Escolar Documentos
Profissional Documentos
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BPCL Kochi Refinery earlier known as Cochin Refineries Limited was incorporated
as a Public Limited Company in September 1963, with technical collaboration &
financial participation from Philips Petroleum Company of USA.
The capacity was first expanded from 2.5 MMTPA to 3.3 MMTPA in September
1973.The production of LPG and Aviation Turbine fuel (ATF) commenced after this
expansion. Bombay High Crude was first processed in 1977.Crude processing capacity
of Kochi Refinery was further increased from 3.3 MMTPA by revamping the crude
unit in the year 1984.
A substantial portion of the atmospheric residue, which varies 30% to 45% of the crude
throughput, depending on the crude, was converted to furnace oil by vibrating or
yielded as Low Sulphur Heavy Stock Oil (LSHS) in the initial setup. The original
scheme was conceived at a time when the price of crude oil was only $1 per barrel
which has now gone up to about $18 per barrel. With the steep rise in the price of crude
oil and petroleum products in the part few years & the country’s policy of conservation
of non-renewable resources out which petroleum resources form the single largest
fraction, it became necessary to review the utilization of atmospheric residue more
economically. Further increased processing of Bombay High Crude generates
substantial quantity of LSHS with subsequent disposal problems. The consumption
pattern of petroleum products in India is such that there is a deficit of middle distillates
and LPG.
proposed secondary processing facility was to utilize the Vacuum Gas Oil (VGO)
derived from a mixture of 3.5 MMTPA of Bombay High and 1.0 MMTPA of Basrah
crude with flexibility to process 100% Bombay High or 100% Middle East Crude at a
total crude throughput of 4.5 million tonnes per annum.
With the above considerations, Fluid Catalytic Cracking Process was selected for KRL.
FCC technology is process one and a number of units are in operation in the country.
LPG yield from FCC from FCC unit is quite high and operation can be adjusted for
lower seventy to give increased yields of middle distillates and lower yields of
gasoline. With this in mind, an FCC unit with a capacity for processing 1.0 MMTPA of
Vacuum Gas Oil was set up along with the revamp in 1985.
The crude capacity was further revamped to 7.5MMTPA (3.5 MMTPA BH and
4.0MMTPA PG), in the year 1994, with the addition of a new crude unit and
consequently the FCC capacity was further increased to 1.4MMTPA in order to
process the increased quantity of VGO generated. The revamped FCC unit is designed
to process VGO derived from 100% BH crude oil or 32% BH and 68% PG crude oil.
During the year 1989 , the company commissioned an Aromatic Recovery Unit with a
design capacity of 87200 Tonnes Per annum(TPA) of Benzene and 12000 TPA of
Toluene, marking Kochi Refinery’s entry into petrochemicals. A captive Power Plant
of 26.3 MW ISO rating was commissioned in March 1991 in order to meet power
requirements of Kochi Refinery.
A light Ends Field Preparation Unit (LEFPU) to supply feedstock to (poly iso butane)
PIBU was commissioned in March 1993. PIBU plant was commissioned in 1994 as a
joint venture company between KRL and Ballmer Lawri. On 19/4/2001, this company
was taken over by KRL.
The PIB plant was designed to produce poly iso butane grades of PIB24, PIB32, and
PIB28 using chevron processing technology. PIB is a feedstock for manufacturing oil
additives, adhesives, coatings and films. Feedstocks, oefin& Butane are supplied by
LEFPU-1&2 in FCCU unit.
During the year2000, the company commissioned diesel hydro desulphurization unit
(DHDS) OF 2.0 MMTPA capacities along with Hydrogen generation unit, Amine
Regeneration Unit to meet the specification of High Speed Diesel (HSD) recommended
by Ministry of Environment and Forest to make it more eco friendly.
2. PLANT OVERVIEW
There are five sections under the manufacturing department , four out of which
corresponds to four process unit block. They are
1. Crude Distillation Unit I ( CDU I)
2. Crude Distillation Unit II (CDU II)
3. Fluidized Catalystic Cracking unit (FCCU)
4. Diesel Hydro De- sulphurisation.
The crude after desalting process is heated to a required temperature in the heater
and is fed to the prefractioner. The over head product obtained here is Naphtha. The
over head product (light naphtha) is fed to LPG recovery unit in Naphtha stabiliser,
light naphtha from the crude prefractioner contains lighter components such as LPG
and fuel gas. This naphtha as such cannot be routed to store due to its high vapour
pressure. The naphtha is stabilized by separating out and recovering the LPG
component in the LPG recovery unit.
The pre-treated crude from the prefractionator column bottom is sent to crude
column after being heated in the crude preheat train in the crude charge heater for
further distillation process. The distilled products are drawn from the different sections
of the columns depending upon their boiling range. Heavy naphtha, kero-1.kero-2 and
diesel are side products. The remaining portion of crude is drawn from the column
bottom and reduced crude oil (RCO) are routed to FCCU block for further separation.
Crude from storage is pumped through a feed preheat train and preheated to 135
degree Celsius. Stripped water from sour water stripes unit is injected into the crude
and the mixed crude is sent to a desalter for removing salts. A high voltage electric
field in the desalter breaks the emulsion and the brine water is separated.
The desalted crude is pumped through another preheat exchanger and then split
into two streams for further preheating in the second and third chains of preheat train.
The preheated crude is finally heated in the charge furnace to 360 degree Celsius and
introduced into the flash zone of the atmospheric column.
Heavy gas oil (HGO). Light gas oil (LGO),kerosene and heavy naphtha are
withdrawn as side streams and are steam stripped in stripper columns. Heavy naphtha
is cooled and routed to gas oil stream. Provision is also given to route heavy naphtha
along with stabilized naphtha. Kerosene after steam stripping is cooled and routed to
storage.
HGO,LGO streams are mixed after cooling and the gas oil streams is further
cooled and its routed to storage and the vacuum diesel from VDU joins gas oil at
battery limit. Provision is given to blend kerosene and LVGO also with gas oil. Gas oil
along with other blend streams goes to the diesel pool as a combined diesel stream.
RCO from the crude column bottom is send to VDU. A part from top reflux
cooling and condensation of vapours at various stages of the column is achieved by
means of the pump around streams of kerosene, LGO and HGO. The heat content of
the pump around streams are mostly recovered in crude preheat trains. LGO is used as
heating medium for stabilizer reboiler.
FCCU BLOCK
The FCCU was commissioned in 1985 with the design capacity of 1MMTPA. Feed
preparation unit (FPU) is a main unit in the FCCU block. The purpose of the feed
preparation unit is to make feed of required quality to be processed in FCC. In this unit
RCO is distilled under vacuum into four different cuts namely vacuum diesel oil
(VDU), Light vacuum gas oil (LVGO), Heavy vacuum gas oil (HVGO) and vacuum
residence. The VDO cut is normally routed to diesel pool. LVGO and HVGO
combined having boiling range approximately between 360C and 555C is the feed of
FCC.
By maintaining the end point VGO below 550C, the metal content like Ni, vanadium
etc and the carbon residue are reduced to an acceptable level. The metals if present in
VGO are poisons to the FCC catalysts. FCCU converts VGO into higher value
products such as LPG, gasoline and diesel by cracking of heavier hydrocarbon
molecules of VGO to lighter components. Silica-alumina catalyst in powder form is
used for promoting the cracking reactions. Reaction takes place at higher temperature
and at pressure above atmospheric pressure.
During cracking. Heavy hydrocarbon molecular of VGO are converted to lower
molecular weight components such as LPG, gasoline etc . Coke is formed as side
product. The entire coke formed is deposited on the catalyst surface, using exothermic
reaction and regenerate the catalyst. H2S present in the LPG is removed by absorbing
in diethanol amine in an absorption column in the amine unit.
3. BPCL-KR PRODUCTS
Liquefied petroleum gas & kerosene for households and industrial uses.
Natural rubber modified bitumen ( Rubberized bitumen)
Petrol and diesel for automobiles.
Naphtha, major raw material for fertilizer and petrochemical industries.
Benzene for manufacture of caprolactum, phenol, insecticides and other
chemicals.
Furnace oil and low sulphur heavy stock for fuel in industries.
Aviation turbine fuel (ATF) for aircrafts.
Bitumen and Natural Rubber Modified Bitumen (NRMB) for road paving.
Special boiling point spirit used as solvent in tyre industry.
Toluene for manufacture of solvents and insecticides, pharmaceuticals and
paint.
Polyisobutenes for manufacture of lubricants, cable jelly etc.
Sulphur for use in fertilizer, sugar, chemical and tyre industry.
The Captive Power Plant (CPP) was set up in 1990 with one 22MW Gas Turbine
Generator (GTG). This machine is capable of using the Refinery Fuel Gas (RFG) as
one of its fuel. If RFG is not available to the requirement levels, the remaining fuel
requirement is met from diesel. The waste heat from the turbine is utilized to produce
steam using a Heat Recovery Steam Generator (HRSG). The GTG generates power at
11KV level and is supplied to the 11KV switchgear-200 at the CPP Substation.
To augment the capacity of CPP, a new Steam Turbo Generator (STG) of 17.8MW
capacity was added to the system in 1998.This generator is producing power at 11KV
level and is also feeding to the 11KV switchgear-200 at the CPP Substation.
In KR, steam consumption in process units are from MP steam header of 18 Kg/cm2
and LP steam header of 4.5 Kg/cm2. But the steam generated in CO Boiler and HRSG
are at a pressure level of 38 Kg/cm2 that envisaged a co-generation of power with
another TG set of 2.5MW and it generates power at a 3.3KV level.
KR receives power from KSEB with a contract of Maximum Demand 20 MVA. Two
66KV feeders Line-1 and Line-2 are tapped from Kalamassery-Vytilla No.1 feeder and
Kalamassery-Vytilla No.2 feeder respectively and are fed to the 66KV switchyard at
CPP. The power at 66KV is stepped down to 11KV by two 35MVA, 66/11KV
transformers and is fed to the 11KV switchgear-2101 at New MRS substation.
The two 11KV switchgears i.e. SWGR-2101 and SWGR-200 are linked together by
two link circuits, Link-1 and Link-2 so that operational flexibility is assured.
Synchronizing with the state grid is done to draw power as and when required.
then to the Motor Control Centre (MCC) at 415V and then finally to Motor/LDB (Light
Distribution Board ). The present power demand of the refinery is to the tune of 31MW
and everyday KR consumes approximately 7lakhs Kilowatt-hour of electrical energy.
FIG : 4.1
SCMS School of Engineering Dept. of Electrical & Electronics
& Technology 11
Existing Distribution System &
Protection using Numerical Relay Project- 2010
FIG: 4.2
Captive Power Plant (CPP) is the heart of KR. It has as gas turbine generator (GTG)
and a steam turbine generator (STG) which caters the electrical load of refinery. BPCL-
KR also has 66KV feeders from KSEB, Kalamassery Substation with a contact
maximum demand of 20 MVA. The 66KV feeder’s line 1 and 2 are tapped from
(Kalamassery- Vytilla) No:1 feeder and ( Kalamassery- Vytilla) No:2 feeder
respectively. The total running load of BPCL-KR comes to around 36MW out of which
5MW is being continuously drawn from KSEB and remaining 31MW will be shared by
GTG.,STG and TG. KSEB power being unstable used for feeding non critical loads
and captive generation is used for feeding critical loads. The BPCL-KR consumes
about 7.5 lakhs units of electrical energy on an average per day. The generated/
imported from KSEB at captive power plant is distributed to different plants using
XPLE cables at 11KV level through two substations namely CPP substation and New
MRS substation. Process substation, FCCU, revamp substation, ACTP substation, CPP
offsite substation, unit station transformers receives power from CPP substation. 11KV
switchgear and CDU-2 substation, ARU substation, Naphtha revamp substation, PIB
substation and colony sector-1 substation receives power from New MRS substation.
BPCL-KR electrical system also consists of around 2500 motors, 80 transformers, and
40 substations/MCC rooms.
6. STG DESCRIPTION
Construction of Stator
Outer frame is of steel plate welded construction of high quality and is of rigid
design. At the inner side of outer frame, stator core is tightened and fitted at ample
pressure by core bolts through the media of stator core clamps.
Stator core is formed by laminating silicon steel sheets of high quality and little iron
loss, ventilation ducts are provided for each proper length in axial direction for the
purpose of effectively cooling the interior. Stator coil is entirely immersed F type
varnish on its which is mainly made of mica and coated special finish coating which
possesses heat resistance, humidity resistance and oil resistance along with sufficient
insulating intensity.
Construction of rotor
Shaft is made of forged steel and field core is formed by laminating steel
sheets. At every suitable length in its axial direction, duct pieces are welded forming
ventilating duct to effectively cool the interior.
Excitation device
Alternating current from three phase AC rectifier is rectified to DC by the
rotary rectifier with silicon rectifier. Then, that DC electric source excites the field coil
of generator. Therefore the generator does not have brush and slip ring.
The AC exciter is revolving armature type i.e. the field is frame side and the armature
is rotor side. The rotary rectifier consists of silicon rectifier, protecting condenser and
attachment ring. The attachment ring keeps the silicon rectifier and condenser against
the centrifugal force.
FIG: 7.1
The shaft is connected to prime mover. At first when shaft rotates the rotor of the PM
generator also rotates. It results an AC voltage induced in stator of PM generator. The
AC voltage induced is given to an Automatic Voltage Regulator (AVR). It rectifies AC
to DC and is given to the stator of main exciter. At same time the rotor winding
rotating in the main exciter field induces a voltage and is given to the diode wheel
through internal wiring. Here the AC is again converted into DC. It is given to the rotor
of main generator. The stator of this generator induces three phase AC as shown in
figure.
Generally fuse performs the function of detection and interruption but it is limited
only to low voltage circuits. For high voltage circuits. Relays and circuit breakers are
used.
So protection must detect faults and abnormal working conditions and isolate the
faulty working conditions and isolate the faulty equipment so as to limit damage
caused by fault energy and to limit effect on rest of the system.
Arcing-energy dissipation.
Faults are rare: Protection must operate even after years of inactivity
Security/Stability
Load switching
Speed
Fast operation
Cost
OVERCURRENT PROTECTION
This scheme of protection is used for the protection of distribution lines, large motors,
equipments etc. It includes one or more over current relays. An over current relay
operates when the current exceeds its pick up value.
DISTANCE PROTECTION
Distance protection is used for the protection of transmission line; usually 33kV, 66kV
lines. It includes a number of relays of same or different types. A distance between the
relay location and the point of fault in terms of impedance, reactance etc. The relay
operates if the point of fault lies within the protected section of the line. There are
various kinds of distance relays. The important types are impedance, reactance mho
type. An impedance relay measures the line impedance between the fault point and
relay location; a reactance relay measures reactance and mho relay measures a
component of admittance.
This scheme of protection is used for the protection of EHV and UHV lines generally
132kV and above. A carrier signal in the range 50-500 kc/sec is generated for the
purpose. A transmitter and receiver are installed at each end of transmission line to be
protected. Information regarding the direction of the fault current is transmitted from
one end of the line section to the other. Depending on the information relays placed at
each end trip if the fault lies within their protected section. Relays do not trip in case of
external faults. The relays are of distance type and their tripping operation is controlled
by their carrier signal.
DIFFERERNTIAL PROTECTION
This scheme of protection is used for the protection of generators, transformers, motors
of very large size, bus zones etc. C.Ts is placed on both sides of each winding of a
machine. The outputs of their secondaries are applied to the relay coils. The relay
compares the current entering a machine winding and leaving the same. Under normal
conditions or during any external faults, the current entering the winding is equal to the
current leaving the winding. But in the case of an internal fault of the winding these are
not equal. This difference in current actuates the relay. Thus the relay operates for
internal faults and remains in operation under normal conditions or during external
faults. In case of bus zone protection C.T are placed on both sides of the bus bar.
The function of protective relaying is to cause the prompt removal from service of any
element of power system when it suffers a short circuit, or when it starts to operate in
any abnormal manner that might cause damage or otherwise interfere with the effective
operation of the rest of the system. The relaying equipment is aided in this task by
circuit breakers that are capable of disconnecting the faulty elements when they are
called upon to do so by the relaying equipment.
Circuit breakers are generally located so that each generator, transformer, bus,
transmission line etc can be completely disconnected from the rest of the system. These
circuit breakers must have sufficient capacity so that they can carry momentarily the
maximum short circuit current that can flow through them, and then interrupt this
current; they must also withstand closing in on such a short circuit and then
interrupting it according to certain prescribed standards.
Although the principle function of protective relaying is to mitigate the effects of short
circuits, other abnormal operating conditions arise that also require the services of
protective relaying. This is particularly true of generators and motors.
Automatic Reclosure
About 90% of faults on overhead lines are of transient nature. Transient faults are
caused by lightning or external bodies falling on the lines. Such faults are always
associated with arcs. If the line is disconnected from the system for a time the arc is
extinguished and the fault disappears. Immediately after this the circuit breaker can be
reclosed automatically to restore the supply.
Most faults on EHV lines are caused by lightning. Flashover across insulators takes
place due to overvoltage caused by lightning and short time. Hence only one
instantaneous reclosure is used in the case of EHV lines. There is no need for more
than one reclosure for such a situation. For EHV lines one reclosure is 12 cycles is
recommended. A fast reclosure is desired from the stability point of view. Statistical
reports show that over 80% faults are cleared after the first reclosure, 10% requires the
second reclosure and 2% need the third reclosure, while the remaining 8% are
permanent faults. If the fault is not cleared after 3 reclosures, it indicates that the fault
is of permanent nature. Automatic reclosure are not used on cables as the breakdown of
insulation cable causes a permanent fault.
Back-up Relaying
Back-up relaying is employed only for protection against short circuits. Because short
circuits are the preponderant type of power failure, there are more opportunities for
failure in short primary relaying. Experience has shown that back-up relaying for other
than short circuits is not economically justifiable.
Auxiliary relays
Auxiliary relays assist protective relays. They repeat operations of protective relays,
control switches etc. They relieve the protective relays of duties like tripping, time lag,
sounding an alarm etc. They may be instantaneous or may have a time delay.
A relay which operates when the system voltage falls below certain preset value.
A time delay operates after a certain preset time delay. The time delay may be due to
its inherent design features or may be due to the presence of a time delay component.
Such relays are used in the protection schemes as a means of time discrimination. They
are frequently used in control and alarm schemes.
Differential Relay:
1. Electromagnetic Relays
2. Static Relays
3. Numerical Relay
Electromagnetic relays include attracted armature, moving coil, and induction disc
induction cup type relays. Electromagnetic relays contain an electromagnet (or a
permanent magnet) and a moving part. When the actuating quantity exceeds a certain
predetermined value, an operating torque is developed which is applied on the moving
part. This causes the moving part to travel and to finally close a contact to energise the
tripcoil of the breaker.
The protective system works with the help of electromagnetic relays which have less
accuracy.
• Decreased lifetime due to the fact of moving parts and thus causes wear.
Static relays contain electronic circuit, which may be transistors, ICs, Diodes and other
electronic components, there is a comparator circuit in the relay, which compares two
or more currents or voltages and gives an output, which is applied to either a slave
relay or a thyristor circuit. The slave relay is an electromagnetic relay, is a semi-static
relay. A relay using a thyristor circuit is a wholly static relay. Static relay possess the
advantage of having low burden on CT and PT, fast operation, absence of mechanical
inertia and contact trouble, long life and less maintenance. Static relays have proved to
be superior to electromagnetic relays and they are being used for the protection of
important lines, power station and substations. Yet they have not completely replaced
electromagnetic relays. Static relays are treated as a family of relays. Electromagnetic
relays continue to be in use because of their simplicity and low cost. Their maintenance
can be done by less qualified personnel whereas the maintenance and repair of static
relays require personnel’s in solid state devices.
Fault occurs when two or more conductors that normally operate with potential
difference coming contact with each other. These faults may be caused by sudden
failure of piece of equipment, accidental damage or short circuit to overhead lines, or
by insulation failure resulting from lightning surges. The faults generally occurring in
power system are
1.Over current
It occurs mainly due to short circuit/leakage due to corona effect sometimes due to
overload on the supply system.
2.Under voltage
It occurs either on short circuits because of more voltage drop in lines and machines
or on failure of alternators field.
3.Unbalance
Occurs either on grounding of one or two phases or on short circuit of two phases or
breaking of one of the conductors. In such cases different current flow through
different phases and fault is known as unbalanced fault.
4.Reverse Power
This fault occurs only in inter-connected systems. A generator, on failure of its field,
start working as a motor and takes power instead of delivering power ie, the flow of
power is reversed. Similarly in case of feeders connected in parallel. whenever some
fault occurs on any one of the feeders, the fault is fed from both ends ie, again direction
of flow of power in faulty feeder is reversed.
5.Surges
Whenever lightning takes place or severe fault occurs in the neighbouring circuits,
some short lived waves of very high voltage and current are set up in lines. Such fault
is known as surge and it may be considered as high voltage of very high frequency.
Relay type MCND 04 is a negative phase sequence over current relay and is
intended primarily for the unbalance protection of generator. Unbalanced loads or
faults in the system can cause negative sequence currents in stator and this induced
double frequency eddy current in rotor of generator. Heating of the rotor is proportional
to its AC resistance at twice system frequencies and even a modest value of negative
sequence current can cause serious over heating. The purpose of the relay is to
disconnect the generator before an excessive temperature is reached.
The type MYTU 04 relay detects the loss of field supply or reduction in the
field current or synchronous generator beyond the stability limits of the machine.
output relay is however prevented from operating during the test. Access to the test
push button requires removal of the front cover.
These type MVAX relay supervises the trip circuit of a circuit breaker. Initiating
audible alarm and visual indication if the trip circuit fails or the mechanism does not
operate. Four types are available giving supervision as follows.
Mechanism.
Type MVAX 31 gives supervision with the circuit breaker in either state, and
type MVAX 21 with circuit breaker closed only. If required, the alarm units of types
MVAX 21 and MVAX 31 can be operated via pilot wires. Type MVAX 91, three
separate MVAX 31’s in a size 8 case.
The MVTU range of relays provides definite time voltage protection. The
MVTU 13 is a definite time delays neutral displacement relay,which is included
primarily for the earth fault protection of alternator stator windings where the neutral is
earthed. The relay is designed such that its response to third harmonic frequencies is
suppressed, thus making it inoperative to the third harmonic loads unbalance which
normally flows in the generator neutral. The application of the relay also includes
protection against unbalanced condition in capacitor banks and the detection of earth
fault is impedance earthed, solidly earthed or unearthed system. The MVTU 18 is a
definite time delayed neutral displacement relay.
These relays are suitable for use in high security CB tripping circuits. In
particular they can be used in distributed ripping or control relays contact logic scheme,
where the initiating contact may be remote from the relay. The relays have a high
burden, which is either cut off at operation or economized to a low figure, either
instantaneously or after a time delay.
The KCEG 140 relay is a three phase over current and earth fault relay. The relay
uses a common measuring element for all the three phases and a separate element to
monitor the residual current. The phase volt settings and earth fault settings are
completely separate. Both the fault element and the earth fault element have 3 tripping
stages, which can be enabled and disabled as required. The relay also features an
alternating setting group, in which 3 tripping stages for both the phase over current and
earth fault element can be enabled or disabled differently to that implemented with the
first setting group. The relay has programmable output relay and opt-isolated digital
inputs.
The type DBAE relay is applied to detect each leakage in alternator field circuits
which are fully isolated from earth. It is suitable for use with thyristors excitation
system. The auxiliary AC bias supply is rectified to establish a small bias on
alternator field circuits so that all points are negative with respective to earth. In the
event of earth leakage current flows in the bias circuit and is detected by the sensitive
Db coil as additional safe guard, the relay functions as a self powered rotor earth fault
relay in the absence of injection supply, effectively covering a large protection of the
field winding. The actual protection covered depends upon the ratio of field voltage to
relay rated voltage and may be high as 95%. The external resistance, supposed with the
relay limits the fault current flowing in the DB coil.
The relay is suitable for any application in industrial plants and for generators where
definite time under or over frequency protection is required. In addition, multi stage
schemes using several relays can be provided for load shedding and reconnection
applications. Integral timers are provided for each operating circuit and a separate
electromagnetic auxiliary relays ensures maximum flexibility of applications.
The relay monitors the three phase voltage supply if the supply is interrupted or
becomes unbalanced due to the failure of the voltage transformers primary or
secondary fuses.
Forward and reverse power relay
The relay has sensitive settings and operates accurately for boundary
conditions upto +/- 87.10(0.05pf). the definite time characteristic ensures that
mal operations does not occur due to momentary power reversals during
synchronizing and power swings on the system.
The relay can be used in applications where time graded over current and earth
fault operation is required. The relay can be used to provide selective protection for
over head and under ground distribution feeders. Other applications include back up
protection for transformers, generators, and HV feeder circuits and protection of
neutral earthing resistors.
For back up over current protection of generators ordinary over current relays
are sometimes difficult to apply, due to the decaying characteristics of the fault current.
The value of the fault current will be progressively reduced due to the reaction, to a
value less than the full load current. Therefore, normal over current relays, set above
the load current or maximum permissible overload cannot be applied to provide time
delayed protection as they will not operate for fault conditions. For successful
With voltage restrained over current relays, when the voltage falls below a set
values, the operating time of the over current characteristics is continuously reduced
with declining voltage. In voltage controlled over current relays, the operating time
characteristic is changed from the load characteristics to the fault characteristics when
voltage falls below the set level. The MCVG 61 is a three phase voltage dependent
over current relay with both voltage restrained and voltage control characteristics
available from the same relay. A switch on the front panel of the relay selects the
desired mode.
The analog to digital (AD) stage consists of memory components, a multiplexer and an
analog to digital (A/D) converter. The A/D converter processes the analog signals from
the IA stage. The digital signals from the converter are input to the microcomputer
system where they are processed as numerical values in the residing algorithms.
Microcomputer System
The actual protection and control functions of the 7SJ62/63/64 are processed in the
microcomputer system. In addition, the microcontroller controls the measured
quantities. Specifically, the microcontroller performs:
The microcomputer obtains external information through the binary inputs such as
blocking commands for protective elements or position indications of CB. The
microcomputer issues commands to external equipments via output contacts. These
output commands are generally used to operate CB’s or other switching devices. They
can also be connected to other protective devices or external carrier equipments for use
in pilot relaying schemes.
Front Elements
The devices with integrated or detached operator panel light emitting diodes (LED) and
displays screen (LCD) on the front panel providing information such as messages
related to events and functional status of the device.
The integrated control and numerical keys in conjunction with the LCD facilitates
local operation with the numerical relay. All information of the device can be accessed
using the integrated control and numerical keys. The information includes protective
and a control settings operating and fault messages and metering values. The settings
can be modified; in addition, control of CB and other equipment is possible from the
front panel.
Serial Interfaces
A serial PC port on device is provided for local communication with the relay through
a personal computer. Convenient operation of all functions of the device is possible.
The operating system facilitates a comfortable handling of all device functions.
All relay data can be transferred to a central control and monitor system through the
SCADA port. Various protocols and physical interfaces are available to suit the
particular operation.
A further port is provided for the time synchronization of the internal clock via external
synchronization sources.Further communication protocols can be realized via
additional interface modules.
Power Supply
The relay can be supplied with any of the common power supply voltages from 24V
DC to 250V DC. The device can also be supplied with 115V AC. Momentary dips of
the supply voltage upto 50ms are bridged by a capacitor. Voltage dips can occur if the
voltage supply system becomes short circuited or experiences a source variation in
load.
15.2 APPLICATIONS
The relay includes the functions that are necessary for protection, monitoring of circuit
breaker position and control of the circuit breaker in straight bus application or breaker
and a half configuration; therefore the devices can be inversely employed. The relay
provides excellent backup facilities of differential protective scheme of lines,
transformers, generators, motors and bus bars of all voltages.
A.Protective Functions
Non directional over current protection is the basis of the numerical relay. Four definite
over current protective elements exists, two for the phase and two for ground current.
The elements can set with time delay where instantaneous tripping is decided. Inverse
time over current protective elements are also available for both the phase and ground
currents.
Depending on the version of the device that is used, the non-directional over current
protection can be supplemented with directional over current protection, breaker failure
protection and sensitive ground fault detection for high resistance ground fault or
system datas are resistively ground. The highly sensitive ground fault detection,
directional or non-directional, include negative sequence current protection, automatic
reclosing, thermal overload protection, over voltage protection, under voltage
protection and over/under frequency protection. For another port, under current
monitoring are optionally available. Finally the relay is equipped with a fault locater.
A port feature can be ordered for the detection of intermittent ground faults which
detects and accumulate transient ground fault. External detectors account for ambient
temperature or coolant temperature. Before re-closing after 3 pole tripping, relay can
verify the validity of the re-closure by voltage check and/or synchronous check. The
sign function can also be controlled externally.
B.Control Functions
The relay supports all control monitoring functions that are required for operating
medium to high voltage substation. Major applications are the reliable control of
switchgear or CB’s. Such control can be accomplished through the integrated operation
panel, the system interface, binary inputs and the serial port using a PC with DIGSI.
The status of the equipment or auxiliary devices can be transmitted to the relay via
auxiliary contacts connected to the binary input. The present status of the primary
equipment can be displayed on the relay. Only the quantity of the binary input and
output available in the numerical relay limits the number of primary devices that can be
operated. Depending on the equipment being controlled, 1 binary input or 2 binary
input can be used in the position monitoring process.
Messages of the relay can be indicated via a number of programmable LED’s of the
front panel externally processed through programmable output contacts and
communicate via the serial interface.
D. Communication
Serial interfaces are available for communication with PC’s, RTU’s and SCADA
systems. A 9-pin D-sub miniature female connector on the front panel is used for local
communication with personal computer. DIGSI 4 software is required to communicate
via this port. Using this, settings and configurations can be made to the relay, real-time
operating quantities can be viewed, waveform capture and event by records can be
displayed and controls can be issued. A DIGSI 4 service interface port, a system port
and a time synchronize port are optionally available on the rear of the device.
A rear service interface can be supplied as RS-232, RS-485 or multimode fibre optics
type ST.DIGSI 4 software is required to communicate via this port. This additional port
is designed exclusively for connection of RTD-Box for entering external temperature.
It can also be operated via data lines or fibre optic cables.
15.3 CHARACTERISTICS
General Characteristics
FIG :16
The SIPROTEC 4 7UM62 includes all necessary protection functions for large
synchronous and asynchronous motors and for transformers. The integrated
programmable logic functions (continuous function chart CFC) offer the user high
flexibility so that adjustments can easily be made to the varying power station
requirements on the basis of special system conditions. The flexible communication
interfaces are open for modern communication architectures with the control system.
The following basic functions are available for all versions:
Current differential protection for generators, motors and transformers, stator earth-
fault protection, sensitive earth-fault protection, stator overload protection, overcurrent-
time protection (either definite time or inverse time), definite-time over current
protection with directionality, under voltage and overvoltage protection,
underfrequency and overfrequency protection, overexcitation and underexcitation
protection, external trip coupling, forward-power and reverse power protection,
negative-sequence protection, breaker failure protection, rotor earth-faults protection
(fn, R-measuring), motor starting time supervision and restart inhibit for motors.
GENERATOR BASIC
One application concentrates on small and medium generators for which differential
protection is required. The function mix is also suitable as backup protection.
Protection of synchronous motors is a further application.
GENERATOR STANDARD
In the case of medium-size generators (10 to 100 MVA) in a unit connection, this scope
of functions offers all necessary protection functions. Besides inadvertent energization
protection, it also includes powerful backup protection for the transformer or the power
system. The scope of protection is also suitable for units in the second protection
group.
GENERATOR FULL
Here, all protection functions are available and the main application focuses on large
block units (more than 100 MVA). The function mix includes all necessary protection
functions for the generator as well as backup protection for the block transformer
including the power system. Additional functions such as protection during start-up for
generators with starting converters are also included. The scope of functions can be
used for the second protection group, and functions that are not used, can be masked
out.
ASYNCHRONOUS MOTOR
Besides differential protection, this function package includes all protection functions
needed to protect large asynchronous motors (more than 1 MVA). Stator and bearing
temperatures are measured by a separate thermo-box and are transmitted serially to the
protection unit for evaluation.
TRANSFORMER
This scope of functions not only includes differential and overcurrent protection, but
also a number of protection functions that permit monitoring of voltage and frequency
stress, for instance. The reverse power protection can be used for energy recovery
monitoring of parallel-connected transformers
TABLE -16.1-1
TABLE: 16.1-2
The current function can be controlled by evaluating the generator terminal voltage.
The “controlled” version releases the sensitive set current stage. With the “restraint”
version, the pickup value of the current is lowered linearly with decreasing voltage.
The fuse failure monitor prevents unwanted operation.
UNDEREXCITATION PROTECTION
(LOSS OFFIELD PROTECTION) (ANSI 40)
Derived from the generator terminal voltage and current, the complex admittance is
calculated and corresponds to the generator diagram scaled in per unit. This protection
prevents damage due to loss of synchronism resulting from underexcitation. The
protection function provides three characteristics for monitoring static and dynamic
stability. Via a transducer, the excitation voltage can be injected and, in the event of
failure, a swift reaction of the protection function can be achieved by timer changeover.
The straight-line characteristics allow the protection to be optimally adapted to the
generator diagram (see Fig16.1-2).The per-unit-presentation of the diagram allows the
setting values to be directly read out. The positive-sequence systems of current and
voltage are used to calculate the admittance. This ensures that the protection always
operates correctly even with asymmetrical network conditions. If the voltage deviates
from the rated voltage, the admittance calculation has the advantage that the
characteristics move in the same direction as the generator diagram.
.
FIG : 16.1-3 Grading of impedance protection
This protection prevents insulation faults that result when the voltage is too high. Either
the maximum line-to-line voltages or the phase-to-earth voltages (for low voltage
generators) can be evaluated. The measuring results of the line-to-line voltages are
independent of the neutral point displacement caused by earth faults.
The frequency protection prevents impermissible stress of the equipment (e.g. turbine)
in case of under or overfrequency. It also serves as a monitoring and control element.
The function has four stages; the stages can be implemented either as underfrequency
or overfrequency protection. Each stage can be delayed separately. Even in the event of
voltage distortion, the frequency measuring algorithm reliably identifies the
fundamental waves and determines the frequency extremely precisely. Frequency
measurement can be blocked by using an undervoltage stage.
The sensitive earth-current input can also be used as separate earth-fault protection. It
is of two-stage form. Secondary earth currents of 2 mAor higher can be reliably
handled. Alternatively, this input is also suitable as rotor earth-fault protection. A
voltage with rated frequency (50 or 60 Hz) is connected in the rotor circuit via the
interface unit 7XR61. If a higher earth current is flowing, a rotor earth fault has
occurred. Measuring circuit monitoring is provided for this application.
This protection has the function of limiting the damage of the generator in the event of
an unintentional switch-on of the circuit breaker, whether the generator is standing still
or rotating without being excited or synchronized. If the power system voltage is
connected, the generator starts as an asynchronous machine with a large slip and this
leads to excessively high currents in the rotor. A logic circuit consisting of sensitive
current measurement for each phase, measured value detector, time control and
blocking as of a minimum voltage, leads to an instantaneous trip command. If the fuse
failure monitor responds, this function is ineffective.
A higher sensitivity is required for larger generators. On the one hand, the disturbing
influence of the rotor earth capacitance must be eliminated more effectively and, on the
other hand, the noise ratio with respect to the harmonics (e.g. sixth harmonic) of the
excitation equipment must be increased. Injecting a low-frequency square wave voltage
into the rotor circuit has proven itself excellently here. The square wave voltage
injected through the controlling unit 7XT71 leads to permanent recharging of the rotor
earth capacitance. By way of a shunt in the controlling unit, the flowing earth current is
measured and is injected into the protection unit (measurement input). In the absence of
a fault (RE≈∞), the rotor earth current after charging of the earth capacitance is close to
zero. In the event of an earth fault, the fault resistance including the coupling resistance
(7XR6004), and also the injecting voltage,defines the stationary current. The current
square wave voltage and the frequency are measured via the second input (control
input). Fault resistance values upto 80 kΩ can be measured by this measurement
principle. The rotor earth circuit is monitored for discontinuities by evaluation of the
current during the polarity reversals.
characteristic in which the impedance vector enters or departs. Tripping occurs when
the set counter value is reached.
The counters are automatically reset if power swing no longer occurs after a set time.
By means of an adjustable pulse, every power swing can be signaled. Expansion of the
characteristic in the R direction defines the power swing angle that can be measured.
An angle of 120 ° is practicable. The characteristic can be tilted over an adjustable
angle to adapt to the conditions prevailing when several parallel generators feed into
the system.
VECTOR JUMP
Monitoring the phase angle in the voltage is a criterion for identifying an interrupted
infeed. If the incoming line should fail, the abrupt current discontinuity leads to a phase
angle jump in the voltage. This is measured by means of a delta process. The command
for opening the generator or coupler circuit-breaker is issued if the set threshold is
exceeded.
• Shaft current protection in order to detect shaft currents of the generator shaft
and prevent that bearings take damage
The sensitive earth-current protection IEE-B uses either the hardware input IEE1 or
IEE2. These inputs are designed in a way that allows them to cut off currents greater
than 1.6 A (thermal limit, see technical data).This has to be considered for the
applications or for the selection of the current transformers. The shaft current
protection function is of particular interest in conjunction with hydro- electric
generators. Due to their construction, the hydroelectric generators have relatively long
shafts. A number of factors such as friction, magnetic fields of the generators and
others can build up a voltage across the shaft which then acts as voltage source
(electro-motive force-emf). This inducted voltage of approx. 10 to 30 V is dependent
on the load, the system and the machine. If the oil film covering a bearing is too thin,
breakdown can occur. Due to the low resistance (shaft, bearing and earthing), high
currents may flow that destroy the bearing. Past experience has shown that currents
greater than 1 A are critical for the bearings. As different bearings can be affected, the
current entering the shaft is detected by means of a special transformer (folding
transformer).
The interturn fault protection detects faults between turns within a generator winding
(phase). This situation may involve relatively high circulating currents that flow in the
short-circuited turns and damage the winding and the stator. The protection function is
characterized by a high sensitivity. The displacement voltage is measured at the open
delta winding by means of 3 two-phase isolated voltage transformers. So as to be
insensitive towards earth faults, the isolated voltage transformer star point has to be
connected to the generator star point by means of a high-voltage cable. The voltage
transformer star point must not be earthed since this implies that the generator star
point, too, would be earthed with the consequence that each fault would lead to a
single-pole earth fault. In the event of an interturn fault, the voltage in the affected
phase will be reduced causing a displacement voltage that is detected at the broken
delta winding. The sensitivity is limited rather by the winding asymmetries than by the
protection unit.
An FIR filter determines the fundamental component of the voltage based and the
scanned displacement voltage. Selecting an appropriate window function has the effect
that the sensitivity towards higher-frequency oscillations is improved and the
disturbing influence of the third harmonic is eliminated while achieving the required
measurement sensitivity.
For recording and processing of external trip information, there are 4 binary inputs.
They are provided for information from the Buchholz relay or generator-specific
commands and act like a protection function. Each input initiates a fault event and can
be individually delayed by a timer.
One or two binary inputs can be used for monitoring the circuit-breaker trip coil
including its incoming cables. An alarm signal occurs whenever the circuit is
interrupted.
If the relay is used in a pumped-storage power plant, matching to the prevailing rotary
field is possible via a binary input (generator/motor operation via phase rotation
reversal).
All binary outputs (alarm or trip relays) can be stored like LEDs and reset using the
LED reset key. The lockout state is also stored in the event of supply voltage failure.
Reclosure can only occur after the lockout state is reset.
The relay comprises high-performance monitoring for the hardware and software. The
measuring circuits, analog-digital conversion, power supply voltages, memories and
software sequence (watch-dog) are all monitored. The fuse failure function detects
failure of the measuring voltage due to short-circuit or open circuit of the wiring or VT
and avoids overfunction of the undervoltage elements in the protection functions. The
positive and negative-sequence system (voltage and current) are evaluated.
FIG: 16.2
If the generator neutral point has low-resistance earthing, the connection illustrated in
Fig 16.2 is recommended. In the case of several generators, the resistance must be
connected to only one generator, in order to prevent circulating currents (3rd
harmonic). For selective earth-fault detection, the earth-current input should be looped
into the common return conductor of the two current transformer sets (differential
connection). The current transformers must be earthed at only one point. The
displacement voltage VE is utilized as an additional enabling criterion. Balanced
current transformers (calibration of windings) are desirable with this form of
connection. In the case of higher generator power (for example, IN approximately2000
A), current transformers with a secondary rated current of 5 A are recommended. Earth
current differential protection can be used as an alternative.
ADVANTAGES
Mechanical and solid-state (static) relays have been almost completely phased out of
our production because numerical relays are now preferred by the users due to their
decisive
advantages:
Compact design and lower costs due to integration of many functions into one
relay
High availability even with less maintenance due to integral self-monitoring
No drift (aging) of measuring characteristics due to fully numerical processing
High measuring accuracy due to digital filtering and optimized measuring
algorithms
Many integrated add-on functions, for example, for load-monitoring,
event/fault recording and thermal monitoring.
Local operation keypad and display designed to modern ergonomic criteria.
Easy and reliable read-out of information via serial interfaces with a PC,
locally or remotely with DIGSI (one tool for all relays).
Possibility to communicate with higher-level control systems using
standardized
DISADVANTAGES
Software intensive
Serial nature
Obsolescence rate
EMI/EMC problems
18. CONCLUSION
REFERENCES
1. Newark,NJ Applied Protective Relaying.: Westinghouse Electric
Corporation
2. The Art of Protective Relaying, Philadelphia, PA: General Electric
Company, Bulletin 1768
3. MASON,C.R “ The Art and science of protective relaying”. New York.
Wiley,1956.
APPENDIX- A
A-1 Technical Particulars of STG
d) Voltage : 11KV
f) Frequency : 50 Hz
h) No. of phases :3
I) No. of poles :4
: Rotor: F
l) Rating : Continuous
m) Type of outer housing : Totally enclosed, internal cooling type (With air
Cooler)
Cylindrical bearing
D Current : 402 A
e) Frequency : 75 Hz
g) No. of phases :3
h) No. of poles :6
j) Insulation class :F
k) Rating : Continuous
n) Bearing : None
APPENDIX- B
Iθ =Is X K
Is=0.8 Im
Is = 18% (6 – 20%)
Alarm I2 = 0.8Is
t=2 Sec
APPENDIX – C
APPENDIX- D