Ieee Recommended Practice For Cement Plant Power D

IEEE Std 277-1983
(Revision of
IEEE Std 277-1975)
IEEE Recommended Practice for

Cement Plant Power Distribution
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IEEE Published by The Institute of Electrical and Electronics Engineers. Inc 345 East 47th Street. New York. NY 10017. USA
September 12, 1983 SH09035
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IEEE
Std 277-1983
(Revision of
IEEE Std 277-1975)

Sponsor
Cement Industry Committee of the
IEEE Industry Applications Society
© Copyright 1983 by
The Institute of Electrical and Electronics Engineers, Inc

345 East 47th Street, New York, NY 10017
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Foreword
(This Foreword is not a part of IEEE Std 277-1983, IEEE Recommended Practice for Cement Plant Power Distri-
bution.)
The continuing expansion and modernization program in the cement industry has placed an in-
creasing importance on the current plant power distribution system. Increasing plant capacity ac-
companied by larger kilns, grinding mills, crushers, and the increasing use of automatic controls
has placed greater stress on the adequacy and reliability of the distribution system. Safety, capac-
ity, reliability, and low maintenance - all at a reasonable cost - are the requirements of the cement
plant power distribution system.
It was for the purpose of establishing recommended practices for the cement industry to realize
these requirements that the Power Generation and Distribution Working Group of the Cement In-
dustry Committee was fonned. The working group undertook this task in 1959.
The first recommended practice of the Power Generation and Distribution Working Group was
titled Report on Preliminary Suggested Recommendations for Cement Plant Power Distribution
and was prepared for publication and presentation at the Milwaukee, WI, 1960 Technical Confer-
ence sponsored by the AlEE Cement Industry Committee. As a result of the comments received at
annual conferences, the report has been revised and expanded each year. It now includes recom-
mendations on the main plant substation, high-voltage distribution, relaying, metering, cables, low-
voltage distribution, and quarry distribution.
Since the Federal Government, through its agency the Occupational Safety and Health Adminis-
tration (OSHA), has adopted the National Electrical Code, conformance with its requirements is
mandatory.
The recommendations given in this recommended practice are those on which the Power Gen-
eration Distribution and Related Products Working Group could reach an agreement. Certainly,
any unusual conditions prevailing in a particular plant may change the advantages or disadvantages
usually realized for a particular scheme. The IEEE Std 141-1976, IEEE Recommended Practice for
Electric Power Distribution for Industrial Plants, brings to attention the important features of well-
designed electric distribution systems that result in satisfactory performance of utilization equip-
ment and efficient operation of plants in general. It is hoped that this recommended practice by
the Power Generation Distribution and Related Products Working Group of the Cement Industry
Committee will be used to augment some of the principles outlined, as they apply particularly to
cement plants.
This recommended practice reflects the thinking of members of the Power Generation Distribu-
tion and Related Products Working Group, consisting of members from cement plants, machinery
manufacturers, electric equipment manufacturers, and cement plant designers and builders.
At the time this recommended practice was approved the members of the Power Generation
Distribution and Related Products Working Group of the Cement Industry Committee were:
A. C. Lordi, Chairman John A. Vidergar, Vice Chairman
J. Alacchi E. D. Cook W. A. Reynolds
R. W. Bender V. Dilsaver A. E. Sarris
J. W. Brinks B. Dixon A. L. Smith
W. Buech W. A. Reynolds R. C. White
When the IEEE Standards Board approved this standard on June 17, 1981, it had the following
membership:
I. N. Howell, Jr, Chairman Irving Kolodny, Vice Chairman
Sava I. Sherr, Secretary
G. Y. R. Allen Jay Forster Faust Rosa
J .. J. Archambault Kurt Greene Robert W. Seelbach
James H. Beall Loering M. Johnson Jay A. Stewart
John T. Boettger Joseph L. Koepfinger William E. Vannah
Edward Chelotti John E. May Virginius N. Vaughan, Jr
Edward J. Cohen Donald T. Michael* Art Wall
Len S. Corey J. P. Riganati Robert E. Weiler
*Member emeritus
Contents
SECTION PAGE
1. Power Distribution for a New Plant 7
1.1 Main Plant Distribution Substation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7
1.2 Cable 19
1.3 Secondary-Unit Substations 20
2. Power Distribution for a Plant Expansion 23
2.1 Consider Expanding the Existing 2400 V System to 4160 V If the Total
Expanded Plant Capacity Will Exceed 10 000 kVA (Self-Cooled) 23
2.2 Utility Power for the Existing 2400 V Equipment Can Be Derived Either from the
High-Voltage Incoming Line Utility Service or from the Proposed New 4160 V System
with a 4160 V to 2400 V Transformation 23
2.3 Consider Grounding the Existing 2400 V System Through a Neutral-Grounding
Resistor or Resistors 23
2.4 Consider Abandoning Existing Generation and Purchase Total Power from the Utility 24
2.5 Consider the Use of Interlocked Armored Cable Carried on Trays 24
3. Quarry Distribution 24
3.1 Quarry Distribution Transformer 24
3.2 Primary Distribution 26
3.3 Distribution 600 V and Below 29
4. Harmonics 29
4.1 General 29
4.2 General Considerations 29
5. References 30
FIGURES
Fig 1 Economic Comparison of Double-Ended Substations 10

Fig 2 Economic Comparison of Single-Ended Substations 11
Fig 3 Economic Comparison of Cable 12
Fig 4 Economic Comparison of Indoor Secondary-Unit Substation 12
Fig 5 Economic Comparison of Ball Mill Drive 13
Fig 6 Economic Comparison of Motor Voltages 14
Fig 7 Typical Cement-Plant Distribution System 15
Fig 8 Maximum Allowable Short-Circuit Current Copper Conductor 17
Fig 9 Quarry Distribution 25
1. Power Distribution for a New Plant 1.1.4 Use Extra-Creepage Insulators and
Bushings on the Exposed Electric Equipment
1.1 Main Plant Distribution Substation in the Outdoor Substation. The use of extra-
1.1.1 Make a Study to Determine the Advis- creepage porcelain in the outdoor substation
ability of Purchasing Electric Power from the extends the time between cleaning periods and
Utility or of Generating Power. The trend in helps keep flashovers to a minimum. Many
cement plants is to purchase power from the operators use silicone waxes or greases to
utility instead of generating power. The deci- facilitate the periodic cleaning of exposed in-
sion to purchase or generate power depends sulators and bushings.
primarily upon economics. Many operators be- Bushings at the distribution voltage level
lieve that the possible increased production by (2.4 kV to 13.8 kV) are best kept enclosed
the use of efficient kilns more than offsets the in terminal chambers. It is also desirable to
additional cost of purchased power in most keep the number of bushings to a minimum
locations in the United States. Other ad- by the use of three-phase instead of single-
vantages in using utility power are phase transformers.
(1) Possibly better voltage regulation dur- 1.1.5 Provide for an Alternate Power Source
ing the starting of large motors to the Plant, Especially for Critical Loads. This
(2) Greater reliability of a larger system power source could be a full-capacity transmis-
(3) Absence of operating problems associated sion line to the plant, a small-capacity line at
with power generation. some lower voltage, standby generation, or
A trend is indicated here, instead of a recom- some combination of these. The use of a loop
mendation, as the decision depends much upon or alternate transmission line allows total
local conditions. plant operation, after a short delay, in the
1.1.2 Locate the High-Voltage (Above 15 kV) event of a transmission line failure. A low-
Part of the Main Substation Outdoors, on the capacity alternate feed or standby generation
Windward Side of the Plant. The costly prac- allows operation of critical loads during the
tice of locating plant substations (above 15 kV) line failure outages.
indoors or under a roof to minimize dust settle- Standby generation should be exercised un-
ment is no longer considered necessary. der load once a week to help ensure its avail-
1.1.3 Make a Study to Determine Whether ability when needed. See ANSI/IEEE Std 446-
the Outdoor Part of the Main Plant Substa- 1980 [3].1
tion Is to be Owned by the Plant or by the
Utility. Here again, economics, including ini- 1.1.6 Use a Circuit Breaker or Circuit Break-
tial, operational, and maintenance costs, should ers for Primary Protection of Substation Ap-
be compared with local utility rates at different paratus. Circuit breakers are preferred over
voltages to determine who should own the fuses for substation primary protection as they
outdoor substation. Excluding economics, allow the use of fast, sensitive relays which
the plant purchasing the substation has the ad- quickly act to isolate faulted equipment and
vantages of choosing the substation equipment more easily coordinate with other protective
arrangement which best fits its needs. How- devices used. Also, the use of relays extends
ever, utility ownership may enable a quicker the zone of protection against limited ground
restoration of power subsequent to equipment faults down to the secondary side of the sub-
failure since utilities generally stock spare station power transformers.
equipment.
A study is indicated instead of a recommenda-
1 The numbers in brackets correspond to those of
tion because of the wide variation of utility the references listed in Section 5 of this recommended
rates and policies. practice.
IEEE
Std 277-1983 IEEE RECOMMENDED PRACTICE FOR
Ground faults occurring in the substation directly to an exposed source generally re-
transformer secondary or between the trans- quires lightning protection. Effective arrester
former secondary and the main secondary cir- protection requires that the arresters be in-
cuit breaker cannot be isolated by the main stalled with a low surge impedance discharge
secondary circuit breaker located on the load path to ground. Where feasible, connect the
side of the ground fault. These grounded faults, arrester ground lead to the ground lead of the
when limited by a neutral grounding resistor protected equipment. Leads should be kept as
are not seen by transformer primary fuses, and short as possible.
must be isolated by a primary circuit breaker. Protection against ligh tning is usually pro-
If not isolated, these ground faults create a vided at the outdoor substation by station or
safety hazard and may result in the destruction intermediate-type surge arresters and over-
of the faulted substation equipment and the head ground wires. Apparatus energized from
grounding resistor. exposed circuits should have arrester protec-
Where cost prohibits the use of a local pri- tion at the terminals of the apparatus to be
mary circuit breaker, a means of remote trip- protected. Apparatus energized through ca-
ping through a pilot scheme, carrier scheme, bles from exposed circuits should usually have
or a grounding switch can be used to effect arrester protection at the junction of the cable
remote tripping of a circuit breaker to isolate and the exposed source. If cables connect to
substation faults. the outdoor transformer terminal chamber,
A primary circuit breaker also enables the and the transformer primary source is exposed,
use of differential relays which quickly initiate the transformer should have primary arrester
action to clear faults, keeping fault damage protection.
to a minimum. The un faulted half of a double- Rotating machines have lower basic im-
ended substation can usually be quickly re- pulse insulation levels than liquid-filled trans-
stored to service subsequent to an outage formers, switchgear, etc. Thus, all rotating
initiated by a properly relayed substation using machines connected to exposed circuits should
a primary circuit breaker. be protected by rotating machine surge ar-
1.1.7 Use a Double-Ended Substation in Sizes resters and surge protective capacitors at or
Above the 5000 kVA to 7500 kVA Range in very near to [less than 1 m (3 ft) from] the
Capacity. The double-ended substation as used machine terminals. Even though large im-
here is defined as a substation having more than portant rotating machines are not connected
one three-phase stepdown transformer. More directly to exposed lines, it is still desirable
than one low side bus may be used where re- to use surge arresters and surge capacitors to
quired. See 1.1.12. reduce the effects of induced lightning and
The double-ended substation allows for switching surges. Surge arresters capable of
greater reliability and flexibility. Double- operating in the contaminants around the
ended substations permit insulator cleaning, cement plant should be used.
no-load tap changing, and reduced-capacity Surge arresters for resistance-grounded sys-
operation without a power outage. The double- tems usually used in cement plants are rated
ended arrangement is desirable at lower capac- for line-to-line voltage. See ANSI/IEEE Std
ities, but the additional cost of the double- 142-1982 [2].
ended arrangement usually does not justify its 1.1.9 Ground the Power System Through a
use in sizes below 5000 kV A (substation costs Neutral-Grounding Resistor or Resistors at the
may be estimated from Figs 1 and 2 for the Primary Distribution Voltage Level (2.4 kV to
single- and double-ended substations). 13.8 kV). Limiting ground-fault current by a
1.1.8 Use Station or Intermediate-Type resistor is desirable to minimize ground-fault
Surge Arresters Selected to Coordinate with damage to the large motors used in the plant
Equipment Insulation Levels to Protect Ex- at the distribution-voltage level. A 10 s resis-
posed Substation Equipment Against Light- tor rating is satisfactory for plant distribution
ning Surges. Surge protection is most ef- service, when ground faults are relayed to trip
fective when applied at the terminals of the the faulted circuit.
apparatus to be protected. Equipment con- The value of resistance used should be low
nected by cable to an exposed (outdoor lines enough to allow the flow of sufficient ground-
subject to lightning strokes) power source or fault current to be selectively relayed with an
IEEE
CEMENT PLANT POWER DISTRIBUTION Std 277-1983
adequate margin. Ground-fault current should A typical suggested substation size is

not be limited to less than the system charging 5000 kVA (with fans for 6250 kVA capacity)
current (usually less than 15 A). Generally, for each 200 000 ton per year plant capacity.
the combination of grounding resistor and The use, or provision for future use of fans on
ground relaying used should result in the pro- the substation transformers should be con-
tection of 90% of the windings of motors and sidered.
transformers. Effective protection of equip- 1.1.12 Use 4160 V as the Primary Distribu-
ment is realized if ground relays pick up at tion Voltage for Plants of 20000 kVA and Be-
10% or less of the maximum ground-fault low. Above 20000 kVA, Either Use the Split-
current. Bus 4160 V System or the 13800 V System.
The interrupting and momentary current ca-
1.1.10 Use One or More Feeder Circuit pacity of the 4160 V circuit breakers and
Breakers for Each Operating Department at motor controls limits the allowable short-
the Distribution-Voltage Level. This section- circuit capacity and thus the substation ap-
alizing of loads allows independent depart- parent power on a bus. However, most existing
mental (or production unit) operation and plants have short-circuit capacities within the
facilitates the metering of each department. limits of 4160 V equipment.
The trend is toward the universal use of metal- When short-circuit capacities are above the
clad switchgear with removable-type circuit limits of 4160 V equipment, the 4160 V bus
breakers. A tie breaker is desirable in the can be split to keep short-circuit capacities
double-ended metalclad lineup for increased within equipment ratings. A higher distribu-
flexibility. It is desirable to use an additional tion voltage can be used as well with the avail-
circuit breaker to separate the large mill motors able equipment having higher short-circuit
on the raw and finish mills from the raw and capacities. The next economical voltage choice
finish mill auxiliaries. This facilitates relay co- is usually 13.8 kV.
ordination and allows closer protection of the The use of 13.8 kV as a primary distribution
connected equipment. voltage may require an additional transforma-
Either indoor or outdoor metalclad circuit tion to 4160 V or 2400 V to enable the eco-
breakers are used, depending upon available nomical use of large motors at the lower pri-
plant area. The preference is toward using in- mary distribution voltages. However, the
door metalclad circuit breakers located in clean double transformation increases system im-
pressurized rooms, rather than outdoor circuit pedance and voltage drop during the starting
breakers. The tripping voltage should be at of the large grinding-mill motors, and should
least 125 V to minimize relay contact continu- be taken into account. It is recommended that
ity failures due to dust. (See ANSI/IEEE Std a study be made to determine the economic
142-1982 [2]). motor voltage for plants of 20 000 kV A and
above.
1.1.11 Allow for Margin in Substation Capac- Figures 1-6 show relative costs for the elec-
ity. Approximately one-third extra apparent tric apparatus at several distribution-voltage
power capacity (in kilovoltamperes) over that levels. See ANSI C2-1981, National Electrical
needed for present plant operation is desirable Safety Code [1]. Also see IEEE Std 141-
in the initial substation installation. Circuit 1976 [5].
breakers also should allow for anticipated in- 1.1.13 Design the Power System to Limit
crease in utility short-circuit capacity for an Voltage Drop During Starting Large Motors
approximate 10 y period. Consideration should (at the Distribution Voltage) to a Maximum
be given to the providing of features in the sub- of 15% of System Nominal Voltage at the
station to facilitate subsequent expansion. Motor Terminals. The possibility of equipment
It is desirable to choose the transformer's size malfunction increases when the voltage drop
of double-ended substations to be large enough exceeds 15%. Special precautions to maintain
to enable starting the large mill motors on a control voltage may be required where a
single transformer within tolerable voltage greater than 15% drop in system voltage is
regulation (see 1.1.13). Mill torque limits anticipated.
should be observed both on single- and two- During normal running, voltage at the large
transformer operations. motors at the distribution voltage should not
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Fig 1
Economic Comparison of Double-Ended
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CEMENT PLANT POWER DISTRIBUTION Std 277 ·1983
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Economic Comparison of Single-Ended
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11
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Economic Comparison of Indoor Secondary-
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12
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45
CURVE A INCLUDES SUBSTATION FROM 13 BOO TO 4160 V at 2 kVA

PER HORSEPOWER, 200% STARTING, 140% PULL IN, 200% PULL OUT
TORQUE, 514 R/MIN 0.8 PF. ALL CURVES INCLUDE MOTOR AND CONTROL.
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Economic Comparison of Ball Mill Drive
Curve A - Substation from 13 800 to 4160 V at 2 kVA/hp 200%
Starting, 140% Pull In, 200% Pull Out Torque, 514 r/min, power factor 0.8;
All Curves Include Motor and Control
vary more than ± 5 % of rated motor voltage. machines, when out of synchronism, may re-
1.1.14 Isolate Synchronous Machines From sult in inrushes and torques well above drive
the Utility System Prior to Any Reclosing Ac- equipment mechanical limits. High-speed un-
tion Subsequent to a Plant Power Interruption derfrequency relays without any intentional
Due to the Utility System. A power interrup- time delay can usually act to isolate loaded
tion allows the synchronous machines to shift synchronous motors prior to a reclosing ac-
in phase position in respect to the utility sys- tion. Note that lightly loaded motors or mo-
tem. Subsequent reapplication of power to the tors connected to high inertia loads or both
13
IEEE
Std 277·1983 IEEE RECOMMENDED PRACTICE FOR
460 V CURVE INCLUDES MOTORS, CONTROLS

120
AND LOW·VOLTAGE UNIT SUBSTATIONS AT $17 PER HP
OTHER CURVES INCLUDE MOTORS AND CONTROLS
MOTORS-GENERAL PURPOSE 1200 R/MIN SQUIRREL
CAGE INDUCTION
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Fig 6
Economic Comparison of Motor Voltages
may not decelerate in time to allow under- enable selective isolation of both phase and
frequency relay action prior to utility reclosing. ground overcurrents for the load on each feed-
Coordination with the utility to block or de- er back to the utility system.
lay reclosing is suggested. Suggested relaying is outlined as follows:
1.1.15 Choose and Set Protective Relays to see Fig 7.
Selectively Initiate the Isolation of Faults on
the Primary Distribution System. Periodically NOTE: Specific relay choices cannot be made since
relay curves vary with different manufacturers, Care
Check Relays to Ensure Proper Operation. A must be exercised to ensure that the proper curve is
relay coordination study should be made to specified.
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1.1.15.1 Department Feeder Circuit Break- without affecting the rest of the primary dis-
ers at the Primary Distribution Voltage Level. tribution system. However, the motor-starter
(1) Phase: Inverse time, moderately inverse must have sufficient interrupting capacity to
time, very inverse time, or extremely inverse isolate the maximum ground-fault current as
time relays, or equivalent as required to prop- limited by the neutral-grounding resistors. If
erly coordinate with the connected load pro- ground relays are not included in the motor
tective devices. The extremely or very inverse starters, the feeder breaker ground relays
time relay may be required to coordinate with should act to quickly isolate ground faults.
fuses in motor starters over 600 V and when Instantaneous tripping means are desirable
used on the primaries of the substation sec- on ground faults for feeder breakers serving
ondary unit transformers. If the feeder circuit secondary unit substation transformers, whether
breaker feeds directly to an unfused secondary fused or unfused. With the resistance-grounded
unit substation transformer, the phase relays system, it is unlikely that secondary unit sub-
should also have instantaneous trip attach- station transformer primary fuses will see or
ments set above the maximum asymmetrical isolate transformer ground faults within the
fault expected at the connected low-voltage desired time. Instantaneous relays are some-
substation secondary. times used as ground-fault protection, when
Refer to 1.3.6 for recommended use of low- used with balanced flux (window type) cur-
voltage secondary unit substation fuses. rent transformers. However, when the residual
Set phase relays to pick up at as Iowa value connection of phase-current transformers is
of current, and to operate at as fast a time as used for ground-fault relays, a time-delay relay
feasible, with the connected equipment. The may be required to prevent nuisance tripping
relays should initiate clearing of fault on equip- due to false residual currents. In order to pro-
ment directly connected to the feeder breaker vide protection over 90% of the transformer
within the capacity of the connected cable and primary winding, the relay should be able to
equipment. See Fig 8 and ANSIjNFPA 70- detect 10% of maximum ground-fault current.
1981[4]. On circuits feeding 2400 V and 4160 V start-
Feeder circuit breakers acting as control for ers, the feeder-circuit ground relay should al-
large motors should have relays provided ex- low at least 0.4 s greater delay (at maximum
pressly for motor protection. Relays recom- ground-fault current) than the starter ground
mended are thermal (or temperature), damper- relay. The starter ground relay should be in-
winding protection, undervoltage, 2 reverse stantaneous when energized from a three-
phase, ground fault, and differential protec- phase balanced flux current transformer. If
tion. Large important motor controls may in- the starter phase current transformers are
clude current-balance relays, negative sequence connected in a residual circuit to realize
relays and temperature indicators. Synchronous ground-fault protection, an inverse or very-
motor controls should include additional field inverse-time ground relay should be used.
loss, synchronizing, pull out, instantaneous These relays allow a time delay to minimize
undervoltage and incomplete-sequence relays. nuisance tripping due to false residual cur-
(2) Ground: Inverse, moderately inverse, very rents. To protect at least 90% of the motor
inverse, or extremely inverse time relays, or windings, the ground relay should be set to
equivalent, as required to coordinate with pick up on 10% or less of the maximum
ground relays included in motor starters over ground-fault current. See IEEE Std 242-
600 V. It is desirable that each motor starter 1975 [6].
over 600 V on the resistance-grounded system 1.1.15.2 Main Plant Distribution Substa-
be equipped with a ground relay to quickly tion Transformers' Secondary Circuit Breakers.
initiate the isolation of motor ground faults (1) Phase: Inverse, moderately inverse, or
very-inverse time relays, or equivalent, without
instantaneous trip attachments, to isolate the
2 Instantaneous tripping on undervoltage offers some
additional motor protection against out-of-phase opera- distribution substation transformer on severe
tion at the expense of nuisance tripping which can oc- overloads and bus faults, and to back up the
cur on momentary dips in plant voltage. Nuisance trip- feeder breakers. The choice of relays should
ping can occur as a result of utility or plant short cir-
cuits, or both. See 1.1.14 on underfrequency protec- be such as to coordinate with the feeder
tion. breaker relays on feeder faults.
16
IEEE
CEMENT PLANT POWER DISTRIBUTION Std 277·1983
100 / , , / ~
,
/ / ~ ~ ~
80
/ ~ / / ~ ~
60 ,/ , ~
/ , ~
, V , , ~
~
~ ~ ~ ~
50
/ / 1/ / / I~
/ / ~ / / / / i/
V
40
/ -/ V /
,
~ ~ ~
/ / / / ~ V / /
,
~
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30
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V
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V
/ V / / /
V / / 1/ / /
20
,C:4.(:V<v c-,,,<vV /V V
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w /
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w
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LL ~ ,4,VV e, / /
o(f)
o
z
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/ <oV VS-/
~(<v'?/
~
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V ,/
« 8 / V '
(f)
::J / ,(0
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o / / / / / n;,~ ,4,VV e, /
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w
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::J / / / / / /
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u
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u
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~ 2
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(f) CURVES 8ASED ON FORMULA
/:: / / [~J ~2~~~4_J

~
V 2 t=C log [
A T1+234
WHERE
/ / I = SHORT-CIRCUIT CURRENT, AMPERES -
-
0.8
/
/
/
A = CONDUCTOR AREA, CIRCULAR MILS
t = TIME OF SHORT CIRCUIT, SECONDS -
T1 = INITIAL CONDUCTOR TEMPERATURE, 75°C -
/
0.6 1/
T2 = FINAL CONDUCTOR TEMPERATURE, 200°C
C = 0.0297 FOR COPPER -
I-
0.5
0.4
0.3
10 8 6 4 2 1/0 2/0 3/0 4/0 250 350 500 750 1000
AWG kcmil
CONDUCTOR SIZE
Fig 8
Maximum Allowable Short-Circuit Current Copper Conductor
17
IEEE
Set relays to coordinate with the feeder- back up feeder breakers. In the event of a
breaker relays. Adjust time to allow 0.4 s mini- fault on one side of the switchgear, it is desir-
mum greater trip time at maximum fault than able to trip the bus-tie breaker and the main
the slowest feeder-breaker relay setting for transformer secondary breaker on the faulted
coordination. side of the bus. This action effects the isola-
(2) Ground: Inverse, very inverse, moderate- tion of the fault without interrupting power
ly inverse, or extremely inverse time relays, or flow to the unfaulted half of the bus. The over-
equivalent, without instantaneous-trip attach- current relays on the main transformer sec-
ments, to initiate isolation of bus faults and to ondary breakers can be used to effect this
provide backup protection on feeder ground simultaneous tripping and still provide back-
faults. These relays should coordinate with the up protection on feeder faults by use of a
feeder-breaker ground-fault relays. summation circuit of current transformers
These ground relays can be energized from a on the tie breaker with those on the main
residual connection of the phase current breakers. See IEEE Std 242-1975 [6].
transformers, balanced flux current trans-
formers, or current transformers included be- 1.1.15.4 Main Plant Distribution Substa-
tween the distribution substation transformers' tion Transformer Primary Breaker.
neutrals and the neutral ground resistors. (1) Phase: Inverse, moderately inverse, or
Set ground relays to pick up at 10% or less very inverse time relays, or equivalent, with
of maximum ground-fault current from each instantaneous-trip attachments chosen to co-
grounding resistor (assuming a neutral ground- ordinate with the distribution substation
ing resistor in each transformer neutral circuit transformer's secondary breaker. This break-
as shown in Fig 7). Set time to allow a mini- er serves to isolate substation high-voltage
mum of 0.4 s longer time than the slowest faults and acts as backup protection on severe
feeder-breaker ground relay for coordination faults at the primary distribution voltage level.
with the feeder breaker seeing maximum Relays should be set to protect substation
ground-fault current from all grounding re- equipment. The relay pickup value must not
sistors. exceed the values in ANSI/NFPA 70-1981 [4].
(3) Differential Relays: Use transformer dif- (2) Ground: Two ground relays. One very
ferential relays to quickly initiate the operation inverse time or extremely inverse time relay,
of the main transformer secondary breaker as or equivalent, to initiate quick isolation of
well as the main transformer primary breaker. ground faults on the high-voltage side of the
These relays could be energized from current distribution substation. This relay is con-
transformers included in the primary bush- nected residually with the bushing current
ings of the distribution substation power transformers in the primary circuit breaker.
transformers and the current transformers in Pickup of this relay should be 10% or less of
the main secondary breaker. For the double- the maximum ground-fault current expected
ended unit substation (two transformers and on the primary system.
two main secondary breakers as shown in Fig The other ground relay is usually an inverse
7), a fault in the cable between one of the time or definite time relay, or equivalent, with-
power transformers and its respective sec- out instantaneous trip attachment, and con-
ondary breaker results in tripping both the nects to a current transformer (or current
primary and secondary breakers of the faulted transformers for the double-ended unit sub-
transformer circuit. Quick restoration of plant station) in the neutral resistor circuit(s). Or,
power by way of the unfaulted transformer this ground relay is a potential relay con-
circuit is effected subsequent to isolation of nected to an unfused potential transform-
the fault. Isolation of the faulted circuit is ef- er with its primary winding connected across
fected by opening the transformer primary the neutral resistor, sensing voltage as a func-
switch after drawing out the transformer tion of ground current. A potential relay will
secondary circuit breaker. See IEEE Std 242- trip on ground faults even if the grounding
1975 [6]. resistor should become open circuited.
1.1.15.3 Bus Tie Breaker at the Primary This relay is set to coordinate with the trans-
Distribution Voltage Level. The tie breaker former secondary breaker on secondary ground
should be relayed to isolate bus faults and to faults and serves to initiate isolation of ground
18
IEEE
faults which may occur in the transformer as the potential gradient, though the conduc-
secondary or between the transformer and tor insulation is being held more uniformly.
the secondary main current breaker. This Cables not protected by armor or conduit
relay serves to protect thermally the inter- should be shielded for personnel safety.
mittently rated grounding resistor, and also Where interlocked armored cable is used in
serves as a partial backup for the transformer the cement plant, the cable should include
differential relays. Pickup setting of this re- ground wires to provide aground return path
lay is at 10% or less of the maximum ground- during fault conditions.
fault current as limited by each neutral ground- 1.2.3 Use Cable Sizes Larger than the Size
ing resistor, and set to allow a minimum of that May Be Thermally Damaged by Maximum
0.4 s longer time than the transformer sec- Fault Current on the Distribution System for
ondary-breaker ground relay. Also, this relay the Time Required to Isolate the Fault. Short-
should trip within the thermal limit of the time ratings of copper cables are shown in
ground resistor. See IEEE Std 242-1975 Fig 8. Consider the time to isolate the fault
[6]. as the sum of the time it takes the protective
breaker relay to operate plus the operating
1.1.16 Meter Total Plant Power Requirement
time of the circuit breaker. The commonly
and Meter the Power Requirements of Each
used circuit breakers isolate faults within 5
Operating Department. Each feeder should
cycles at 60 Hz above 2 kV. Low-voltage
have a kilowatthour meter, an ammeter, and
breakers are faster and may only require
possibly an indication available for feeder
1 112 to 2 cycles to clear a fault.
power factor. Demand meters, indicating 15 or
1.2.4 Choose Cables Suitable for the Current
30 min maximum demand, are sometimes used.
to Be Carried After Ensuring that the Cable
Meter multipliers should be easily used round
Size is Adequate for the Thermal Stresses
numbers.
Caused by Short-Circuit Currents. Cables can
Totalizing metering should include both in-
usually be selected on the basis of thermal
tegrating and recording meters to approximate
the utility metering and to enable control of capacity as cable voltage regulation is usually
demand. A more accurate check on the utility not significant for the short runs in the plant
metering requires the use of equivalent ac- area. However, the desire for selectivity may
curacy meters and equivalent accuracy and indicate a choice of larger cable than that
burden on current transformers. dictated by either thermal or short-circuit
Voltmeters are desirable on each main break- current considerations alone or by both.
er to indicate potential of each incoming line. Sometimes additional cables are used in
Periodic tests should be made on meters to feeder circuits to enable quick restoration of
ensure accuracy. power by way of the unfaulted cable in the
event of a fault in one of the feeder cables.
1.2 Cable Consider ambient temperatures when choos-
1.2.1 Choose Cable Rated for the Voltage on ing cable capacity.
Which It Is To Be Used. At 600 V and below, 1.2.5 Consider Using Multiple Cable where
no distinction is made between grounded and Cable Sizes Above 500000 cmil (250 mm 2 )
ungrounded systems. However, at voltages Are Required to Realize the Current Capacity.
above 600 V consideration must be given to Cable sizes above 500000 cmil (250 cm 2 )
system grounding in the choice of cable insula- are difficult to handle an an appreciable re-
tion thickness. Cables for the higher voltage duction in current capacity per circular mil
levels are furnished with the designation for of copper penalizes the larger sizes.
grounded or ungrounded service.
1.2.2 Use Shielded Cable for Distribution 1.2.6 Install Cables So that They are Pro-
Voltages Above 2000 V. Cable shielding, prop- tected from Moving Equipment, Falling Ob-
erly grounded, promotes safety in that the jects, Etc. Cables in underground ducts or con-
shield, at ground potential, surrounds each conduit are commonly used in the cement plant
ductor. Phase-to-phase faults are discouraged. and are preferred by many plant engineers. The
Thus, with the resistance-grounded system, use of interlocked armored cable in rigid cable
cable fault damage is minimized. Also, longer supports obviates the use of ducts or conduit.
cable life may be realized in shielded cables Another technique for handling power cables
19
IEEE
is the use of self-supporting aerial cables, either accurately and which should have a minimum
preassembled or spun on the job site. of noise should be given the following addi-
1.2.7 Use Care in the Installation and Splic- tional consideration:
ing of Cable. In general, all types of cable are (1) Electrostatic and magnetic shielding
reliable when properly installed. Sheaths that should be provided for each pair (or possibly
are scraped and damaged in handling and groups of pairs) of cables. Cable shielding
pulling, and cables damaged by failure to main- should be insulated and grounded at only one
tain adequate radii are subject to premature point to minimize noise pickup due to shield
failure. Lead-covered cable is particularly sensi- currents.
tive to mechanical damage and requires special- (2) Pairs of cables carrying low-level signals
ly trained personnel to do the splicing. Thus, should be tightly twisted together to minimize
an increasing trend toward the use of non- noise pickup.
metallic sheathed cable having synthetic rub- (3) Cable splices should be kept to a mini-
ber or plastic insulation has been noted. mum.
1.2.8 Use Stress Cones at Cable Terminations (4) Physically separate power and control
of Shielded Power Cables. Stress cones reduce cables.
the voltage gradient at the termination of the (5) Thermocouple leads should be compen-
cable shield and are desirable at voltages above sating as determined by the thermocouples
2 kV. Sufficient space should be made avail- used.
able in electric equipment to facilitate the con- SCR (semiconductor-controlled rectifier) and
struction of stress cones. Rain shields, silicone- inverter drives generate electrical noise. Isolat-
tape terminals, porcelain terminators, or other ing high-impedance transformers are recom-
suitable methods are required for stress cones mended for these drives.
used on outdoor installations.
1.2.9 Use Fire-Retardant Cable to Minimize 1.3 Secondary·Unit Substations
Fire Hazards. A careful choice of cable insula- 1.3.1 Derive Power at Utilization Voltages
tion and cable jacketing is recommended to of 600 V and Less by Using Individual Second-
minimize propagation of fires and generation ary-Unit Substations for Each Department
of toxic gases. Rather than Large Centrally Located Units.
Arcproofing of power cables in manholes is Better voltage regulation, lower cable and
desirable to minimize the number of circuits equipment cost, lower cable power loss, and
affected by a severe fault in the vicinity of a more flexibility are realized by the use of the
manhole accommodating more than one cir- smaller units located at load concentrations.
cuit. Arcproofed cables are also desirable from 1.3.2 Use 480 V as the Utilization Voltage.
a personnel safety standpoint. The use of 240 V results in a higher cost sys-
1.2.10 Choose Conduit Size Adequate for tem both initially and in the form of cable
the Cable To Be Used. Proper conduit size is of costs and losses. The use of 600 V systems is
importance in facilitating cable installation discouraged by the limited availability of
with the minimum of cable damage. Conduit equipment from stock in the United States.
size is even more critical when pulling single- 1.3.3 Use the Radial Distribution System.
conductor cables, since three cables may jam if The radial distribution system is satisfactory
the triangular configuration is not maintained. for cement-plant service where department
Conduit sizes shall meet NEC requirements. storage capacity allows independent depart-
1.2.11 Use Special Care in the Choice and mental operation for short times. Where an
Installation of Cables for Low-Level Signals. additional degree of continuity is desirable,
Use separate ducts or physical separation of such as in the kiln or slurry preparation de-
power and control cables. The possibility of partment, additional primary cable capacity
elevated voltages on control circuits during or a secondary normally open tie arrange-
fault conditions is always present when con- ment is often used.
trol cables are in intimate contact with power 1.3.4 In General, Choose Secondary-Unit
cables. Also, magnetic fields incident to power Substation Capacity Approximately 85% of
cables can cause unwanted noise pick up in the Maximum Operating Horsepower Con-
sensitive control circuits. nected to the Secondary-Unit Substation. The
Cables carrying signals which must be read 85% figure varies in different operations and
20
IEEE
plant departments, depending on the standby adequately protected by the feeder circuit
capacity and overmotoring used. The 85% breaker relays. A separate set of relays may be
figure usually allows for addition of some required instead in the feeder circuit breaker
future loads. for the smaller loads.
1.3.5 Use Secondary-Unit Substations Rated Means should be provided to enable isola-
1000 kVA or Less (Self-Cooled Rating) to tion of the secondary-unit substation primary.
Limit Secondary Short-Circuit Capacity Within A visible-blade disconnect switch, key inter-
Economical Circuit-Breaker Ratings. Where locked with the main secondary circuit break-
capacity, in addition to 1000 kVA is required er, gives a visible indication of circuit isolation.
in a department, a double-ended unit or addi- 1.3.7 Use Fully Rated Low-Voltage Switch-
tional secondary-unit substations are usually gear for Feeder-Circuit Protection on Sec-
used. In any event, secondary ties are normally ondary-Unit Substations. Where desired, an ad-
operated open, and only closed when a low- ditional degree of service continuity is avail-
voltage substation transformer is out of service. able from the use of selective circuit breaker
Secondary-unit substations at 480 V up to tripping, as only the faulted secondary-unit
750 kVA rating, 5.75% impedance, can usually substation feeder is isolated.
be used to feed control centers braced for Some plants use control centers which are
22 000 A rms symmetrical. However, in the closed coupled to the transformer for eco-
application of control centers, it is essential nomic and spatial reasons. The control center
that the short-circuit rating of the control main air circuit breaker serves as the low-
center be adequate. voltage feeder circuit breaker.
Depending on system short-circuit current 1.3.8 Use a Main Low-Voltage Breaker on
capacity, control centers connected to 480 V the Secondary-Unit Substation. A main low-
secondary-unit substations rated above 750 kVA voltage circuit breaker is recommended when:
may require additional means of protection (1) The transformer primary protection is
against short circuits. Coordinated combina- by fuses, or the setting of primary protective
tions of current-limiting fuses and molded-case equipment is above 250% rated transformer
circuit breakers can be used in the main incom- current. The main secondary circuit breaker
ing line circuit to limit fault duty on the small permits much closer overload protection and
circuit breakers. Reactors, cable impedance, or facilitates interlocking with primary discon-
additional impedance built into the secondary- necting means.
unit substation transformers can be used to (2) The secondary system is connected to
limit fault currents. other sources of supply, such as through a tie
Additional kilovoltampere secondary-unit breaker in double-ended unit or secondary se-
substation capacity, which does not add addi- lective systems. The main circuit breaker pro-
tional transformer short-circuit capacity, is vides a means of isolating a transformer and
available by fan cooling. However, the addi- its associated primary system from the sec-
tional short-circuit capacity added by the addi- ondary bus.
tionalload must be considered. (3) The transformer is located at a consider-
1.3.6 Use Primary Fuses on the Secondary- able distance from the utilization equipment.
Unit Substation Primary. The Transformer (4) There are more than six secondary feed-
Secondary Breaker Should Be Set at Not More er circuit breakers.
than 250% Rated Current. (See ANSI/NFPA The transformer secondary circuit breaker
70-1981 [4].) On circuits feeding large motors should have a continuous-current rating greater
as well as secondary-unit substations at the dis- than the continuous-current rating of the
tribution voltage level, the large motor inrush transformer.
may require feeder circuit breaker relay set- 1.3.9 Choose and Set Secondary Circuit
tings above that which is required for sec- Breaker Trip Units to Quickly Initiate the Iso-
ondary substation protection. Where a small lation of Secondary Faults. Suggested trip
secondary-unit substation is placed on the same unit settings are outlined as follows (see
circuit as a much larger load, the relay setting Fig 7):
dictated by the large load may be too high to 1.3.9.1 Secondary Feeder Circuit Breakers.
protect the smaller substation. Fuses are re- Choose current trip units for secondary circuit
quired on the secondary-unit substation not breakers rated for the load current normally
21
IEEE
expected. The continuous-current rating of the feeder circuit breaker time-current character-
circuit breaker should not be exceeded by the istic.
normal rms load current. Set the instantaneous trip setting above the
Set the pickup value of the trip units only asymmetrical inrush of the largest motor to be
slightly above the normal load current ex- supplied by the largest feeder circuit breaker,
pected. Set the long-delay setting to that value and above the maximum normal peak current
required to override the accelerating inrush of expected. This circuit breaker is not expected
the largest motor. Set the instantaneous set- to coordinate with the feeder circuit breaker
ting only slightly above the maximum normal on faults above the instantaneous setting for
asymmetrical value of load current expected. the fully rated system.
This condition may occur when the load cur- As with feeder circuit breakers, sensitive
rent consists of the normal load of the feeder ground fault tripping is recommended on the
plus the inrush current of the motor or motors main circuit breaker, and may be required by
being started. In no case should the feeder cir- ANSI/NFPA 70-1981 [4].
cuit breaker instantaneous trip setting be If selective tripping is desired on the main-
above 80% of the fault current expected at transformer secondary circuit breaker, a trip
the load supplied by the feeder circuit breaker. unit having a short delay instead of the trip
Sensitive ground fault tripping is recom- unit with an instantaneous setting is required.
mended on each feeder to quickly isolate de- As with the selective-trip feeder circuit break-
structive arcing ground faults. Set ground re- ers, the preceding main circuit breaker short-
lays at their minimum settings. time ratings must be observed and either spring
If selective tripping is desired on feeder cir- closing or electric operation must be used. Set
cuit breakers, use a trip unit having a short the short delay on the main circuit breaker for
delay instead of the trip unit with the instan- the intermediate delay if the feeder circuit
taneous setting. However, the use of the short- breaker short delay is set for the minimum de-
time rating of the circuit breaker must be ob- lay. If the feeder circuit breakers have instan-
served. Also, the use of spring closing or elec- taneous-trip units, set the main circuit breaker
tric operation of the feeder circuit breaker is short delay to be selective with the upper tol-
required for selective tripping of faults over erance band of the instantaneous trip char-
14 000 A, symmetrical current, rms. The mini- acteristic. See IEEE Std 242-1975 [6].
mum time band short delay is used for selec- 1.3.10 Locate Secondary-Unit Substations
tive tripping with the instantaneous molded- in Clean Pressurized Rooms. Both the venti-
case circuit breaker used in the control center. lated dry-type and the high fire point or non-
See IEEE Std 242-1975 [6]. flammable vapor-filled secondary-unit substa-
Listed are 480 V alternating-current inter- tion transformers are suitable for use in rooms
rupting and short-time ratings of commonly that are ventilated and cleanly maintained. When
used circuit breakers: located in the plant area or subjected to mois-
ture and dust, the sealed dry-type or high fire
30-Cycle point or non-flammable vapor-filled trans-
Continuous Interrupting Short-Time formers apply. Secondary-unit substation trans-
Rating Rating Rating formers should have terminal chambers to
(A) (RMS symm) (RMS symm) eliminate the settlement of dust and moisture
on exposed bushings, enhancing safety to both
800 30000 30000 personnel and equipment.
1600 50000 50000 1.3.11 Use Delta Primary, Wye Secondary
3200 65000 65000 Connected Secondary-Unit Substation Trans-
formers. (A secondary neutral bushing should
1.3.9.2 Secondary Main Circuit Breakers. be available for grounding each secondary-
Choose the current trip unit and set the current unit substation transformer.) The wye-con-
pickup value at approximately 125% of the nected secondary provides a neutral to ground
transformer full-load current. the system. The delta winding stabilizes the
Set the long delay at the minimum time set- neutral and suppresses harmonic voltages.
ting enabling normal-load operation without When operated ungrounded, the secondary sys-
tripping, and to coordinate with the slowest tem should be equipped with ground detectors,
22
IEEE
CEMENT PLANT POWER DISTRIBUTION Std 277·1983
and a ground should be cleared as soon as In small expansions, the addition of trans-
feasible. former fans or the addition of duplicate elec-
Essentially ungrounded operation can be ef- tric equipment will often satisfactorily serve
fected without the possible hazard of transient to supply power to the new machinery. Larger
overvoltages associated with large secondary expansions may require main plant distribution
systems by use of a 5 or 10 A continuously substation equipment, secondary-unit substa-
rated neutral-grounding resistor. Where a neu- tions, and may be accompanied by partial re-
tral is not available, a 1 112 to 3 kV A zig-zag tirement of existing equipment - either im-
grounding transformer can economically pro- mediately or gradually.
vide a secondary system neutral. When modernizing an electrical installation,
The solidly grounded secondary system is government regulations may require replace-
recommended. See IEEE Std 242-1975 [6]. ment or modification of equipment that does
1.3.12 Design the Secondary System to Limit not comply with Government requirements.
the Voltage Range to ± 10% of Motor Rating. The principles outlined under Section 1 of
Adjust Secondary-Unit Substation Transformer this recommended practice also apply to this
Taps To Have the Rated Transformer Voltage section. In addition, several comments are of-
Available at the Secondary-Unit Secondary fered below for consideration as they apply to
Terminals Under No-Load Conditions. With the expansion of an existing cement plant.
rated transformer voltage available at the sec-
ondary-unit substation, a combined total of 2.1 Consider Changing the Existing 2400 V
approximately 5% voltage drop is allowed to System to 4160 V If the Total Expanded Plant
the motor, for the motor to operate at rated Capacity Will Exceed 10000 kVA (Self-
voltage. Economic factors indicate (see Fig 6) Cooled). The 2400 V system becomes uneco-
that motors 250 hp (200 kW mechanical out- nomical above 10000 kV A. The limited capac-
put) and above should be energized at the ity of switchgear and motor control at 2400 V
4160 V level, or motors 200 hp (150 kW me- limits the substation capacity on a bus. (See
chanical output) and above should be ener- Figs 1-6.)
gized at the 2400 V level, depending on the
distribution voltage available. 2.2 Utility Power for the Existing 2400 V
Where automatic equipment requires closer Equipment Can Be Derived Either from the
regulation than ± 10%, the system design High-Voltage Incoming Line Utility Service or
should consider these special requirements. from the Proposed New 4160 V System with a
1.3.13 Use Metering to Indicate Secondary 4160 V to 2400 V Transformation. (Auto-trans-
Voltage and Current. A visible indication of formers should not be used.) Care should be
secondary-unit substation loading is desirable taken to ensure that the short-circuit capacity
to enable spot checks of equipment operation. of the existing 2400 V switchgear and starters
An ammeter on each feeder circuit breaker is is not exceeded. The double transformation
desirable also, to indicate loading of individual outlined above reduces short-circuit capacity
control centers. at the expense of 4160 V substation capacity.
2.3 Consider Grounding the Existing 2400 V

System Through a Neutral-Grounding Resis-
2. Power Distribution for a Plant Expansion tor or Resistors. The 2400 V transformer could
be delta primary, wye secondary to have a
Many local factors not considered in new secondary neutral available. Where a system
plant construction influence the choice of elec- neutral is not available, derive a neutral by
tric equipment in a plant expansion program. the use of a grounding transformer. Ground re-
Age and condition of existing equipment, lays would be required and should be added on
existence of generation capacity, voltage of existing 2400 V feeders, as most older 2400 V
existing systems, spare capacity available, and systems were initially installed ungrounded.
other factors influence the choice of power Grounding the 2400 V system through a re-
distribution equipment. Thus, it is difficult to sistor reduces fault damage as well as voltage
generalize on recommendations when condi- stress on existing equipment during fault con-
tions vary so widely. ditions. See ANSI/IEEE Std 142-1982 [2].
23
IEEE
2.4 Consider Abandoning Existing Generation is cyclic, and the rms load will normally be
and Purchase Total Power From the Utility. slightly less than the machine continuous rat-
The trend is toward the retiring of existing ing. The 2 kVA/hp rating may result in a slight-
generation capacity and purchasing power ly oversized transformer where several shovels
from the utility, especially if the existing in- are used. However, the transformer size is justi-
stallation is more than 20 y. fied by better voltage regulation and margin
The economics involved in continuing or for additional loads. A larger distribution
abandoning generation depends heavily upon transformer capacity is required to keep volt-
local conditions. Coordination with the utility age regulation within tolerable limits during
is required when generation is to be paralleled full-voltage starting and peak loading of mo-
with the utility system. tors that approach the size of the substation.
3.1.2 Use a Delta Primary, Wye Secondary
2.5 Consider the Use of Interlocked Armored
Isolation Transformer to Supply the Quarry
Cable Carried on Trays. The addition of new
Equipment When the Power Source to the
circuits in an existing installation is often re-
Quarry is Not Already Safety Resistance
quired after the duct system is filled up and
Grounded. Almost all existing cement-plant
new ducts or conduits are found difficult to
main substations are either solidly grounded,
install. The installation of armored cable on
low-resistance grounded, or ungrounded at
racks or trays is particularly convenient as
the primary distribution-voltage level. Thus,
ducts are not required. Interlocked armored
a quarry distribution transformer is almost al-
cable should include ground wires to ensure
ways required to isolate the main-plant system
an adequate return-current path during fault
from the quarry system and enable the high-
conditions. Where interlocked armor is subject
resistance safety grounding of the quarry port-
to corrosion, a protective coating on the armor
able equipment. A fully insulated transformer
is recommended. Galvanized steel armor is pre-
secondary neutral bushing should be available.
ferred over aluminum to minimize alkali at-
See Fig 9.
tacks.
3.1.3 Use an Automatic Circuit-Interrupting
Care must be taken to ensure that NEC and
Device on the Quarry Substation Primary. The
plant insurance fire protection requirements
primary protective device is a circuit breaker
are met for tray installations. Trays must be
or a high-capacity fused starter. Use of these
located in protected areas.
automatic devices allows the use of protective
relays which are sensitive to the low secondary
ground-fault currents, and operate to isolate
ground faults not seen by primary fuses. Use of
only primary fuses and a secondary circuit
3. Quarry Distribution breaker results in an area of unprotected ex-
posure on ground faults between the trans-
Special problems exist in the quarry that are former and the secondary breaker. A means of
not normally problems in the plant proper. The remote tripping a primary breaker on these
use of portable equipment and the widely vary- ground faults should be provided.
ing ground impedance that exists in the quarry 3.1.4 Use a Safety Neutral Resistance-
necessitate grounding precautions to minimize Grounded System at the Primary Distribution
shock hazards. Also, the use of long lines and Voltage in the Quarry. The safety grounded
cables feeding concentrated loads gives rise to system recommended for quarry operations
voltage-regulation problems. requires the limiting of single line-to-ground
This part of the recommended practice out- fault current to a low value and carrying a
lines preliminary recommendations for the ground wire from the resistor's earth ground
quarry distribution system. point to the frames of the portable equipment.
Resistors commonly used limit the maximum
3.1 Quarry Distribution Transformer ground-fault current flow to either 25 or 50 A.
3.1.1 Size the Quarry Distribution Trans- The final result desired from the system is to
former at Approximately 2 kVA per Con- limit equipment-frame-to-ground voltage to
nected Horsepower. The load reflected by less than 100 V during single line-to-ground
shovels and draglines during normal operation faults. In addition to limiting frame-to-ground
24
IEEE
r- l~WE.:FROMMA~ 'CAN' SUBS;AnoN
r------
I
__ ¢
ISOLATION
CIRCUIT
BREAKER
lI
I
TRANS-~
FORMER
~
I r-.r--..r--..r-.
I
I
I
CB
SAFETY GROUND- _ I CABLE OR OVERHEAD LINES ON POLES

<5£1 - I
50 It (15 m) FROM :
SUBSTATION GROUND GRID ......
I \
I \
I I
I I
~
I \ '''''o!::==::::Y
'--_ .... SWITCHHOUSE
SAFETY GROUND WIRE I SHOVEL
I
I
Fig 9
Quarry Distribution
voltages to safe levels, the safety grounded sys- ground faults. The unfused potential trans-
tem limits the damage to equipment during former with the primary connected across the
25
IEEE
Std 277·1983 IEEE RECOMMENDED PRACTICE FOR
grounding resistor and its secondary connected portable equipment during a ground fault is
to an inverse time potential relay will initiate subject to the approximate voltage drop in the
the isolation of the supply on ground faults, ground wire.
even with an open circuit in the ground re- Thus, the product of maximum ground-
sistor. See ANSI/IEEE Std 142-J.982 [2]. fault current and ground-wire impedance
3.1.5 Use an Extended Time Rated Neutral- should be kept below 100 V to be considered
Grounding Resistor to Limit Single-Line-to- safe.
Ground Fault Current. Use of an extended With the ground-wire impedance of 2 nand
time rated resistor helps ensure that the ground- a 50 A neutral resistor, the frame-to-ground
ing system will not be rendered ineffective if voltage would be approximately two times 50,
for some reason a ground fault is not immedi- or 100 V. If ground-fault current were limited
ately isolated. The resistor and ground wire to 25 A, the frame-to-ground voltage would be
combination will continue to limit fault cur- about 50 V during the ground fault, with a 2 n
rent and frame-to-ground voltage as long as the ground wire.
ground fault is on the system. Grounding Loss of the safety ground wire renders the
transformers, where used to derive a neutral, safety grounded system ineffective against
should be continuously rated and be of low shock hazard. Continuous monitoring of
(2% to 5%) impedance. See ANSI/IEEE Std ground-wire continuity is required and iso-
142-1982 [2]. lates the circuit in the event of an open circuit
3.1.6 Separate the Quarry Distribution Sub- either in the cable pilot wire or ground wires.
station Ground Grid from Safety Ground Grid. An extremely low voltage of less than 24 V
A minimum distance of 15 m (50 ft) is recom- should be utilized as the power source to
mended. This separation helps minimize the eliminate personnel shock hazards.
voltage of the safety ground wire due to the The pilot wire can also be used for remote
rise in substation ground grid potential during tripping of the primary breaker and electrical-
primary ground faults and lightning surges. Re- ly interlocking cable receptacles and switches.
sistance to earth of the main grid should be See ANSI/IEEE Std 142-1982 [2].
no more than 2 n. The safety ground grid
should be no more than 5 n to earth. 3.2 Primary Distribution
In some areas where the earthen ground con- 3.2.1 Design the Quarry Primary Distribu-
ditions are very poor, an elaborate grid system tion System to Realize Not Less Than Rated
may be required in order to meet these re- Portable Equipment Voltage in Normal Opera-
sistance-to-earth ohmic values. tion. A 20% system voltage drop at the motor
The burial of metal pipes, water lines, etc, terminals during motor starting is acceptable.
should not reduce the 15 m (50 ft) minimum Shovel and dragline motors are usually rated
separation between the substation ground grid approximately 10% below system transformer
and the safety ground grid. voltage, so that a 10% system drop is allowable
All of the substation equipment, frames, for normal operation. For example, shovel and
fence, structures, and lightning arresters tie to dragline motors are rated 3810 V for a 4160 V
the substation ground grid. The safety ground system and 2200 V for a 2400 V system. Nor-
grid ties only to the safety ground wire at the mally, industrial motors are rated 4000 and
substation. The safety ground wire should be 2300 V when used on 4160 and 2400 V sys-
insulated in the vicinity of items grounded to tems, respectively.
the main ground grid, so a person does not 3.2.2 Use a Pole Line to Distribute Power at
bridge two grounds. See ANSI/IEEE Std 142- the Primary Distribution Voltage From the
1982 [2]. Quarry Distribution Transformer to the Quar-
3.1.7 Limit Impedance of the Ground Wire ry Portable Equipment. The use of a pole line
Connecting the Safety Ground Grid to the to carry power to the area of the portable ma-
Portable Equipment Frame So That the Frame- chine is desirable to keep cables off the ground
to-Ground Voltage Will Be Held to a Safe and less subject to damage from quarry equip-
Value During Single-Line-to-Ground Faults. ment. This pole line could be messenger cable,
A figure of 100 V has been used as a safe maxi- mine power cable, or open wire.
mum in quarry system design. A man standing The use of open-wire line is preferred by
on earth and touching the frame of the some engineers since the open line provides a
26
IEEE
degree of flexibility at the lowest cost. Damages Overhead Feeder Lines and the Large Rotating
to the line which occur during normal opera- Apparatus in Addition to the Surge-Protective
tions can be repaired at a lower cost with a Equipment Used at the Quarry Substation.
minimum of down time. However, the voltage Surge arresters should be installed at either end
regulation of the open line is usually greater of the overhead lines and at each tap point
than cable because of the relatively high reac- feeding loads at primary distribution voltage
tance. Consider voltage drop carefully, espe- and earthed greater than 15.m (45 ft) from the
cially during shovel and dragline motor-genera- safety ground connections to earth. For equip-
tor set starting, when using the open line. A ment protection, surge arresters and surge
fourth conductor, to carry the quarry distribu- capacitors should be located close to (less than
tion transformer safety ground to the vicinity 1 m [3 ft] from) the terminals of the equip-
of the portable machines is required. See ANSI ment to be protected, and connected to low
C2-1981 [1]. surge impedance grounds. Additional protec-
The messenger cable with suspension line has tion is recommended by placing surge arresters
less reactance than open line and should be 500 to 650 m (1500 to 2000 ft) ahead of
considered when voltage regulation is a prob- terminations going to rotating equipment.
lem. The suspension line can be used as the Surge arresters for the high-resistance safety
ground wire to carry the safety ground to the grounded system used in the cement-plant
portable cables. However, care must be used to quarry should be rated for line-to-line voltage.
ensure that the over-all ground wire impedance Surge arresters are required by Mine Safety and
from the quarry substation to the portable Health Administration regulations. 3
equipment at the distribution voltage is less 3.2.5 Use Portable Switchhouses To Protect
than 4 n (with the 25 A safety ground source) the Quarry Portable Equipment. Portable
or less than 2 n (with the 50 A safety ground switchhouses include circuit breakers which
source). enable automatic isolation of the faulted
Mine power cable with individual conductor equipment on both phase and ground faults.
shielding and ground wires in the cable inter- A switch or other means of providing a visible
stices offers a greater degree of safety at greater means of circuit isolation is desirable ahead of
cost. The voltage regulation is the lowest of the the switchhouse circuit breaker.
above lines, and ground wires are built into The switch or other means of providing the
the cables for carrying the safety ground to the visible means of circuit isolation could be at
area of the portable equipment at the distribu- the tap point of the cable at the pole line,
tion voltage. Phase-to-phase faults are dis- in the switchhouse enclosure, or both. In any
couraged by the individually shielded conduc- event, for safety reasons it is desirable to inter-
tors. Cables with a pilot wire are available to lock the disconnect means with the switch-
enable the continuous monitor of ground-wire house circuit breaker to prevent the discon-
continuity, a valuable safety feature. nect from being opened under load. Where the
Mine power cable is the most difficult to re- switchhouse is located remote from the pole-
pair, requires the greatest care in splicing and line termination, a disconnect in the switch-
terminating, and ground faults on the safety house, mechanically interlocked with the cir-
grounded system are difficult to locate. How- cuit breaker, is desirable, providing a local vis-
ever, the safety features and good voltage reg- ible means of circuit isolation. See Fig 9. Also
ulation inherent in the all-cable system are see 3.2.8 on cable plugs and receptacles, and
felt to outweigh these disadvantages. The trend 3.1.7 on the use of a ground-wire monitor.
is toward the all-cable system. 3.2.6 Trailing Cables for Shovels, Draglines,
3.2.3 Size the Pole-Line Conductors To Be and Drills Used in the Quarry Should Be Manu-
Adequate for the Thermal Capacity and Volt- factured to ICEA Standards. 4 (The Cable
age Regulation Required in the Quarry. Cables
and open-line conductors based on thermal 3 Mine Safety and Health Administration documents
capacity alone may result in prohibitive voltage are available from the Superintendent of Documents,
regulation. Consider the overall system voltage U.S. Government Printing Office, Washington, DC
20402.
regulation as outlined in 3.2.2 when choosing
4 ICEA standards are available from the Insulated
conductor sizes. Power Cable Engineers Association, 192 Washington
3.2.4 Provide for Lightning Protection of Street, Belmont, Mass 02178.
27
IEEE
Classification should be Type SHD.) The Type 3.2.9.1 Quarry Substation Primary Breaker
SHD cable is recommended for portable equip- (1) Phase: Very inverse, moderately inverse,
ment since it is designed to provide the flexibil- or inverse time relays, or equivalent, with in-
ity required for this type of service. The braided stantaneous-trip attachments to isolate danger-
shield over each conductor plus the increased ous overloads and faults.
conductor stranding allows the cable to be Instantaneous trips should be set above the
handled with much less danger of damaging maximum secondary asymmetrical fault cur-
the cable. rent (referred to the primary) available at the
Type SHD cable provides the greatest de- transformer. Time settings are to coordinate
gree of safety to both personnel and equip- with the switchhouse breakers and with back-
ment, since a shield surrounds each power con- up breakers supplying the quarry substation
ductor. Type SHD cable includes ground con- from the main plant substation. Allow a mini-
ductors to carry the safety ground to the port- mum of 0.4 s (at maximum fault) longer time
able equipment at the distribution voltage. for the main breaker relays than the switch-
Also, Type SHD cables are available with a house phase relays.
pilot wire to enable the continuous monitor of (2) Isolating Transformer-Primary Ground
groundwire continuity, a valuable safety fea- Protection: Inverse, very inverse or extremely
ture. inverse time relay, or equivalent, to be ener-
3.2.7 Trailing Cables Should Be Handled gized from the current transformer(s) located
with Care and Maintained Properly. The life in the primary breaker. This relay will operate
of a trailing cable depends heavily upon the to trip the breaker on primary ground faults.
amount of mechanical handling and abuse to Pickup should be less than 10% of the maxi-
which the cable is subjected. Cable life is se- mum available ground-fault current.
riously reduced by dragging, by kinking from (3) Isolating Transformer-Secondary Ground
too short a bending radius, and by crushing Backup Protection: Extremely inverse, very
from vehicle traffic and rock slides. Store sur- inverse, or moderately inverse time relay, or
plus cable on skids. equivalent, to be energized from the current
Consideration should be given to grounded transformer located in the substation trans-
stress cones on the ends of cables since the lack former-secondary neutral. This relay operates
of stress cones is a major contributing factor to to trip the primary breaker on secondary
cable faults. ground faults, and is to coordinate (by time)
All splices should be done by an experienced with the instantaneous ground relays located
splicer and according to the cable manufac- in the switchhouse. Additional protection is
turer's recommendations. obtained by utilizing a potential transformer
and relay as discussed in 3.1.4.
3.2.8 Use Cable Plugs and Receptacles To When a high-capacity fused starter is used
Facilitate Equipment Moves in the Quarry. for primary protection, the contactor to be re-
Multiconductor cable receptacles are avail- layed should be capable of interrupting the
able with ground, phase, and pilot-conductor current it may be expected to interrupt. Fuses
prongs. This enables quick connecting and will not see the ground-fault current as limit-
disconnecting of de-energized circuits in the ed by the neutral-grounding resistor in the
quarry. The pilot prong separates first upon quarry transformer secondary neutral. The con-
disconnecting the plug and receptacle, enabling tactor operates on ground faults. and the fuses
electric interlocking so that the backup circuit back up the contactor on severe phase faults.
breaker trips to protect the worker who inad- See IEEE Std 242-1975 [6].
vertently attempts to disconnect an energized
cable receptacle. Cable receptacles are also 3.2.9.2 Quarry Distribution Transformer
available with provisions for key interlocking Secondary Breaker (When Used Instead of
to mechanically prevent them from being Primary Breaker)
connected or disconnected while energized. (1) Phase: Very inverse, moderately inverse,
3.2.9 Special Sensitive Relaying is Required or inverse time relays, or equivalent, to quick-
in the Quarry Because of the Low Ground- ly isolate dangerous overloads and faults. The
Fault Currents Involved. Suggested Relaying time setting is to coordinate with switchhouse
Is Outlined As Follows: breakers and backup breakers supplying the
28
IEEE
quarry from the plant distribution substation. Loads at the Utilization-Voltage Levels of
(2) Ground: Extremely inverse, very inverse, 600 V and Below. Again, the limiting of
or moderately inverse, time relay, or equiva- ground-fault current to a low value (25 A or
lent. This relay is energized from a current less) and using a metallic ground wire to the
transformer in the substation transformer frame of the connected electric equipment is
neutral and is to coordinate (by time) with recommended to maintain safety to shock
the switchhouse relays. See 3.1.4 for poten- hazards. It is not required to separate the low-
tial transformer and relay scheme. voltage safety ground grid from the safety
See 3.1.3 on primary breaker recommenda- ground at the primary distribution-voltage
tions. level since the safety grounded system at the
primary distribution-voltage level limits the
3.2.9.3 Switchhouse elevation of the low-voltage substation sec-
(1) Phase: Long time or inverse time relays, ondary frames from earth potential.
or equivalent, with instantaneous-trip attach- A delta primary, wye secondary transform-
ments, to override the shovel and dragline ac- er (with fully insulated neutral) is preferred.
celerating inrush and yet provide some mea- Where a secondary neutral is not available, a
sure of cable thermal protection. Phase faults small (approximately 5 kVA) zig-zag ground-
are instantaneously relayed. These above relays ing transformer is used to derive a neutral.
are to coordinate with back-up protection. Continuously rated grounding transformers
(2) Ground: Instantaneous. This relay should and resistors should be used.
be energized from a balanced flux current Air circuit breakers usually provide sec-
transformer (window type) to realize sensitive ondary protection for feeder circuits. Phase
instantaneous ground relaying without the protection is effected by inverse time and in-
nuisance tripping associated with residual- stantaneous trip units. Ground-fault relaying
current relaying on circuits feeding large is effected by balanced flux current trans-
motors. Pickup value of this relay should be as formers energizing sensitive ground-fault trip-
low as feasible to pick up high-resistance faults. ping for each feeder circuit. See ANSI/IEEE
At least a pickup value of 25% of the maxi- Std 142-1982 [2].
mum ground-fault current is desirable to pro-
tect 75% or more of motor and transformer
windings on ground faults. See IEEE Std 242-
1975 [6].
3.3 Distribution 600 V and Below 4. Harmonics

3.3.1 The Capacity of the Portable Quarry
Low-Voltage Substation Should Be Approxi- 4.1 General. With the trend toward more and
mately 1 kVA per Connected Horsepower. Ca- larger thyristor controlled equipment, the pos-
pacity is also influenced by the maximum volt- sibility of harmonic problems on cement plant
age drop tolerated. Voltage range for the sec- power distribution systems must be consider-
ondary quarry system should be within 10% ed. These problems may be manifested in elec-
of rated motor voltage. trical noise, damaging harmonic voltages as-
sociated with parallel resonance, and excessive
3.3.2 Use Portable Cables to Feed Portable fuse blowing on capacitors.
Loads at 600 V and Below. The same ad- General considerations only are noted here.
vantages from using the portable cable with These are offered as a guide. Where rule-of-
ground and pilot wires in the interstices at the thumb limits are approached, it is recom-
primary distribution-voltage levels are also mended that appropriate filters and isolating
available at the 600 V and below level. It is transformers be included in the design to sup-
also desirable to use shielded cable to the port- press harmonics.
able low-voltage equipment to discourage
phase-to-phase faults, enhancing safety to both 4.2 General Considerations
personnel and equipment. 4.2.1 Make a Study to Determine the Short
3.3.3 Use the Safety Neutral Resistance- Circuit Ratio on the Plant Load Bus, that is,
Grounded System for Feeding the Portable Primary Distribution Voltage. A rule-of-thumb
29
IEEE
Std 277-1983
is that if the short-circuit ratio is more than 20, 5. References

the possibility of hannonic problems is low.
Short Circuit Ratio = When the following Standards referred to in
load bus short circuit MV A this recommended practice are superseded by
an approved revision, the revision shall apply:
total converter MW
[1] ANSI C2-1981, National Electrical Safe-
4.2.2 Make a Study to Determine the Prob- ty Code. 5
ability of Harmonic Problems with Shunt
Capacitor Banks. [2] ANSI/IEEE Std 142-1982, IEEE Recom-
mended Practice for Grounding of Industrial
Frequency (per unit) = and Commercial Power Systems.
load bus short circuit MV A)1fz [3] ANSI/IEEE Std 446-1980, IEEE Recom-
( capacitor bank MV A mended Practice for Emergency and Standby
Power Systems for Industrial and Commercial
If the per unit frequency is close to the 5,7, Applications.
11, or 13th harmonic, there is a probability of
producing excessive harmonic voltages and cur- [4] ANSI/NFPA 70-1981, National Electrical
rents, since the SCR equipment (6 pulse) Code. 6
typically generates 6N ± 1 hannonics. [5] IEEE Std 141-1976, IEEE Recommended
4.2.3 Isolate Harmonic Generating Equip- Practice for Electric Power Distribution in In-
ment from the Plant Bus by Isolating Trans- dustrial Plants.
formers. Use of isolating transformers helps
prevent the electrical noise from affecting [6] IEEE Std 242-1975, IEEE Recommended
other equipment. Practice for Protection and Coordination of
Industrial and Commercial Power Systems.
5 This document is available from the Institute of

Electrical and Electronics Engineers, Service Center, 6 The National Electrical Code is published by the
445 Hoes Lane, Piscataway, NJ 08854. It is also avail- National Fire Protection Association, Batterymarch
able from the Sales Department, American National Park, Quincy, MA 02269. Copies are also available
Standards Institute, 1430 Broadway, New York, NY from the Sales Department, American National Stan-
10018. dards Institute, 1430 Broadway, New York, NY 10018.
30

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IEEE Std 277-1983

IEEE Recommended Practice for

September 12, 1983 SH09035

IEEE Recommended Practice for

The Institute of Electrical and Electronics Engineers, Inc

No part of this publication may be reproduced in any form,

Fig 1 Economic Comparison of Double-Ended Substations 10

adequate margin. Ground-fault current should A typical suggested substation size is

3000 5000 7500 10 000 20000

kVA SUBSTATION CAPACITY

2500 3750 5000 7500 10000 20000

kVA SUBSTATION CAPACITY

3·1/C POWER CABLE

480 2400 4160 7200 13 BOO

300 500 750 1000 1500 2500

CURVE A INCLUDES SUBSTATION FROM 13 BOO TO 4160 V at 2 kVA

15 L-. +- -+- -+ --+ +-- -+- -+__

460 V CURVE INCLUDES MOTORS, CONTROLS

25 50 75 100 150 200 300 500 1000

~-_. 'NDDDR'''O~ t:l

9;~gK 9 9 9~,~~:» 9~~~

Typical Cement-Plant Distribution System oot':l

/:: / / [~J ~2~~~4_J

2.3 Consider Grounding the Existing 2400 V

r- l~WE.:FROMMA~ 'CAN' SUBS;AnoN

SAFETY GROUND- _ I CABLE OR OVERHEAD LINES ON POLES

3.3 Distribution 600 V and Below 4. Harmonics

is that if the short-circuit ratio is more than 20, 5. References

5 This document is available from the Institute of

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