Commissioning & Maintenance

of Protective Relays
Test Options (1)

1. Primary injection sensitivity tests only

Minimum of time consumed

If results incorrect, secondary injection and CT tests
required
Unable to check :-
a. Adequate timing curves
b. Directional properties
c. Power and impedance relays
Not suitable for maintenance tests
Test Options (2)

2. Secondary injection tests

(But with C.T.s still connected)

True primary sensitivity easily equated

If results incorrect isolated relay and CT mag.

curve checks necessary

Ref. for maint., but system outage required

Primary tests on C.T. ratio and polarity still

required on commissioning
Test Options (3)

3. Secondary injection tests

(But with relays isolated by test facility)

Proof of isolated relay characteristic obtained

Ref. for maintenance obtained

(relay if necessary tested with system on load)

Full primary injection/on load tests done on

initial commissioning only
Test Options (4)

4. On load tests

Checks that expected C.T. / V.T. quantities

present at test facility

Scheme stability for external faults

Proof of correct directional characteristics

Summary

Arevas preference:-

1. Secondary injection (isolated relay)

2. Primary injection
(incl. C.T. ratio, phasing and mag. curve)

3. On load tests
Site Testing and Commissioning
of Protection Equipment

To assure ourselves, and the interested authorities, that

the overall protective system functions correctly

Resist pressures to take risks

Study wiring diagrams and protection requirements

Key diagram
Delegate responsibilities
Observe safety of self and others
Commissioning Flow Chart
Summary (1)

To assure ourselves, and the interested

authorities, that the overall protective
system functions correctly.

Study of wiring diagrams and protection
requirements.

Careful delegation of responsibilities to
reduce the duplication of effort and to
ensure that all the following aspects are
covered :-

Commissioning Flow Chart
Summary (2)

Insulation Tests

Secondary Injection Tests (Relay Tests)
Ensure clean dust free area
Mechanical inspection
Out-going contact wiring
External resistors
C.T. shorting and isolating switches
Contact follow-through and pressures
Electrical checks on each basic electrical function to
prove satisfactory operation
Prove trip and alarm circuits
Test results (record and maintenance purposes)

Commissioning Flow Chart
Summary (3)

Primary injection tests

D.C. flick tests on C.T.s

C.T. mag curve tests
C.T. ratio and polarity tests
Primary sensitivity tests
Stability tests
Test results

Commissioning Flow Chart
Summary (4)

z Line / Transformer / Generator energisation

z V.T. ratio and phasing tests

z On load tests
z Stability tests
z Directional properties

At the end of each stage ask yourself :-

Is there anything wrong, wiring or otherwise, that I
have not checked that may prevent correct operation?
If so, CHECK IT OUT !
 z Measuring instruments
z D.C. auxiliary supplies
Peak 1.6 x AV.

Average D.C.

0V.

Mean D.C. Peak to Peak V

<12% of mean D.C. comp.

0V.

z Faulty relays
Maintenance of
Protective Relays (1)

Frequency of Maintenance

Dictated by :-
a) The site condition
b) The availability of maintenance staff and
resources
c) The availability of plant outage times
d) The risks involved if the protection should fail
e) The type of relay construction
Maintenance of
Protective Relays (2)

Frequency of Maintenance (continued)

f) The proven reliability of devices under

identical site conditions
g) The availability of built-in self-check features
or semi-automatic test facilities, and the
difficulties of alternative tests
h) The interval of time an unexpected catastrophic
failure, component or otherwise, that may go
undetected and leave the system unprotected
Maintenance of
Protective Relays (3)

Onerous site conditions :-

1. Dusty or dirty environments

2. Corrosive chemical atmospheres
3. Frequent or continuous vibration
4. High humidity
5. High or cycling temperatures
6. Consistently high levels of energising or auxiliary
quantities

Typically maintain every 12-18 months under ideal

conditions and decrease frequency
Maintenance of
Protective Relays (4)

z Visual inspections

The commissioning test stage

At each maintenance test
After heavy fault clearance
More regularly if onerous site conditions

z Calibration tests
z Trip testing
Maintenance of
Protective Relays (5)

Recommended maintenance tests

Instruction manuals
Record relay settings
Visual inspection
Secondary injection tests
Contact integrity
Return to in-service settings
Check energising quantities
Maintenance of
Protective Relays (6)

z Relays involving static (electronic) components

Electro-static discharge (ESD)

Wrist straps

z Modern static relays (K-SERIES, MiCOM etc.)

Fault find to board level only

Protect boards
Corrective Maintenance of
Protective Relays (1)

Cleaning solvents
Trichlortrifluorethane (Ozone damaging)
(Arklone, Freon, Flourisol and Supersolve)
PROZONE
Contact lubricants and other lubricants
Contact cleaning burnishers
Contact pressures and settings
Dust removal
Relay recalibration (Why?)
Contents of Section 23 of PRAG (1)
(Protective Relay Application Guide)

z Insulation tests
z Current transformer tests
z Voltage transformer tests
z Test facilities
z Secondary injection tests O.C. and E.F.
Differential
Pilot wires
Negative phase sequence
Directional
Distance
D.C. operated
Contents of Section 23 of PRAG (2)
(Protective Relay Application Guide)

z Primary Injection Test (+ on load tests)

O.C. and E.F. relays
Directional
Generator Differential
Transformer Differential
Restricted E.F.
Pilot Wire
Busbar
Negative phase sequence
Contents of Section 23 of PRAG (3)
(Protective Relay Application Guide)

z Tripping and Alarm Annunciation

z Periodic Maintenance

In addition to PRAG :-

Consult instruction manuals

 Test Terminal Block

To relay coils

A B C A B C N A B C N
To CT test To main To main VT
windings current
(if any) transformers
 Test Switch and Sockets
To relay coils

A A
Current B B Voltage
test
sockets C C test
sockets
N N

Test selector switch

Make before break
on CT Circuits

To main current To main VT

transformers
Current Transformer
Polarity Check

P2 P1

- S2 S1 +

Push
button
- + switch
A

Battery
Current Transformer
Ratio Check

A B C Test plug
A2 insulation
Temporary 51
short
circuit
51
P1
S1
51

64
P2 S2
Relay or test block
A1
contact fingers
Primary injection
test set
250V AC supply
 Testing Current Transformer
Magnetizing Curve

A B C Test plug isolating

current transformers
from relay coils
Variable
transformer
250V 8A
A
250V
To relay AC
P1 coils supply
S1 V

S2
P2
Main circuit Step-up transformer
breaker open if required
Voltage Transformer
Phasing Check
A
B
C A
V1
V2 C B

VN
V
VL
V1

V2

A B C Phase rotation
meter
 Overcurrent Test Set

Fine control Coarse A

variable Range
control adjusting CT
transformer reactor

K1 I
K2
250V
AC 51 Relay
supply coil

Start Stop
timer timer

Supply Backing Injection

switch transformer Medium transformer Relay short-
10% control control circuiting switch
reactor
Relay current I = Ammeter reading (A) x K1 K2
 Basic Current Control Circuit
of CFBA Test-Set

A
60Hz
L1 L2
50Hz
0.1A
10X 5X 2X 1X
0.2A

O/V Detector
220/250V
AC 60Hz

Circuit
0.5A Output
Supply to
Variac V1 50Hz
50/60Hz 1A Relay
2A

5A
Supply Shorting 10A
Switch Timer
Supply T1 Injection
Contractor Start Matching
(Break to Start) C.T.
Thermal Overload / Overvoltage
Protection
Sensitivity Check on
Biased Differential Relay

B B
OP

Test plug
fingers

To main current
Overcurrent transformers
test set
250V
A.C. supply
OP Relay operating coil
B Relay bias coil
Testing Bias Characteristics
(Using Overcurrent Test Set)

B B
OP
I1+I2 I1 I2
Test plug
fingers
A1 A2

R
To main current
transformers
Overcurrent
test set
250V A.C.
supply
Testing Relay Bias Characteristic
(Using Resistances)

B B
OP
I1+I2 I1 I2
Test plug
fingers
A1 A2

R1 R2
To main current
transformers

250V A.C. A1 and A2 Ammeters

supply OP Relay operating coil
B Relay bias coil
Sensitivity Test

Feeder isolated
A
B
C

Test Relay
plug Overcurrent 250V
contact
test set A.C. supply fingers

B B
OP OP

Pilots
 Testing Sensitivity of Negative
Phase Sequence Relay

A
To main
current B Relay
46
250V transformers coil
A.C. C
supply
Overcurrent N
test set Test plug Filter
in test block network
Test Equipment for
Directional Relays
Supply switch
A 440V
B 3 phase
C 4 wire supply
N
Variable Choke
transformer
for current Relay
67
control current coil
Range adjusting CT
440/110V
phase shifting A PA
transformer
PA Relay
V 67
voltage coil
Variable transformer
for voltage control
To other voltage coils V Voltmeter
of relay under test A Ammeter
(if required) PA Phase angle meter
Primary Injection Test Set

A
250V A.C.
supply

Variable transformer 40A

Injection transformer
250/10 + 10 + 10V
10kVA
 Primary Check on
Main Current Transformers

Temporary three-
phase short circuit
Primary A
51
injection
test set B
51
250V
A.C. supply C
51

51 Overcurrent relay
64 Earth fault relay A 64

A Ammeter
Sensitivity Test on
Earth Fault Relay

250V
Primary injection
A.C. test set
supply

A 51

B
51

C
51

64
Load Test on Directional
Overcurrent Relays
Direction of power flow
A B C for relay operation Load current

A PA
A PA V

AA Ammeter
B
Ammeter
VV Voltmeter
Voltmeter
PA Phase C
PA Phaseangle
angle
meter
meter Directional overcurrent relays
Test Plug Link Connections to
Reverse Current seen by Relay
To relay

20 19 18 17 16 15 14 13 12 11

1 2 3 4 5 6 7 8 9 10
Test plug

To main VT and CT
 Load Test on Directional
Earth Fault Relay
ABC P1 P2 Load current
S1 S2

V1
IA Temporary
short circuit V2
connections
A Insulating strips in
51
relay or test block VL VN
51 51 PA contact fingers V

PA

A Ammeter
V Voltmeter Directional earth
PA Phase angle meter fault relay
Testing Sensitivity of Generator Differential
Protection Using Primary Injection Test

87 Generator differential relay

Primary injection 250V A.C. supply V Voltmeter
test set A Ammeter

A Generator Isolating links

A
B
C

87 87 87
V
Testing Sensitivity of Generator Differential Protection
Using Generator to Supply Primary Current

Temporary
short circuit Isolating
Generator links
A
B
C

87 87 87
V

87 Generator differential relay

V Voltmeter
Checking Stability of Generator
Differential Protection

Temporary
Isolating short circuit
Generator links
A
B
C

A A A

87 87 87

Shorts across relay/

stabilising resistors 87 Generator differential relay
A Ammeter
 Earth Fault Sensitivity Check on
Transformer Differential Protection

Temporary
short circuit
A A
B
Primary
injection
test set
C
250V
A.C.
supply Bias coils

Operating 87 87 87
coils
 Phase Fault Sensitivity Check on
Transformer Differential Protection

Temporary
A short circuit
A
Primary
injection
B
test set
C
250V
A.C.
supply Bias coils

Operating 87 87 87
coils
 Stability Check on Transformer
Differential Protection

Generator Temporary short circuit

~
Bias coils
A

87 87 87
Operating coils
Instantaneous current distribution for three-phase
short circuit with phase A current at maximum
Sensitivity Check of Restricted Earth
Fault Protection

250V A.C.
supply A

Primary
injection
test set A
B
C

64 Earth Fault Relay 64

A Ammeter
V Voltmeter V
Stability Check of Restricted Earth
Fault Protection

250V A.C. supply

A Temporary short circuit
Primary
injection
test set A
B
C

64 Earth Fault Relay

A 64
A Ammeter
Sensitivity Check of Negative Phase
Sequence Relay

A B C

Temporary
short circuit
Filter 46
network

Primary injection
test set

250V 46 Negative phase sequence relay

A.C. supply A Ammeter
Test Plug Link Connections for
Load Current Test
To relay
filter network

20 19 18 17 16 15 14 13 12 11

1 2 3 4 5 6 7 8 9 10

A B C N
Earth Fault Sensitivity Check of
Pilot Wire Relay

A A

B
C
Primary
injection
test set

B 250V A.C. supply

OP
Pilots to remote
end relay

B Relay bias coil OP Relay operating coil A Ammeter

Phase Fault Sensitivity Check
of Pilot Wire Relay
A B C

OP

B Relay bias coil

OP Relay operating coil
A Ammeter

Primary
injection Pilots to remote
test set
end relay
250V A.C. supply
 Load Current Distribution
A B C A B C
Feeder

Instantaneous current
distribution of three-phase
balanced load with B
B
phase A current at
OP OP
maximum

Pilots
Short-Circuiting Connections on Test
Plug for Load Test

To relay summation CT
Short circuiting connections
on rear of test plug

20 19 18 17 16 15 14 13 12 11

1 2 3 4 5 6 7 8 9 10

A A B C N
To main current
transformers
 Ratio Check of Current Transformers
of Reference Circuit

A1

250V A.C.
supply
Primary injection A2
test set Test links

A
B Zone
C bus wires
N
A1 and A2 Ammeters
87 Busbar Protection relay
95 Supervision relay 95X
95 87 87 87
95X Bus wires short-circuiting
relay
 Polarity Check of Reference Circuit
Current Transformers
A Ammeter A B C
Temporary short circuit
87 Busbar Protection
relay A
95 Supervision relay
95X Bus wires short-
circuiting relay

Test links
A
250V A.C.
supply A
B Zone
Primary injection C bus wires
N
test set
95X

95 87 87 87
 CT Inter-Group Ratio and Polarity
Check in Busbar Protection Scheme
Reference circuit Test circuit

Temporary
short circuit Test
links
A
A1 A1 A1 A1
250V A.C. supply

A
Primary injection

B
C
test set

N
Zone
A1 Ammeter for ratio check A2
A2 Ammeter for polarity A2
bus
check A2 wires
87 Busbar protection relay 95X
95 Supervision relay 95 87 87 87
95X Bus wires short-
circuiting relay
 Sensitivity Check of Busbar
Protection Scheme
A B C

250V A.C.
supply
Primary injection
test set Test links

A
B Zone
C bus wires
N

95X

V 95 87 87 87
Stability Test

A
B
C

Test Test
plug Overcurrent plug
test set

250V
B A.C. supply B
OP OP

Pilots