Mate - Final Report

TEST REPORTS ON
11KV PROTECTION RELAYS
Client :
Motherson Automative Technologies & Engineering
PRESENTED BY
TESTCOM ENGINEERS Chennai, INDIA Contacts : Mr.V.B.Aravindhan email : testcom.engineers@yahoo.com / gmail.com

Mob:+91 -9841131621
INDEX
SL.NO DESCRIPTION PAGE NO
1 2 3 4 5
Site Study Report Revised Relay Settings chart Relay Secondary Injection Report CT Primary Injection Report Fuse Tripping Test Report
SITE TEST REPORT

Client:
TESTCOM ENGINEERS
Project :
Mother Son Automotive Technologies & Engineering. Chittamanur Village, M.M Nagar Relay Co-Ordination Study
Page : Date : 03.03.2013
REPORT ON SITE STUDY

OBSERVATIONS ON 11KV PANEL PROTECTION SYSTEMS : 1. It was found that the relay mounted in Incomer & Tr-2 feeder does not have High Set protection. 2. Tr-2 feeder Tripping circuit found open. There is no Electrical Tripping function by Relays. It was found that Maximum Demand Tripping connections at TNC switch (external wiring) disturbed the tripping circuit. 3. It was understood that the recent tripping on 28/02/13 in TR-2 Feeder due to some faults in the load side the TR-2 VCB did not tripped due to failure of Trip Circuit. 4. More over the Incomer also did not tripped since the set value was more than 200A which is excess than the Fuse wire provided in the 8 pole structure. Due to this the Fuse blown before the relay operates CORRECTIONS DONE: 1. The relay in Tr-1 which has High Set feature replaced with the Incomer Panel Relay. Now the Incomer & FSP II feeder has High Set protection and Tr1 & 2 has only Over Current Protection. 2. Tr-2 Tripping circuit wiring rectified. MD controller Tripping wiring shifted from TNC switch to Emergency Push Button terminals. 3. Now the VCB tripping thru Protection relays checked by Primary injection Tests on CTs. 4. In the Incomer Feeder CT ratio adopted to Lower ratio (200/5A) to have better Relay Discrimination and to match the sanctioned Demand. 5. In the FSP II feeder also CT ratio adopted to Lower ratio (150/5A) to have better Relay Discrimination. 6. All four panels Trip test conducted by Primary Injection of CTs 7. All the Relays were tested by Secondary Injection method to prove the Operating time matches to the co-ordination chart. 8. 8 pole Structure Fuse were tested and found it was breaking at 200Amps, based on this 200Amps Relay settings were adopted to isolate the fault before the fuse fails.
Tested By : V.B.Aravindhan T&C ENGINEER
PRE-COMMISSIONING RELAY TESTING - H.V.ELECTRICALS SYSTEM STUDIES, HIPOT TEST, FAULT LEVEL CALCULATIONS, METER S TROUBLE SHOOTING ON TRANSFORMERS / MOTORS / SWITCHGEARS / TRANSMISSION LINES ETC. Contact Details : 28, S.S.Nagar, Karambakkam, Porur, Chennai 116. Tele fax : (091)-(044)-24762522, 98411 31621 E-mail-testcom.engineers@yahoo.com
Witnessed By :
Approved By :
SITE TEST REPORT

Client:
TESTCOM ENGINEERS
Project :
Mother Son Automotive Technologies & Engineering. Chittamanur Village, M.M Nagar Relay Co-Ordination Study
Page : Date : 03.03.2013
REVISED RELAY SETTINGS :
Protection
Relay Type CT Ratio Adop Over Current I> t> Charac.Curve I>> t>> Earth fault Ie> Te> Charac.Curve Ie>> Te>>
Incomer
C&S IRI-PRO-3I-EI 200/5A 1.00xIn (200A) 0.05(TMS) EI 2.00xIn(400A) 0.2(DEFT) 0.20xIn(40A) 0.2(DEFT) DEFT 0.50xIn(100A) 0.1(DEFT)
TR-1
C&S IRI-PRO-30-E0 120/5A C&S IRI-PRO-3I-EI 0.01(TMS) EI N.A N.A 0.15xIn(18A) 0.1(DEFT) DEFT N.A N.A
TR-2
C&S IRI-PRO-30-E0 120/5A 0.50xIn(60A) 0.01(TMS) EI N.A N.A 0.15xIn(18A) 0.1(DEFT) DEFT N.A N.A
FSPII (Outgoing)
C&S IRI-PRO-3I-EI 150/5A 0.50xIn(75A) 0.06(TMS) EI 1.00xIn(150A) 0.1(DEFT) 0.10xIn(15A) 0.15(DEFT) DEFT 0.50xIn(75A) 0.1(DEFT)
Plant 2
ER 2TJM10 200/5A 0.50xIn(100A) 0.2(TMS) NI N.A N.A 0.20xIn(40A) 0.2(TMS) NI N.A N.A
Tested By : V.B.Aravindhan T&C ENGINEER
Witnessed By :
Approved By :
SITE TEST REPORT

Client:
TESTCOM ENGINEERS
Project :
Mother Son Automotive Technologies & Engineering Chittamanur Village, M.M Nagar Relay Co-Ordination Study
Page : Date : 03.03.2013
TEST REPORT FOR OVER CURRENT & EARTH FAULT RELAY

LOCATION PANEL NAME FEEDER NAME : 11KV SWITCH BOARD (OUTDOOR VCB) : 4 PANEL VCB 11 KV HT PANEL : INCOMER
1. NAME PLATE DATAS Manufacturer : C&S Electric Model : IRI PRO-V2-3I-EI-5-5 Sl.No : 2011124743 CT Ratio : 200/5A Vx : 24-270V DC / AC 2. RELAY SETTINGS ADOPTED: OVER CURRENT ELEMENT Over Load Setting I> : 1.0xIn (100%) Time Lever Setting (TMS): 0.05 (EI Curve) EARTH FAULT ELEMENT Over Load Setting Ie> : 0.2xIn (20%) Time Lever Setting (TMS): 0.2 (DMT)
Short Circuit Setting I>> Time Setting TI>> Short Circuit Setting Ie>> Time Setting TI>>
: 2.0xIn (200%) : 0.2Secs : 0.5xIn (50%) : 0.1Secs
3. PHASE OVER CURRENT PROTECTION ELEMENT: (E.I) SET CURRENT IN AMP 1.00*In 1.00*In 1.00*In OPERATING TIME IN SEC 2*Is 5*Is As per As per OPER. OPER. CURVE CURVE TIME TIME TIME TIME 1.342 0.179 1.337 1.33 0.180 0.17 1.340 0.182
PHASE
TMS
RELAY P/U 5.12A 5.13A 5.17A
I>
R Y B
0.05 0.05 0.05
4. PHASE OVER CURRENT PROTECTION ELEMENT: (DMT) SET CURRENT IN AMP 2.00*In 2.00*In 2.00*In TIME SETTING 0.2 0.2 0.2 OPERATING TIME IN SEC 0.217 0.215 0.216
PHASE R Y B
RELAY P/U 10.14A 10.11A 10.16A
I>>
Tested By : V.SOMASUNDARAM T&C ENGINEER
Witnessed By :
Approved By :
SITE TEST REPORT

Client:
TESTCOM ENGINEERS
Project :
Page : Date : 03.03.2013
5. Ie > EARTH FAULT PROTECTION: (DMT) SET CURRENT IN AMP 0.20*In 0.20*In 0.20*In TIME SETTING 0.20 0.20 0.20 OPERATING TIME IN SEC 0.202 0.210 0.212
PHASE R Y B
RELAY P/U 1.04A 1.09A 1.10A
Ie>
6. Ie >> EARTH FAULT PROTECTION: (DMT) SET CURRENT IN AMP 0.50*In 0.50*In 0.50*In TIME SETTING 0.10 0.10 0.10 OPERATING TIME IN SEC 0.114 0.101 0.112
PHASE R Y B
RELAY P/U 2.52A 2.53A 2.52A
Ie>>
REMARKS: TEST RESULTS ARE QUITE SATISFACTORY
Witnessed By :
Approved By :
SITE TEST REPORT

Client:
TESTCOM ENGINEERS
Project :
Page : Date : 03.03.2013

LOCATION PANEL NAME FEEDER NAME : 11KV SWITCH BOARD (OUTDOOR VCB) : 4 PANEL VCB 11 KV HT PANEL : OUTGOING -01(FISP-2)
1. NAME PLATE DATAS Manufacturer : C&S Electric Model : IRI PRO-V2-3I-EI-5-5 Sl.No : 2012020204 CT Ratio : 150/5A Vx : 24-270V DC / AC 2. RELAY SETTINGS ADOPTED: OVER CURRENT ELEMENT Over Load Setting I> : 0.50xIn (50%) Time Lever Setting (TMS): 0.06 (EI Curve) EARTH FAULT ELEMENT Over Load Setting Ie> : 0.10xIn (10%) Time Lever Setting (TMS): 0.15 (DMT)
: 1.0xIn (100%) : 0.15Secs : 0.5xIn (50%) : 0.1Secs
PHASE
TMS
RELAY P/U 2.54A 2.52A 2.53A
I>
R Y B
0.06 0.06 0.06
4. PHASE OVER CURRENT PROTECTION ELEMENT: (DMT) SET CURRENT IN AMP 1.0*In 1.0*In 1.0*In TIME SETTING 0.1 0.1 0.1 OPERATING TIME IN SEC 0.110 0.115 0.112
PHASE R Y B
RELAY P/U 5.14A 5.11A 5.16A
I>>
Witnessed By :
Approved By :
SITE TEST REPORT

Client:
TESTCOM ENGINEERS
Project :
Page : Date : 03.03.2013
PHASE R Y B
RELAY P/U 0.51A 0.49A 0.50A
Ie>
6. Ie >> EARTH FAULT PROTECTION: (DMT) SET CURRENT IN AMP 0.50 0.50 0.50 TIME SETTING 0.10 0.10 0.10 OPERATING TIME IN SEC 0.113 0.121 0.109
PHASE R Y B
RELAY P/U 2.50A 2.54A 2.52A
Ie>>
REMARKS: TEST RESULTS ARE QUITE SATISFACTORY.
Witnessed By :
Approved By :
SITE TEST REPORT

Client:
TESTCOM ENGINEERS
Project :
Page : Date : 03.03.2013

LOCATION PANEL NAME FEEDER NAME : 11KV SWITCH BOARD (OUTDOOR VCB) : 4 PANEL VCB 11 KV HT PANEL : OUTGOING -02 (TRANSFORMER-02)
1. NAME PLATE DATAS Manufacturer : C&S Electric Model : IRI PRO-V2-30-E0-5-5 Sl.No : 2011124731 CT Ratio : 120/5A Vx : 24-270V DC / AC 2. RELAY SETTINGS ADOPTED: OVER CURRENT ELEMENT Over Load Setting I> : 0.50xIn (50%) Time Lever Setting (TMS): 0.01 (EI Curve) EARTH FAULT ELEMENT Over Load Setting Ie> : 0.15xIn (15%) Time Lever Setting (TMS): 0.10 (DMT)
: N/A : -: N/A : --
PHASE
TMS
RELAY P/U 2.52A 2.57A 2.56A
I>
R Y B
0.01 0.01 0.01
PHASE R Y B
RELAY P/U 0.75A 0.77A 0.76A
Ie>
Witnessed By :
Approved By :
SITE TEST REPORT

Client:
TESTCOM ENGINEERS
Project :
Page : Date : 03.03.2013

LOCATION PANEL NAME FEEDER NAME : 11KV SWITCH BOARD (OUTDOOR VCB) : 4 PANEL VCB 11 KV HT PANEL : OUTGOING -03 (TRANSFORMER-01)
1. NAME PLATE DATAS Manufacturer : C&S Electric Model : IRI PRO-V2-30-E0-5-5 Sl.No : 2012020230 CT Ratio : 120/5A Vx : 24-270V DC / AC 2. RELAY SETTINGS ADOPTED: OVER CURRENT ELEMENT Over Load Setting I> : 0.50xIn (50%) Time Lever Setting (TMS): 0.01 (EI Curve) EARTH FAULT ELEMENT Over Load Setting Ie> : 0.15xIn (15%) Time Lever Setting (TMS): 0.10 (DMT)
: N/A : -: N/A : --
PHASE
TMS
RELAY P/U 2.56A 2.59A 2.53A
I>
R Y B
0.01 0.01 0.01
PHASE R Y B
RELAY P/U 0.76A 0.75A 0.76A
Ie>
Witnessed By :
Approved By :
SITE TEST REPORT

Client:
TESTCOM ENGINEERS
Project :
Mother Son Automotive Technologies & Engineering Chittamanur Village, M.M Nagar Relay Co-Ordination Study TEST REPORT FOR CURRENT TRANSFORMER
Page : Date : 03.03.2013
LOCATION : 11KV SWITCH BOARD (OUTDOOR VCB) PANEL NAME : 4 PANEL VCB 11 KV HT PANEL FEEDER NAME : INCOMER 1. CT PRIMARY INJECTION TEST: CT RATIO: 400-200/5-5A CORE-2 :( PROTECTION, CT RATIO SELECTED: 200/5A) APPLIED PRI CURRENT (%) CORE-2 25% 50% 75% 100% MEASURED SEC. CURRENT(A) Y-PHASE 2S1-2S2 2S1-2S3 1.25 1.24 2.50 2.49 3.75 3.74 5.00 4.99
R-PHASE 2S1-2S2 2S1-2S3 1.25 1.25 2.50 2.49 3.75 3.74 5.00 5.00
B-PHASE 2S1-2S2 2S1-2S3 1.25 1.24 2.49 2.50 3.75 3.74 5.00 4.99
CORE-1 :( METERING, CT RATIO SELECTED: 400/5A) APPLIED PRI CURRENT (%) CORE-1 25% 50% 75% 100% MEASURED SEC. CURRENT(A) Y-PHASE 1S1-1S2 1S1-1S3 1.25 1.24 2.50 2.49 3.75 3.74 4.99 4.99
R-PHASE 1S1-1S2 1S1-1S3 1.25 1.25 2.50 2.50 3.75 3.74 5.00 5.00
B-PHASE 1S1-1S2 1S1-1S3 1.25 1.24 2.49 2.49 3.74 3.74 4.99 4.99
3. Group Test: (CT RATIO SELECTED: 200/5A) Loop Between RY YB BR Y Alone E\F Primary Current 50.00A 50.00A 50.00A 50.00A Secondary Current in Amps R-Phase 1.25A --1.25A --Y-Phase 1.25A 1.25A --1.25A B-Phase --1.25A 1.25A --Breaker Tripping OK OK OK OK
REMARKS: THE TEST RESULTS ARE QUITE SATISFACTORY.
Witnessed By :
Approved By :
SITE TEST REPORT

Client:
TESTCOM ENGINEERS
Project :
Page : Date : 03.03.2013
LOCATION : 11KV SWITCH BOARD (OUTDOOR VCB) PANEL NAME : 4 PANEL VCB 11 KV HT PANEL FEEDER NAME : OUTGOING-1(FISP-2) 1. CT PRIMARY INJECTION TEST: CT RATIO: 300-150/5-5A CORE-2 :( PROTECTION, CT RATIO SELECTED: 150/5A) APPLIED PRI CURRENT (%) CORE-2 25% 50% 75% 100% MEASURED SEC. CURRENT(A) Y-PHASE 2S1-2S2 2S1-2S3 1.25 1.25 2.50 2.49 3.75 3.75 5.00 5.00
R-PHASE 2S1-2S2 2S1-2S3 1.25 1.25 2.50 2.50 3.75 3.75 5.00 5.00
B-PHASE 2S1-2S2 2S1-2S3 1.25 1.25 2.49 2.50 3.75 3.75 5.00 5.00
CORE-1 :( METERING, CT RATIO SELECTED: 300/5A) APPLIED PRI CURRENT (%) CORE-1 25% 50% 75% 100% MEASURED SEC. CURRENT(A) Y-PHASE 1S1-1S2 1S1-1S3 1.25 1.25 2.50 2.50 3.75 3.75 5.00 5.00
R-PHASE 1S1-1S2 1S1-1S3 1.25 1.25 2.50 2.50 3.75 3.74 5.00 5.00
B-PHASE 1S1-1S2 1S1-1S3 1.25 1.24 2.49 2.49 3.74 3.74 4.99 4.99
Witnessed By :
Approved By :
SITE TEST REPORT

Client:
TESTCOM ENGINEERS
Project :
Page : Date : 03.03.2013
LOCATION : 11KV SWITCH BOARD (OUTDOOR VCB) PANEL NAME : 4 PANEL VCB 11 KV HT PANEL FEEDER NAME : OUTGOING-2(TRANSFORMER-2) 1. CT PRIMARY INJECTION TEST: CT RATIO: 120/5-5A CORE-2 :( PROTECTION) APPLIED PRI CURRENT (%) CORE-2 25% 50% 75% 100% MEASURED SEC. CURRENT(A) R-PHASE Y-PHASE B-PHASE 2S1-2S2 2S1-2S2 2S1-2S2 1.25 1.25 1.25 2.50 2.50 2.49 3.75 3.75 3.75 5.00 5.00 5.00
CORE-1 :( METERING) APPLIED PRI CURRENT (%) CORE-1 25% 50% 75% 100% MEASURED SEC. CURRENT(A) R-PHASE Y-PHASE B-PHASE 1S1-1S2 1S1-1S2 1S1-1S2 1.25 1.25 1.25 2.50 2.50 2.49 3.75 3.75 3.75 5.00 5.00 5.00
Witnessed By :
Approved By :
SITE TEST REPORT

Client:
TESTCOM ENGINEERS
Project :
Page : Date : 03.03.2013
LOCATION : 11KV SWITCH BOARD (OUTDOOR VCB) PANEL NAME : 4 PANEL VCB 11 KV HT PANEL FEEDER NAME : OUTGOING-3(TRANSFORMER-1) 1. CT PRIMARY INJECTION TEST: CT RATIO: 120/5-5A CORE-2 :( PROTECTION) APPLIED PRI CURRENT (%) CORE-2 25% 50% 75% 100% MEASURED SEC. CURRENT(A) R-PHASE Y-PHASE B-PHASE 2S1-2S2 2S1-2S2 2S1-2S2 1.24 1.24 1.25 2.50 2.49 2.49 3.74 3.74 3.75 5.00 5.00 4.99
CORE-1 :( METERING) APPLIED PRI CURRENT (%) CORE-1 25% 50% 75% 100% MEASURED SEC. CURRENT(A) R-PHASE Y-PHASE B-PHASE 1S1-1S2 1S1-1S2 1S1-1S2 1.25 1.25 1.25 2.50 2.49 2.49 3.74 3.75 3.75 5.00 5.00 4.99
Witnessed By :
Approved By :
SITE TEST REPORT

Client:
TESTCOM ENGINEERS
Project :
Mother Son Automotive Technologies & Engineering Chittamanur Village, M.M Nagar Relay Co-Ordination Study TEST REPORT FOR HT FUSE
Page : Date : 03.03.2013
LOCATION
: 11KV 8 POLE STRUCTURE
1. FUSE TRIPPING CHECKS Fuse Size : Not known Fuse rating : Not known APPLIED CURRENT 160A 170A 180A 190A 200A OPERATING TIME No Tripping up to 10Mins No Tripping up to 10Mins No Tripping up to 10Mins No Tripping up to 10Mins Trips instantaneously
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TEST REPORTS ON

11KV PROTECTION RELAYS

Motherson Automative Technologies & Engineering

TESTCOM ENGINEERS Chennai, INDIA Contacts : Mr.V.B.Aravindhan email : testcom.engineers@yahoo.com / gmail.com

SITE TEST REPORT

Page : Date : 03.03.2013

REPORT ON SITE STUDY

SITE TEST REPORT

Page : Date : 03.03.2013

REVISED RELAY SETTINGS :

Tested By : V.B.Aravindhan T&C ENGINEER

SITE TEST REPORT

Page : Date : 03.03.2013

TEST REPORT FOR OVER CURRENT & EARTH FAULT RELAY

: 2.0xIn (200%) : 0.2Secs : 0.5xIn (50%) : 0.1Secs

RELAY P/U 5.12A 5.13A 5.17A

0.05 0.05 0.05

RELAY P/U 10.14A 10.11A 10.16A

Tested By : V.SOMASUNDARAM T&C ENGINEER

SITE TEST REPORT

Page : Date : 03.03.2013

RELAY P/U 1.04A 1.09A 1.10A

RELAY P/U 2.52A 2.53A 2.52A

REMARKS: TEST RESULTS ARE QUITE SATISFACTORY

Tested By : V.SOMASUNDARAM T&C ENGINEER

SITE TEST REPORT

Page : Date : 03.03.2013

TEST REPORT FOR OVER CURRENT & EARTH FAULT RELAY

: 1.0xIn (100%) : 0.15Secs : 0.5xIn (50%) : 0.1Secs

RELAY P/U 2.54A 2.52A 2.53A

0.06 0.06 0.06

RELAY P/U 5.14A 5.11A 5.16A

Tested By : V.SOMASUNDARAM T&C ENGINEER

SITE TEST REPORT

Page : Date : 03.03.2013

RELAY P/U 0.51A 0.49A 0.50A

RELAY P/U 2.50A 2.54A 2.52A

REMARKS: TEST RESULTS ARE QUITE SATISFACTORY.

Tested By : V.SOMASUNDARAM T&C ENGINEER

SITE TEST REPORT

Page : Date : 03.03.2013

TEST REPORT FOR OVER CURRENT & EARTH FAULT RELAY

RELAY P/U 2.52A 2.57A 2.56A

0.01 0.01 0.01

RELAY P/U 0.75A 0.77A 0.76A

REMARKS: TEST RESULTS ARE QUITE SATISFACTORY.

Tested By : V.SOMASUNDARAM T&C ENGINEER

SITE TEST REPORT

Page : Date : 03.03.2013

TEST REPORT FOR OVER CURRENT & EARTH FAULT RELAY

RELAY P/U 2.56A 2.59A 2.53A

0.01 0.01 0.01

RELAY P/U 0.76A 0.75A 0.76A

REMARKS: TEST RESULTS ARE QUITE SATISFACTORY.

Tested By : V.SOMASUNDARAM T&C ENGINEER

SITE TEST REPORT

Page : Date : 03.03.2013

REMARKS: THE TEST RESULTS ARE QUITE SATISFACTORY.

Tested By : V.SOMASUNDARAM T&C ENGINEER

SITE TEST REPORT

Page : Date : 03.03.2013

REMARKS: THE TEST RESULTS ARE QUITE SATISFACTORY.

Tested By : V.SOMASUNDARAM T&C ENGINEER

SITE TEST REPORT