Commissioning & Maintenance

of Protective Relays

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

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

Arevas 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 :-

Commissioning Flow Chart

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)

Commissioning Flow Chart

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

Commissioning Flow Chart

Summary (4)
z Line / Transformer / Generator energisation
z V.T. ratio and phasing tests
z On load tests
z Stability tests
z 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 !

z Measuring instruments
z 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.

z 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
Protective Relays (2)

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
Protective Relays (3)
Onerous site conditions :1.
2.
3.
4.
5.
6.

Dusty or dirty environments

Corrosive chemical atmospheres
Frequent or continuous vibration
High humidity
High or cycling temperatures
Consistently high levels of energising or auxiliary
quantities

Typically maintain every 12-18 months under ideal

conditions and decrease frequency

Maintenance of
Protective Relays (4)
z Visual inspections
The commissioning test stage
At each maintenance test
After heavy fault clearance
More regularly if onerous site conditions
z Calibration tests
z Trip testing

Maintenance of
Protective Relays (5)
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
Protective Relays (6)

z Relays involving static (electronic) components

Electro-static discharge (ESD)
Wrist straps
z Modern static relays (K-SERIES, MiCOM etc.)
Fault find to board level only
Protect boards

Corrective Maintenance of
Protective Relays (1)
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)
z Insulation tests
z Current transformer tests
z Voltage transformer tests
z Test facilities
z Secondary injection tests

O.C. and E.F.

Differential
Pilot wires
Negative phase sequence
Directional
Distance
D.C. operated

Contents of Section 23 of PRAG (2)

(Protective Relay Application Guide)
z 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

Contents of Section 23 of PRAG (3)

(Protective Relay Application Guide)

z Tripping and Alarm Annunciation

z Periodic Maintenance

In addition to PRAG :Consult instruction manuals

Test Terminal Block

To relay coils

A B C
To CT test
windings
(if any)

B
C N
To main
current
transformers

A B C N
To main VT

Test Switch and Sockets

To relay coils
A
B Voltage
C test
sockets
N

A
Current B
test
sockets C
N

Test selector switch

Make before break
on CT Circuits

To main current
transformers

To main VT

Current Transformer
Polarity Check
P2

P1
S2

S1

Battery

Push
button
switch

Current Transformer
Ratio Check
A

C
A2

Temporary
short
circuit

Test plug
insulation
51
51

P1

S1

P2 S2

51
64

Relay or test block

contact fingers

A1
Primary injection
test set
250V AC supply

Testing Current Transformer

Magnetizing Curve
A

Test plug isolating

current transformers
from relay coils
Variable
transformer
250V 8A

A
To relay
coils

P1
S1

250V
AC
supply
V

S2
P2
Main circuit
breaker open

Step-up transformer
if required

Voltage Transformer
Phasing Check
A
B
C

V1
V2

VN

VL
V1

V2
A

Phase rotation
meter

Overcurrent Test Set

Fine control
variable
transformer

Coarse
control
reactor

Range
adjusting CT

K1
K2

250V
AC
supply

51

Start
timer
Supply
switch

Backing
transformer
10% control

Relay
coil

Stop
timer

Injection
Relay shortMedium
transformer
circuiting switch
control
reactor
Relay current I = Ammeter reading (A) x K1 K2

Basic Current Control Circuit

of CFBA Test-Set
A
60Hz

L2

50Hz
0.1A

10X 5X 2X 1X

0.2A

220/250V
AC
Supply
50/60Hz

Variac V1

60Hz

0.5A

50Hz

1A
2A

O/V Detector
Circuit

L1

5A

Supply
Contractor
Thermal Overload / Overvoltage
Protection

Supply Shorting
Switch

10A

Timer
T1
Start
(Break to Start)

Injection
Matching
C.T.

Output
to
Relay

Sensitivity Check on
Biased Differential Relay

B
OP

Test plug
fingers

Overcurrent
test set
250V
A.C. supply

To main current
transformers

OP Relay operating coil

B Relay bias coil

Testing Bias Characteristics

(Using Overcurrent Test Set)
B

B
OP

I1+I2

A1

Overcurrent
test set
250V A.C.
supply

I2

I1

To main current
transformers

A2
R

Test plug
fingers

Testing Relay Bias Characteristic

(Using Resistances)
B

B
OP

I1+I2

R1

Test plug
fingers

A2

A1

250V A.C.
supply

I2

I1

To main current
transformers

R2

A1 and A2 Ammeters
OP Relay operating coil
B Relay bias coil

Sensitivity Test
Feeder isolated
A
B
C
Test
plug

Overcurrent
test set

Relay
contact
fingers

250V
A.C. supply

B
OP

OP

Pilots

Testing Sensitivity of Negative

Phase Sequence Relay

250V
A.C.
supply

To main
current
transformers
Overcurrent
test set
Test plug
in test block

B
46

C
N
Filter
network

Relay
coil

Test Equipment for

Directional Relays
A
B
C
N

Supply switch
440V
3 phase
4 wire supply
Choke

Variable
transformer
for current
control

67

Relay
current coil

Range adjusting CT
440/110V
phase shifting
transformer

A
PA

PA

Variable transformer
for voltage control
To other voltage coils
of relay under test
(if required)

67

Relay
voltage coil

V Voltmeter
A Ammeter
PA Phase angle meter

Primary Injection Test Set

250V A.C.
supply

Variable transformer 40A

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

Primary Check on
Main Current Transformers
Temporary threephase short circuit

Primary
injection
test set

51

B
51

250V
A.C. supply

C
51

51 Overcurrent relay
64 Earth fault relay
A Ammeter

64

Sensitivity Test on
Earth Fault Relay
250V
A.C.
supply

Primary injection
test set

51

B
51

51

64

Load Test on Directional

Overcurrent Relays
A B C

Direction of power flow

for relay operation
Load current

AA
VV
PA
PA

Ammeter
Ammeter
Voltmeter
Voltmeter
Phase
Phaseangle
angle
meter
meter

PA

PA

B
C
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

9 10

Test plug
To main VT and CT

Load Test on Directional

Earth Fault Relay
ABC

P2

P1

S2

S1

Temporary
short circuit
connections

IA

51
51

51

Load current

PA

V1
V2

Insulating strips in
relay or test block VL
contact fingers

VN
V
PA

A
Ammeter
V
Voltmeter
PA Phase angle meter

Directional earth
fault relay

Testing Sensitivity of Generator Differential

Protection Using Primary Injection Test

Primary injection
test set

250V A.C. supply

Generator

87 Generator differential relay

V Voltmeter
A Ammeter

Isolating links
A
B
C

87

87

87

Testing Sensitivity of Generator Differential Protection

Using Generator to Supply Primary Current

Temporary
short circuit Isolating
links
Generator
A
B
C

87

87

87

87 Generator differential relay

V Voltmeter

Checking Stability of Generator

Differential Protection
Isolating
links

Generator

Temporary
short circuit
A
B
C

87

87

87

Shorts across relay/

stabilising resistors

87 Generator differential relay

A Ammeter

Earth Fault Sensitivity Check on

Transformer Differential Protection
Temporary
short circuit
A

Primary
injection
test set

250V
A.C.
supply

C
Bias coils

Operating
coils

87

87

87

Phase Fault Sensitivity Check on

Transformer Differential Protection

Temporary
short circuit
A
B

Primary
injection
test set

250V
A.C.
supply

C
Bias coils

Operating
coils

87

87

87

Stability Check on Transformer

Differential Protection
Temporary short circuit

Generator

~
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

Primary
injection
test set

A
B
C

64 Earth Fault Relay

A Ammeter
V Voltmeter

64

Stability Check of Restricted Earth

Fault Protection
250V A.C. supply
A

Temporary short circuit

Primary
injection
test set

A
B
C

64

64 Earth Fault Relay

A Ammeter

Sensitivity Check of Negative Phase

Sequence Relay
A B

Temporary
short circuit

Filter
network

46

Primary injection
test set

250V
A.C. supply

46 Negative phase sequence relay

A Ammeter

Test Plug Link Connections for

Load Current Test
To relay
filter network

20 19 18 17 16 15 14 13 12 11

10

Earth Fault Sensitivity Check of

Pilot Wire Relay

B
C
Primary
injection
test set

250V A.C. supply

B
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

C
B
OP

B Relay bias coil

OP Relay operating coil
A Ammeter

Primary
injection
test set

Pilots to remote
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
maximum

B
OP

OP

Pilots

Short-Circuiting Connections on Test

Plug for Load Test
Short circuiting connections
on rear of test plug

To relay summation CT

20 19 18 17 16 15 14 13 12 11

10

To main current
transformers

Ratio Check of Current Transformers

of Reference Circuit

A1

250V A.C.
supply
A2

Primary injection
test set

A1 and A2 Ammeters
87
Busbar Protection relay
95
Supervision relay
95X
Bus wires short-circuiting
relay

Test links

A
B
C
N

Zone
bus wires

95X
95

87

87

87

Polarity Check of Reference Circuit

Current Transformers
A
87

Ammeter
Busbar Protection
relay
95 Supervision relay
95X Bus wires shortcircuiting relay

A B C

Temporary short circuit

A

Test links

250V A.C.
supply
Primary injection
test set

A
B
C
N

Zone
bus wires

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
Primary injection
test set

250V A.C. supply

A1

A1

A1

A1

A
B
C
N

A1
A2

Ammeter for ratio check

Ammeter for polarity
check
87
Busbar protection relay
95
Supervision relay
95X Bus wires shortcircuiting relay

A2

95X
95

87

87

87

A2

A2

Zone
bus
wires

Sensitivity Check of Busbar

Protection Scheme
A

250V A.C.
supply
Primary injection
test set

Test links

A
B
C
N

Zone
bus wires

95X
V

95

87

87

87

Stability Test
A
B
C
Test
plug

Test
plug

Overcurrent
test set

250V
A.C. supply

B
OP

OP

Pilots