7

1.6

1.5

1.4
0

180

240

300

360

ANGLE OF I WITH2REFERENCE TO I

FIGURE 11

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TORQUE

Motor Torques

NORMAL
VOLTAGE

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

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% OF MOTOR FULL LOAD

% OF MOTOR FULL LOAD

Unbalance Tripping
100

100

80

80

Z1/Z2 = 6

Z1/Z2 = 6

60

60

40

40

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

20

10

12

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

20

14

VOLTAGE UNBALANCE (E2/E1 x 100%)

RESPONSE OF RELAY FOR

Imax - I average
I average

FIGURE 13a

10

12

14

VOLTAGE UNBALANCE (E2/E1 x 100

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

3 (Rct)

1 (Rl)

10v
CAG14

120 v

relay

300/1

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
FRAME SIZE (shaft height in mm)

MOTOR

DESIGN 355 400 450 500 560 630 710 800 900 1000
O

20

25

28

30

35

40

50

60

65

70

45

50

55

60

70

80

90

30

35

40

45

50

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
VR

V
R1
VW-B

SINGLE PHASE VOLTAGE

VB2

V
R2

VW2

V
B1

VW1
VW

VB

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 TEMPERATURE1 ie I 2+ 6I )

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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

2

IN THERMAL MODEL (I 1 + 6I2 )

2

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

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SYSTEM UNDERVOLTAGE

Under Voltage Protection

MOTOR TORQUE IS PROPORTIONAL TO2 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

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
E

AC WINDINGS - >200kW to <5000kW 60

75

80 105 125

60

75

80 105 125

AC WINDINGS - 600W to 200kW

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

E
0.7

0.8 1.0 1.25

ON 1% PER 100m FOR CLASS F

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

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

1000

1,04 1,00 1,03 1,00 1.03 1,00 1,03 1,00 1.02 1,00

1500

1,03 0,98 1.02 0,98 1,01 0,98 1,00 0,97 0,99 0,97

2000

1,01 0,97 1,00 0,96 0,99 0,96 0,97 0,95 0.96 0,94

2500

1.00 0,95 0,98 0,95 0,97 0,94 0,95 0,92 0,92 0,90

3000

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

hope you benefitted from the workshop.

We

dont stop here...

...if

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