PROJECT NUMBER PSU330B by date

WORK PACKAGE ELEC Prepared A Cahyono 30/03/2016

ELEMENT CAL Checked H De Wet 30/03/2016
REVISION A Comments
FILE NAME Revised

CLIENT NAME RIO TINTO IRON ORE

PROJECT DESCRIPTION Cape Lambert Power Station
CALCULATION DESCRIPTION 220kV & 11kV Differential Protection CT Sizing Calculations

Scope

This document calculates and specifies the protection current transformer (CT) requirements for the new 220/11kV Generator
Step Up Transformer (GSUT) at Cape Lambert Power Station. `

Purpose

1. To identify suitable CT ratios

2. To determine the knee point voltage requirement for high speed transformer protection schemes

Reference Documents

1. Olex Low Voltage Cable Catalogue

2. AS 60044.1-2003 Part 1 : Current Transformers
3. 220kV Cape Lambert Substation Single Line Diagram : CL-5510-VE-02229
4. Cape Lambert Power Station HV Protection Key Diagram : CL-5510-VE-02330
5. Cape Lambert Power Station Site Plant Layout : CL-5510-VM-00591
6. ABB RET670 Application Manual : Doc ID 1MRK 504 116-UEN B, Section 2.1.5.
7. ABB REG670 Application Manual : Doc ID 1MRK 502 030-UEN A, Section 2.1.6.

Method of Calculation

1. CT numbers and locations are based on the attached cape Lambert Power Station HV Protection Key Diagram
2. Distance between the CTs and the protective relays required for the lead resistance calculations
are assumed based on the proposed general power plant arrangement layout drawing.
3. System fault levels are as per the DigSilent Simulation - Maximum Cases, Design Creteria and through fault currents.
4. The exact CT requirements shall be derived by protection relay manufacturers. Base on the RET670 or REG670 Application Manual,
whichever is more stringent. For accurate relay operations, the following formulas shall be used and both shall be met;

Eal ≥ Ealreq = 30.Int. (Isn/Ipn).(RCT+RL+Sr/I2r) Equation (1)

and
Eal ≥ Ealreq = 2.Itf. (Isn/Ipn).(RCT+RL+Sr/I2r) Equation (2)

where,
Eal = CT secondary knee point voltage (V)
Ealreq = Minimum required stability voltage (V)
Int = Rated primary current of the power transformer (A)
Itf = Maximum primary through fault current from which stability is required (A)
Isn = Secondary CT current (A)
Ipn = Primary CT Current (A)
RCT = CT secondary winding resistance
RL = Total lead resistance between the CT and the protection relay
Sr = Total relay burden, Sr=0.020 VA/channel for Ir=1A.
Ir = Rated Current of the protection relay

Calculations

1. CT Class Selection
Under internal short circuit conditions the differential CT shall faithfully transform the primary currents
and remain stable during external faults. Due to heavy fault currents at the 220kV side of the transformer
and large contribution from the power generations, therefore the transformer differential schemes demand superior
performance from the CTs, without exception PX class CTs are used.

2. 220kV CT Ratio Selection

Two requirements when selecting CT ratios for transformer differential protection. First, HV CT ratio shall be the next
preferred value above the maximum continuous current rating of the transformer. Second, the LV ratio should be selected
to meet the protection relay's CT mismatch range.

CLPS - Protection CT Sizing Calculations Rev A.xlsx

printed: 31/03/2016 page 1 of 5
PROJECT NUMBER PSU330B by date
WORK PACKAGE ELEC Prepared A Cahyono 30/03/2016
ELEMENT CAL Checked H De Wet 30/03/2016
REVISION A Comments
FILE NAME Revised

CLIENT NAME RIO TINTO IRON ORE

PROJECT DESCRIPTION Cape Lambert Power Station
CALCULATION DESCRIPTION 220kV & 11kV Differential Protection CT Sizing Calculations

Full load current of the 60MVA transformer can be calculated as follows;

Ifull load tx = 60MVA / (√3*220kV)
= 157.5 Amp @ 220 kV
= 3149.2 Amp @ 11 kV

In order to cope heavy fault currents at the 220kV side of the transformer strengthen and bigger CT is required.
AS 2374.7 - Table 1 states that for Medium Power Transformers, it can be loaded up to 1.5 times of the nominal
rated current under Long-Time Emergency Cyclic Loading (LTER) , therefore HV CT primary rating will selected base
on this consideration.
ILTER Tx = 1.5*Ifull load tx
= 236.2 Amp @ 220 kV

The next preferred primary CT rating is 250A. Thus, a CT ratio of 250/1 shall be used for the HV Transformer Differential.
The following CT ratio shall be used in the HV transformer protection scheme:
Primary (A) Secondary (A)
HV Winding (220kV) = 250 1

3. 11kV CT Ratio Selection

LV CT ration shall be stable under through fault currents and capable to carry the maximum continous current of the generator or
power transformer whichever is the greater. The generator is rated to 65.25MVA at 15° C and this is considered as
the maximum continuous current to flow the CTs.
Ifull load Gen = 65.25MVA / (√3*11kV)
= 3424.7 Amp @ 11 kV

The available ratio on the 11kV CTs is 4000/1 or about 118% of the generator total capacity or 127% of the transformer rating.
Hence, this meets the continuous rating requirements.

The CT mismatch ratio is defined as:

CT mismatch (HV-LV) = (CTHV*TXHV)/(CTLV*TXLV)
= (250*220kV)/(4000*11kV)
= 1.25

ABB RET670 could cater for a CT mismatch ratio of 3, hence this a LV CT ratio of 4000/1 meets the protection relay
requirements.

The following CT ratio shall be used in the LV transformer protection schemes:

Primary (A) Secondary (A)
LV Winding (11kV) = 4000 1

5. CT Knee Point Voltage Requirement

5.1 220kV CT Knee Point Voltage and CT Secondary Resistance Requirements

The current transformers requirements are based on the maximum fault current for fault in the different locations. For 220kV
CTs the maximum fault current will be at the 220kV busbar. Power system modelling DigSilent using 2019 Model shows
the maximum short circuit current at the 220kV bus of the Cape Lambert Substation was 5.03 kA and 6.05 kA for 3-phase
and 1-phase fault respectively.

Through fault current assuming, the transformer impedance is 16.48% @ 60MVA and transformer is connected to an
infinite bus;
Itx through fault 3p (220kV) = TX MVA /(sqrt3*220kV*ZTx)
= 960.1 Amp @ 220 kV

Itx through fault 3p (11kV) = TX MVA /(sqrt3*11kV*ZTx)

= 19202.3 Amp @ 11kV

The 220kV substation is designed for 16kA/1 s.

Considering ultimate configuration the short circuit based on the design criteria will be used to assess the adequately of the CTs.

CLPS - Protection CT Sizing Calculations Rev A.xlsx

printed: 31/03/2016 page 2 of 5
PROJECT NUMBER PSU330B by date
WORK PACKAGE ELEC Prepared A Cahyono 30/03/2016
ELEMENT CAL Checked H De Wet 30/03/2016
REVISION A Comments
FILE NAME Revised

CLIENT NAME RIO TINTO IRON ORE

PROJECT DESCRIPTION Cape Lambert Power Station
CALCULATION DESCRIPTION 220kV & 11kV Differential Protection CT Sizing Calculations

The knee point calculations start from determining the length of the secondary wire from the CTs to the relays, identify
cable size and relay burden. A 6.0 mm2 cable is believed to be used for this application which meets the knee point voltage
requirements.

Estimated Cable Length (L) 217 meters

Cable Size 6 mm2
Lead Resistance ( R ) 0.00308 ohm/meter As per Olex-Product Handbook 2013-2014 Page 91
Rleads = (2 x L x R) 1.33672 ohms
Rrelay = (Sr/I2r) 0.02 ohm
Ifault (220kV Design Criteria) 16 kA Max S/C based on 2019 DigSilent Model was 6.05kA
RCT 1.5 ohms Assumed 0.006ohm/turn
X/R Ratio 9.173 Base on DigSilent 2019 Model
CTR = (Isn/Ipn) 250

The performance of the CTs will now be compared with the relay requirements. According to the ABB RET670
relay manual the CT requirements for correct operation and restraint are to be calculated based on Equations 1&2 .

Eal ≥ Ealreq = 30.Ifull load tx. (Isn/Ipn).(RCT+RL+Sr/I2r) Equation (1)

Eal ≥ Ealreq = 54.0 Volt

and

Eal ≥ Ealreq = 2.Itf. (Isn/Ipn).(RCT+RL+Sr/I2r) Equation (2)

Eal ≥ Ealreq = 365.7 Volt

Using 220kV system design criteria of 16kA, the minimum knee point requirement of 366 Volts shall be achieved.
The specified CTs will not saturate during internal faults and be stable for through faults.

Therefore, the proposed 220kV neutral CT of 250/1, 0.15PX400R1.5 is accepable and satisfies the protection relay requirements.

5.2 HV Neutral CT Knee Point Voltage and CT Secondary Resistance Requirements

Neutral CT must be stable and free of saturation during internal faults. For an internal fault simetrical component is drawn to show the
zero sequence impedances of the transformer (Z0tx) and 220kV network (Z0sys). The measured GSUT zero impedance was 15.59%
Z0tx = 0.1559 whilst Z0sys is 0 ohm (i.e. infinite bus).

Itx through fault 1ph (220kV) =3*TX MVA /(sqrt3*220kV*(2*ZTx+Z0tx))

= 973.0 Amp @ 220 kV

CLPS - Protection CT Sizing Calculations Rev A.xlsx

printed: 31/03/2016 page 3 of 5
PROJECT NUMBER PSU330B by date
WORK PACKAGE ELEC Prepared A Cahyono 30/03/2016
ELEMENT CAL Checked H De Wet 30/03/2016
REVISION A Comments
FILE NAME Revised

CLIENT NAME RIO TINTO IRON ORE

PROJECT DESCRIPTION Cape Lambert Power Station
CALCULATION DESCRIPTION 220kV & 11kV Differential Protection CT Sizing Calculations

Estimated Cable Length (L) 217 meters

Cable Size 6 mm2
Lead Resistance ( R ) 0.00308 ohm/meter As per Olex-Product Handbook Page 88
Rleads = (2 x L x R) 1.33672 ohms
Rrelay = (Sr/I2r) 0.02 ohm
Ifault 1.0 kA
RCT 4 ohms Assumed 0.016ohm/turn
CTR = (Isn/Ipn) 250

The performance of the CTs will now be compared with the relay requirements. According to the ABB RET670
relay manual the CT requirements for correct operation and restraint are to be calculated based on Equations 1&2 .

Eal ≥ Ealreq = 30.Ifull load tx. (Isn/Ipn).(RCT+RL+Sr/I2r) Equation (1)

Eal ≥ Ealreq = 101.2 Volt

and

Eal ≥ Ealreq = 2.Itf. (Isn/Ipn).(RCT+RL+Sr/I2r) Equation (2)

Eal ≥ Ealreq = 22.2 Volt

At maximum short circuit ground fault current of 1031A at 220kV the minimum knee point required by ABB670 relay is 104.5 Volts.

Therefore, the proposed 220kV neutral CT of 250/1, 0.15PX400R4 is accepable and satisfies the protection relay requirements.

5.3 LV CT Knee Point Voltage Requirement

Knee point requirements for LV protection CTs will be designed base on the through fault currents from both transformer
and generator in case of a fault takes place at the HV side of the Unit Auxiliary Transformer (UAT).

Generator through fault current is calculated based the generator capacity 65.25MVA and the sub-transient
reactance X"d = 13.9% at 65.25MVA.
Ifull load gen = Gen MVA /(sqrt3*11kV)
3424.7

Igen through fault (11kV) = Gen MVA /(sqrt3*11kV*X"d)

= 24638.4 Amp @ 11kV

Transformer contribution;
Igen through fault (11kV) = 19202.3 Amp @ 11kV

Estimated Cable Length (L) 100 meters

Cable Size 4 mm2
Lead Resistance ( R ) 0.0046 ohm/meter As per Olex-Product Handbook Page 88
Rleads = (2 x L x R) 0.92 ohms
Rrelay = (Sr/I2r) 0.02 ohm
Ifault (Tx&Gen through fault currents) 43840.7 Amp @ 11kV
RCT 15.72 ohms Measured value
CTR = (Isn/Ipn) 4000

The performance of the CTs will now be compared with the relay requirements. According to the ABB RET670 technical
application manual the CT requirements for correct operation and restraint are to be calculated based on Equations 1&2 .

Eal ≥ Ealreq = 30.Ifull load gen. (Isn/Ipn).(RCT+RL+Sr/I2r) Equation (1)

Eal ≥ Ealreq = 427.9 Volt
and
Eal ≥ Ealreq = 2.Itf. (Isn/Ipn).(RCT+RL+Sr/I2r) Equation (2)
Eal ≥ Ealreq = 365.2 Volt

CLPS - Protection CT Sizing Calculations Rev A.xlsx

printed: 31/03/2016 page 4 of 5
PROJECT NUMBER PSU330B by date
WORK PACKAGE ELEC Prepared A Cahyono 30/03/2016
ELEMENT CAL Checked H De Wet 30/03/2016
REVISION A Comments
FILE NAME Revised

CLIENT NAME RIO TINTO IRON ORE

PROJECT DESCRIPTION Cape Lambert Power Station
CALCULATION DESCRIPTION 220kV & 11kV Differential Protection CT Sizing Calculations

The minimum knee point to fulfil the protection relay requirement is 394 Volts.

The knee point of 2000V would easily meet the knee point requirements under through fault current and ensure free saturation
of 60ms when examining highset requirements until the protection relay detects and assigns a trip command.

Therefore, the proposed CT 4000/1, 0.05PX2000R20 is accepable and satisfies the protection relay requirements.

6. Conclusions

Transformer protection CTs specified in the HV Protection Key Diagram SLD,CL-5510-VE-02330 are acceptable
and meet the protection requirements for the present and future developments.

220kV Substation
Core No Ratio Specification Purpose Location
Transf. Diff
1 1000/500/250/1 0.15PX400R1.5 220kV Yard
Prot 1
Transf. Diff
2 1000/500/250/1 0.15PX400R1.5 220kV Yard
Prot 2

220kV Generator Step Up Transformer

Core No Ratio Specification Purpose Location
HV REF
1 250/1 0.15PX400R4.0 HV Neutral Bushing
Prot 1
HV REF
2 250/1 0.15PX400R4.0 HV Neutral Bushing
Prot 2

11kV Generator Switchgear (PCM MV)

Core No Ratio Specification Purpose Location
Transf. Diff
1 4000/1 0.05PX2000R20 11kV GCB - 52G
Prot 1
Transf. Diff
2 4000/1 0.05PX2000R20 11kV GCB - 52G
Prot 2
Transf. Diff
1 4000/1 0.05PX2000R20 11kV UAT CB - 52F
Prot 1
Transf. Diff
2 4000/1 0.05PX2000R20 11kV UAT CB - 52F
Prot 2

CLPS - Protection CT Sizing Calculations Rev A.xlsx

printed: 31/03/2016 page 5 of 5