Protective Relay Testing and Commissioning

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
> Commissioning & Maintenance of Protective Relays
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
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 :-

Summary (2)
Insulation Tests
Secondary Injection Tests (Relay Tests)
Ensure clean dust free area
Prove trip and alarm circuits
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
Test results (record and maintenance purposes)

Summary (3)
Primary injection tests
D.C. flick tests on C.T.s
C.T. ratio and polarity tests
Primary sensitivity tests
Stability tests
Test results
C.T. mag curve tests

Summary (4)
Line / Transformer / Generator energisation
V.T. ratio and phasing tests
On load tests
Stability tests
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 !
10
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
11
Maintenance of
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
12
Maintenance of
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
13
Maintenance of
Visual inspections
The commissioning test stage
At each maintenance test
After heavy fault clearance
More regularly if onerous site conditions
Calibration tests
Trip testing
14
Maintenance of
Recommended maintenance tests

Instruction manuals
Record relay settings
Visual inspection
Secondary injection tests
Contact integrity
Return to in-service settings
Check energising quantities
15
Maintenance of
Relays involving static (electronic) components
Electro-static discharge (ESD)
Wrist straps
Modern static relays (K-SERIES, MiCOM etc.)
16
Fault find to board level only
Protect boards
Corrective Maintenance of
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?)
17
Contents of Section 23 of PRAG (1)

(Protective Relay Application Guide)
Insulation tests
Current transformer tests
Voltage transformer tests
Test facilities
Secondary injection tests
18
O.C. and E.F.

Differential
Pilot wires
Negative phase sequence
Directional Distance
D.C. operated

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
19

Tripping and Alarm Annunciation

Periodic Maintenance
In addition to PRAG :Consult instruction manuals
20
Test Terminal Block

To
To relay
relaycoils
coils
To CT
CT test
To
test
windings
windings
(if any)
(if any)
21
B
To main
main
To
current
current
transformers
transformers
C N
A
To
To main
mainVTVT
Test Switch and Sockets

To relay coils
A
CurrentB
test
socketsC
B Voltage
test
C sockets
N
Test selector swit

Make before brea
on CT Circuits
To main current
transformers
22
To main VT
Current Transformer
Polarity Check
P2
P1
S2
S1
Battery
23
Push
button
switch
Current Transformer
Ratio Check
A
C
A2
Temporary
short
circuit
51
P1
51
S1
P2 S 2
51
64
Relay or test block

contact fingers
A1
Primary injection
test set
250V AC supply
24
Test plug
insulation
Testing Current Transformer

Magnetizing Curve
A
Test plug isolating

current transformers
from relay coils
A
P1
To relay
coils
V
S1
Variable
transformer
250V 8A
250V
AC
supply
S2
P2
Main circuit
breaker open
25
Step-up transform
if required
Voltage Transformer
Phasing Check
A
B
C
A
V1
V2
C
VN
VL
V1
V2
A
26
Phase rotation
meter
Overcurrent Test Set

Fine control
variable
transformer
Coarse
control
reactor
Range
adjusting CT
K1
K2
250V
AC
supply
51 Relay
coil
Start
timer
Supply
switch
Backing
transformer
10% control
Stop
timer
Injection
Medium transformer Relay shortcircuiting switch
control
reactor
Relay current I = Ammeter reading (A) x

27
Basic Current Control Circuit

of CFBA Test-Set
A
60Hz
L2
50Hz
0.1A
10X5X2X1X
0.2A
220/250V
AC
Supply
50/60Hz
Variac V1
60Hz
0.5A
50Hz
1A
2A
O/V Detector
Circuit
L1
5A
Supply
Contractor
Supply Shorting
Switch
Thermal Overload / Overvoltage

Protection
28
10A
Timer
T1 Injection
Start
Matching
(Break to Start)
C.T.
Output
to
Relay
Sensitivity Check on
Biased Differential Relay
B
B
OP
Test plug
fingers
Over current
test set
To main current
transformers
250V
A.C. supply
29
OP Relay operating coi

B
Relay bias coil
Testing Bias Characteristics

(Using Overcurrent Test Set)
B
B
OP
I1+I2
A1
Overcurrent
test set
To main current
transformers
250V A.C.
supply
30
I2
I1
A2
R
Test plug
fingers
Testing Relay Bias Characteristic

(Using Resistances)
B
B
OP
I1+I2
R1
Test plug
fingers
A2
A1
To main current
transformers
250V A.C.
supply
31
I2
I1
R2
A1 and A2 Ammeters
OP Relay operating coil
B Relay bias coil
Sensitivity Test
Feeder isolated
A
B
C
Test
plug
Relay
contact
fingers
Overcurrent 250V
test set A.C. supply
B
OP
OP
Pilots
32
Testing Sensitivity of Negative

Phase Sequence Relay
250V
A.C.
supply
To main
current
transformers
C
N
Overcurrent
test set
Test plug
in test block
33
Filter
network
46
Relay
coil
Test Equipment for Directional Relays

Supply switch
440V
3 phase
4 wire supply
A
B
C
N
Choke
Variable
transformer
for current
control
67
Relay
current coil
Range adjusting CT
440/110V
phase shifting
transformer
PA
PA
67
Relay
voltage coil
Variable transformer
for voltage control
To other voltage coils V Voltmeter

A Ammeter
of relay under test
PA Phase angle mete
(if required)
34
Primary Injection Test Set
250V A.C.
supply
Variable transformer 40A

Injection transformer
250/10 + 10 + 10V
10kVA
35
Primary Check on
Main Current Transformers
Temporary three
phase short circu
Primary
injection
test set
250V
A.C. supply
51 Overcurrent relay
64 Earth fault relay
A
Ammeter
36
5
1
5
1
5
1
6
4
Sensitivity Test on Earth Fault Relay

250V
A.C.
suppl
y
Primary
injection
test set
5
1
B
51
C
51
64
37
Load Test on Directional

Overcurrent Relays
A B
C
Direction of power
flow
Load
for relay operationcurrent
A
V
PA
38
Ammeter
Voltmeter
Phase angle
meter
>
PA
PA
B
C
Directional overcurrent
relays
Commissioning & Maintenance of Protective Relays
Test Plug Link Connections to

Reverse Current seen by Relay
To relay
20 19 18
17 16 15
14 13 12 11
Test plug
To main VT and CT
39
10
Load Test on Directional Earth Fault Relay

A B C
1S
2
S
2
IA
A
51
51
A
V
PA
40
51
Ammeter
Voltmeter
Phase angle meter
Load
Load
current
current
PA
P
A
Temporar
y
short
circuit
connectio
Insulating
ns
strips
in
relay or test
block
contact fingers
Directional
earth
fault relay
V
1V
2
V
L
V
V
P
PA
A
Testing Sensitivity of Generator Differential

Protection Using Primary Injection Test
Primary
injection
test set
87 Generator differential re
V
Voltmeter
A Ammeter
250V A.C.
supply
Generato
r
Isolating
links
A
B
C
41
87
87
87
Testing Sensitivity of Generator Differential Protection

Using Generator to Supply Primary Current
Temporary
short
Isolating
circuit
links
Generato
r
A
B
C
87
87
87
87 Generator differential r
V
Voltmeter
42
Checking Stability of Generator

Differential Protection
Isolatin
g
links
Generato
r
Temporary
short
circuit
A
B
C
87
87
87
Shorts across
relay/
stabilising
resistors
43
87 Generator differential r
A Ammeter
Earth Fault Sensitivity Check on Transformer

A
Primar
y
injectio
250V n
A.C. test
set
suppl
y
Temporary
short
circuit
B
C
Bias
coils
Operatin
g
coils
44
87
87
87
Phase Fault Sensitivity Check on Transformer

A
Temporary
short
circuit
A
B
Primary
injection
test set
250V
A.C.
suppl
y
C
Bias
coils
Operatin
g
coils
45
87
87
87
Stability Check on Transformer

Temporary short
circuit
Generato
r
~
Bias
coils
87 87 87
Operating
coils
Instantaneous current distribution for

three-phase short circuit with phase A
current at maximum
46
Sensitivity Check of Restricted

Earth Fault Protection
250V A.C.
supply
Primary
injection
test set
A
B
C
64 Earth Fault Relay

A Ammeter
V Voltmeter
47
64
Stability Check of Restricted Earth

Fault Protection
250V A.C.
supply
Temporary short
circuit
Primary
injection
test set
A
B
C
A
48
64
64 Earth Fault Rela

A Ammeter
Sensitivity Check of Negative

Phase Sequence Relay
A
B C
Temporary
short circuit
Filter
network
46
Primary
injection
test set
49
>
250V
A.C.
supply
Commissioning & Maintenance of Protective Relays
46 Negative phase sequence r

A Ammeter
Test Plug Link Connections for

Load Current Test
To relay
filter network
20 19 18
17 16 15
6
A
50
14
13 12 11
7
B
8
C
9
N
10
Earth Fault Sensitivity Check

of Pilot Wire Relay
B
C
Primary
injection
test set
250V A.C. supply
B
OP
51
B Relay bias coil

Ammeter
Pilots to
remote
end relay
OP Relay operating coil
Phase Fault Sensitivity Check

of Pilot Wire Relay
A
B
OP
B
Relay bias coil
OP Relay operating
coil
A
Ammeter
A
Primary
injection
test set
52
Pilots to
remote
end relay
250V A.C. supply
Load Current Distribution

A
A
C
C
Feede
r
Instantaneous current
distribution of three-phase
balanced load with
phase A current at
B
maximum
B
OP
OP
Pilots
53
Short-Circuiting Connections
on Test Plug for Load Test
Short circuiting connections
on rear of test plug
20 19 18
To relay summation CT
17 16 15
A A
14 13
7
B
12
8
C
9
N
To main current
transformers
54
Ratio Check of Current Transformers

of Reference Circuit
A1
250V
A.C.
supply
A2
Primary
injection
test set
A1 and A2
87
relay
95
95X
circuiting
55
Ammeters
Busbar Protection
Supervision relay
Bus wires shortrelay
Test
links
A
B
C
N
Zone
bus
wires
95
87
87
87
95
X
Polarity Check of Reference

Circuit Current Transformers
A
87
A
Ammeter
Busbar ProtectionC
relay
95 Supervision relay
95X Bus wires shortcircuiting relay
250V
A.C.
supply
Temporary short circuit

A
Tes
t
link
s
Primary
injection
test set
A
B
C
N
95
X
95
56
87
87
87
Zone
bus
wires
CT Inter-Group Ratio and Polarity Check in

Busbar Protection Scheme
Reference
circuit
Test circuit
Temporar
y
short
circuit
57
Primary
injection
test set
250V A.C. supply
A
A
B
C
N
A1
A2
87
95
95X
Test
link
s
Ammeter for ratio check

Ammeter for polarity
check
Busbar protection relay
Supervision relay
95
Bus wires shortcircuiting relay
A2
95X
87
87
87
A2
A2
Zon
e
bus
wire
s
Sensitivity Check of Busbar

Protection Scheme
A
C
A
250V
A.C.
supply
Primary
injection
test set
Test
links
A
B
C
N
58
95
X
95
87
87
87
Zone
bus
wires
Stability Test
A
B
C
Test
plug
Overcurrent
test set
250V
A.C. supply
Pilots
B
OP
OP
59
Test
plug

Protective Relay Testing and Commissioning

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Protective Relay Testing and Commissioning

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Test Options (1)

1. Primary injection sensitivity tests only

Minimum of time consumed

Unable to check :a.

Adequate timing curves

Power and impedance relays

Not suitable for maintenance tests

> Commissioning & Maintenance of Protective Relays

Test Options (2)

2. Secondary injection tests

True primary sensitivity easily equated

Ref. for maint., but system outage required

> Commissioning & Maintenance of Protective Relays

Test Options (3)

3. Secondary injection tests

Proof of isolated relay characteristic obtained

Full primary injection/on load tests done on initial

> Commissioning & Maintenance of Protective Relays

Test Options (4)

Checks that expected C.T. / V.T. quantities present at test

Scheme stability for external faults

> Commissioning & Maintenance of Protective Relays

Secondary injection (isolated relay)

> Commissioning & Maintenance of Protective Relays

Site Testing and Commissioning

Observe safety of self and others

> Commissioning & Maintenance of Protective Relays

Commissioning Flow Chart

Study of wiring diagrams and protection

Careful delegation of responsibilities to

> Commissioning & Maintenance of Protective Relays

Commissioning Flow Chart

Secondary Injection Tests (Relay Tests)

Ensure clean dust free area

Prove trip and alarm circuits

> Commissioning & Maintenance of Protective Relays

Commissioning Flow Chart

Primary injection tests

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

C.T. ratio and polarity tests

Primary sensitivity tests

C.T. mag curve tests

> Commissioning & Maintenance of Protective Relays

Commissioning Flow Chart

V.T. ratio and phasing tests

> Commissioning & Maintenance of Protective Relays

> Commissioning & Maintenance of Protective Relays

Frequency of Maintenance (continued)

> Commissioning & Maintenance of Protective Relays

> Commissioning & Maintenance of Protective Relays

The commissioning test stage

At each maintenance test

After heavy fault clearance

More regularly if onerous site conditions

> Commissioning & Maintenance of Protective Relays

Recommended maintenance tests

> Commissioning & Maintenance of Protective Relays

Relays involving static (electronic) components

Electro-static discharge (ESD)

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

Fault find to board level only

> Commissioning & Maintenance of Protective Relays