FR-EE-403-00003-L

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L 5-NOV-2014 Issued for COMPANY Review TAT NAS MTH

Rev. Date Description Prepd By Chkd By Apprd By

COMPANY EPC CONTRACTOR

Abu Dhabi Polymers Company Limited (Borouge)

PROJECT

BOROUGE PO FLARE GAS RECOVERY PROJECT

TITLE

RELAY SETTINGS & PROTECTION COORDINATION STUDY

Contractor Project No.:6502 Contractor Doc No: 6502-10-100-M1380-005-01

Document Class: 1

BOROUGE Document Inform ation:

Project No. Document Number Page Rev.

PE/000451 FR-EE-403-00003 1 OF 14 L

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Issued date Project No. Document Number Page Rev.

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Revision / Changes:

RevisionNo.

Page No. Section Change(s)

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TABLE OF CONTENTS

1 INTRODUCTION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 STUDY OBJECTIVE . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . 4

3 REFERENCE DOCUMENTS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4

ETAP MODEL . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . 5

5

BASIS & ASSUMPTIONS . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . 6

6 NETWORK DESCRIPTION FOR STUDY .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

7 MODEL SIMULATION CONDITIONS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

8 FAULT CURRENT LEVELS . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . 7

9

RELAY TYPE . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . 9

10 HV PROTECTION RELAY SETTINGS DATA .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

11

TIME CURRENT CURVES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

12 CONCLUSION AND RECOMMENDATIONS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Attachments:

Attachment A: ETAP SLD

Attachment B: ETAP Report

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1 INTRODUCTION

The intent of this study report is to carry out electrical power system analysis by performing protectioncoordination study of the electrical network under the scope of Borouge PO Flare Gas Recovery project (B3).

2 STUDY OBJECTIVEThe main objectives of protection coordination study are as follows:

To determine the characteristics, ratings, and settings of over current protective devices that minimizes plantoutages and interrupts short circuits as rapidly as possible.

To verify the existing protection device settings.

To verify the proper margin between protective devices in series to enable a back-up protection system.That is, upstream devices are on a standby basis to act expeditiously in case the immediate device nearer

to the fault location fails to operate.

Relay Coordination study is performed on the basis & recommendations of following international standards

IEEE Std 399-1997. (IEEE Recommended Practice for Industrial & Commercial PowerSystem Analysis)

IEEE Std 242-2001. (IEEE Recommended Practice for Protection and Coordination ofIndustrial and Commercial Power Systems)

3 REFERENCE DOCUMENTS

The documents listed below have been considered as the basis/reference for the relay settings & protectioncoordination study:

Document Name Borouge Document No. Contractor Document No.

Electrical Cable Schedule FR-EE-403-00006 6502-10-100-D1-1382-001-01

Electrical Load Summary (B3) STU-EE-FR-003 6502-10-100-D1381-002-01

Electrical One Line DiagramB3 PE5 Process Substation Unit N-42(11KV, 3.3

KV, 0.415 KV)TEC-EE-FR-0044 ----

11 KV SWITCHGEAR 42-ES-9001Protection and Metering One Line Diagram

TEC-EE-FR-0045 ----

Electrical One Line DiagramB3 PP4 Process Substation UNIT N-45

TEC-EE-FR-0046 ----

11 KV SWITCHGEAR 45-ES-9001Protection and Metering One Line Diagram

TEC-EE-FR-0047 ----

3.3 KV SWITCHGEAR 45-ES-9002

Protection and Metering One Line Diagram

TEC-EE-FR-0048 ----

3.3 KV SWITCHGEAR 42-ES-9002Protection and Metering One Line Diagram

TEC-EE-FR-0050 ----

BOR 3 PO SUBSTATIONProtection and Metering Diagram 0.415 KV

SwitchgearTEC-EE-FR-0049 ----

Electrical One Line DiagramPE5 Extrusion Substation

Unit N-42(11KV, 3.3 KV, 0.415 KV)42-EE-153-920001 ----

Electrical One Line DiagramPP4 Extrusion Substation

Unit N-42(11KV, 3.3 KV, 0.415 KV)45-EE-153-920001 ----

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4 ETAP MODEL

As per Descon / Contractor scope (DOC: Electrical System Description and Scope Definition for EPCPackage) in Borouge 3 expansion project, Descon has to analyze the impact of newly added loads (which arein Descon scope, DOC: Electrical Load Summary B3) on the electrical network of B3 by performing theprotection coordination study.

The details of ETAP model provided by Company are as follows:

Name:ETAP-3583-PO

This contains the following switchgears with associated electrical equipment (Motors, Transformers, andCables etc).

80-ES-1802 (33 KV) 41-ES-9001 (11 KV) 41-ES-9002 (3.3 KV)

41-ES-9203 (3.3 KV) 41-ES-9011 (0.415) 41-ES-9211 (0.415 KV)

42-ES-9213 (0.415 KV) 41-ES-9212 (0.415 KV) 41-ES-9201 (11 KV)

42-ES-9201 (11 KV) 42-ES-9001 (11 KV) 42-ES-9002 (11 KV)

42-ES-9203 (3.3 KV) 42-ES-9011 (0.415 KV) 42-ES-9211 (0.415 KV)

42-ES-9212 (0.415 KV) 44-ES-9001 (11 KV) 44-ES-9002 (3.3 KV)

44-ES-9202 (3.3 KV) 44-ES-9011 (0.415 KV) 44-ES-9211 (0.415 KV)

44-ES-9212 (0.415 KV) 45-ES-9001 (11 KV) 45-ES-9002 (3.3 KV)

45-ES-9202 (3.3 KV) 45-ES-9011 (0.415 KV) 45-ES-9211 (0.415 KV)

Loads in Contractors scope have been modeled along with associated cables.

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5 BASIS & ASSUMPTIONS

The basis and assumptions are listed below

The protection data for motors i.e starting time, thermal withstand limits, thermal time constants etc arebased on technical data provided by vendor and assumptions are made where vendor data is pending.

Thermal overload settings of motors shall be performed at site during commissioning stage.

For simulation purposes, exact Relay/ETU model is used as available in standard ETAP device library. Incase of unavailability of particular model, nearest match having similar characteristics is used.

In this report, following switchgears of Unit 42 (PE5) and Unit 45 (PP4) are under observation as most ofthe loads under contractors scope are being fed from theses switchgears. However attached ETAP reportwill reflect the results of other switchgears as well.

42-ES-9001 (11 KV) 45-ES-9001 (11 KV) 42-ES-9011 (0.415 KV) 45-ES-9011 (0.415 KV)

6 NETWORK DESCRIPTION FOR STUDY

For the simulation, ETAP models have been updated as per the reference documents mentioned in section 3of this report. The Network Description for the study is as follows:

The main power sources for 11 KV switchgear 42-ES-9001 are 2 Nos. 33 KV feeders supplied byswitchgear 80-EE-1802 through 31.5 MVA, 33/11.5 KV transformers (42-EP-9011, 42-EP-9012).

2 Nos. 11 KV feeders (from switchgear 42-ES-9001) are stepped down by 2 Nos. 3.15 MVA, 11/0.433 KVtransformers (42-EP-9031, 42-EP-9032) to feed 0.415 KV switchgear 42-ES-9011.

The main power sources for 11 KV switchgear 45-ES-9001 are 2 Nos. 33 KV feeders supplied byswitchgear 80-EE-1803 through 31.5 MVA, 33/11.5 KV transformers (45-EP-9011, 45-EP-9012).

2 Nos. 11 KV feeders (from switchgear 45-ES-9001) are stepped down by 2 Nos. 2.5 MVA, 11/0.433 KVtransformers (45-EP-9031, 45-EP-9032) to feed 0.415 KV switchgear 45-ES-9011.

Following Generators are operating in Standby mode and considered OFF in the analysis.

42-EG-9201 42-EG-9001 45-EG-9001 45-EG-9201

7 MODEL SIMULATION CONDITIONS

Following are the basis of model simulation conditions.

Loads are categorized into Continuous, Intermittent and Stand by 100%, 50% & 0% loading respectively.

All Lump Loads are considered as Continuous and operating at 80% loading.

Loading Category is selected as Normal.

Primary tap positions are set at +2.5% of nominal voltage, for all transformers (for Unit 42 & 45).

33kV Grid bus is considered as slack/swing bus.

The by-pass switches for VFDs are closed to get maximum short circuit contribution from motors.

Maximum short circuit power from utility to switchgears of unit 42 and 45 is considered 1257 MVA (3-phase)as per etap model/etap report submitted by Company described in section 5 of this report.

Minimum short circuit power from utility to switchgears of unit 42 and 45 is considered 850 MVA (3-phase)as per etap model/etap report submitted by Company described in section 5 of this report.

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8 FAULT CURRENT LEVELS

Initial Symmetrical Short Circuit Current (maximum):

BusNominal

Voltage (kV)Rated ShortCircuit (kA)

Initial Symmetrical RMS Current kA (Ik )

Three Phase Line to Ground Line to LineDouble Line to

Ground

42-ES-9001 A 11 31.5 26.3 0.4 23.1 23.2

42-ES-9001 B 11 31.5 26.3 0.4 23.1 23.2

42-ES-9011 A 0.415 80 54.2 47.3 46.8 52.8

42-ES-9011 B 0.415 80 54.2 47.3 46.8 52.845-ES-9001 A 11 31.5 25.1 0.4 21.8 21.9

45-ES-9001 B 11 31.5 25.1 0.4 21.8 21.9

45-ES-9011 A 0.415 80 47.7 42.8 41.2 46.845-ES-9011 B 0.415 80 47.7 42.8 41.2 46.8

Peak Short Circuit Current (maximum):

BusNominal


Peak Short Circuit Current kA (ip)


Ground

42-ES-9001 A 11 31.5 67.7 1.08 59.4 59.7

42-ES-9001 B 11 31.5 67.7 1.08 59.4 59.7

42-ES-9011 A 0.415 80 124.3 108.6 107.3 121.3

42-ES-9011 B 0.415 80 124.3 108.6 107.3 121.3

45-ES-9001 A 11 31.5 64.9 1.08 56.4 56.7

45-ES-9001 B 11 31.5 64.9 1.08 56.4 56.7

45-ES-9011 A 0.415 80 110.4 99.1 95.3 108.2

45-ES-9011 B 0.415 80 110.4 99.1 95.3 108.2

Symmetrical Short Circuit Breaking Current (maximum):

BusNominal


Symmetrical Short Circuit Breaking Current kA (Ib)

Line to Ground Line to Line Double Line to Ground

42-ES-9001 A 11 31.5 0.4 23.1 23.2

42-ES-9001 B 11 31.5 0.4 23.1 23.2

42-ES-9011 A 0.415 80 47.3 46.8 52.8

42-ES-9011 B 0.415 80 47.3 46.8 52.8

45-ES-9001 A 11 31.5 0.4 21.8 21.9

45-ES-9001 B 11 31.5 0.4 21.8 21.9

45-ES-9011 A 0.415 80 42.8 41.2 46.8

45-ES-9011 B 0.415 80 42.8 41.2 46.8

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Initial Symmetrical Short Circuit Current (minimum):

BusNominal


Initial Symmetr ical RMS Current kA (I k)

Three Phase Line to Ground Line to Line Double Line toGround

42-ES-9001 A 11 31.5 14.1 0.3 12.2 12.3

42-ES-9001 B 11 31.5 14.1 0.3 12.2 12.3

42-ES-9011 A 0.415 80 29.7 30.6 25.7 30.2

42-ES-9011 B 0.415 80 29.7 30.6 25.7 30.2

45-ES-9001 A 11 31.5 14.1 0.3 12.2 12.3

45-ES-9001 B 11 31.5 14.1 0.3 12.2 12.3

45-ES-9011 A 0.415 80 28.1 28.9 24.3 28.5

45-ES-9011 B 0.415 80 28.1 28.9 24.3 28.5

Peak Short Circuit Current (minimum):

BusNominal


Peak Short Circuit Current kA (ip)


Ground

42-ES-9001 A 11 31.5 36.7 0.9 31.8 32

42-ES-9001 B 11 31.5 36.7 0.9 31.8 32

42-ES-9011 A 0.415 80 74.7 77.1 64.7 76

42-ES-9011 B 0.415 80 74.7 77.1 64.7 76

45-ES-9001 A 11 31.5 36.7 0.9 31.8 32

45-ES-9001 B 11 31.5 36.7 0.9 31.8 32

45-ES-9011 A 0.415 80 70.2 72.3 60.8 71.4

45-ES-9011 B 0.415 80 70.2 72.3 60.8 71.4

Symmetrical Short Circuit Breaking Current (minimum):

BusNominal


Symmetrical Short Circuit Breaking Current kA (Ib)

Line to Ground Line to Line Double Line to Ground

42-ES-9001 A 11 31.5 0.3 12.2 12.3

42-ES-9001 B 11 31.5 0.3 12.2 12.3

42-ES-9011 A 0.415 80 30.6 25.7 30.2

42-ES-9011 B 0.415 80 30.6 25.7 30.2

45-ES-9001 A 11 31.5 0.3 12.2 12.3

45-ES-9001 B 11 31.5 0.3 12.2 12.3

45-ES-9011 A 0.415 80 28.9 24.3 28.5

45-ES-9011 B 0.415 80 28.9 24.3 28.5

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9 RELAY TYPE

The relays used for HV motor feeder protection are ABB make REF630 with following protection functions.

Motor FeederREF 630

50P Phase definite time OC

51P Phase inverse OC

50N Earth definite time OC

51N Earth inverse OC

87M Differential protection

74 Alarm

42R Running CB

86 Lockout

46 Phase balance current relay

38 Bearing protection49 Thermal protection

49T Temperature protection

48 Incomplete Sequence Relay

66 Jogging device

10 HV PROTECTION RELAY SETTINGS DATA

Only over current protection function settings (50P, 50G, 51P, 51G) are proposed in this document. All othersettings shall be performed at site during commissioning stage.

Motor TAG 47-XK-921-KM-921 47-XK-931-KM-931

Description Motor feeder Motor feeder

Relay REF 630 REF 630

CT Ratio 250-1 200-1OVERCURRENT STAGE I> (51) Settings

Pickup Value 0.9 0.9

TMS 3.5 2.11

Characteristic CurveIEC-

Extremely InverseIEC-

Extremely Inverse

OVERCURRENT INSTANTANEOUS I>> (50) Settings


Time 0.05 0.05

RESIDUAL CURRENT INSTANTANEOUS I02 > (50N) Settings


Time 0.05 0.05

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11 TIME CURRENT CURVES

Time current curves (TCC) are plotted to verify the present state of coordination.

a. 47-XK-921-KM-921 PE compressor motor relay phase TCC.

Figure 1

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b. 47-XK-921-KM-921 PE compressor motor relay earth time current curves

Figure 2

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c. 47-XK-931-KM-931 PP compressor motor relay phase time current curves

Figure 3

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d. 47-XK-931-KM-931 PP compressor motor relay earth time current curves

Figure 4

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12 CONCLUSION AND RECOMMENDATIONS

Relay coordination study has been performed after incorporating protection settings of existing system andproposed protection settings of newly added loads. The study reflects that both HV & LV electrical systemsare adequate and properly coordinated after the Borouge project load additions and no modification/updatein protection settings of existing system is required at this stage.

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PROTECTION COORDINATION STUDY

ETAP SLD

ATTACHMENT A

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-Line Diagram - SCMAX (Star Sequence-of-Operation)

12:05:32 Oct 31, 2014 Project File: ETAP-3583-PO

42- ES- 9001 A

42-

XE-

705-

NM-

701A

1400kW

42-XE- 705- EC- 701A

42- XE-705-EP- 701A1750 kVA

R

CB330

42-EP-9233

R

CB331

42- EP-9031

R

CB332

C/ 42- ES-9001 B

XC/42-

ES-

001B

0 A

CB326

42-EP-9032

CB32R

CB338Open

80- ES-1802 B

I>

R

42-EP-901231. 5 MVA

CB339

R

CB341

R

CB334

C/ 42- ES-9001 A

XC/42-

ES-

001A

0 A

R

CB335

80- ES- 1802 A

I>

R

42- EP-901131. 5 MVA

CB336

R

42-EP-9231

R

CB337

42-

XK-

402-

KM-

402

2300kW

R

CB17CB40

R

47-ECC

-500

01

1-3/

C18

5

47-

XK-

921-

KM-

921

3300kW

42- XE-705-EP- 701A1750 kVA

42-XE- 705- EC- 701A

42-

XE-

705-

NM-

701A

1400kW

80- ES- 1802 A 80- ES- 1802 B

42- ES- 9001 A

CB335CB334CB332CB331CB330

CB338Open

CB32CB341CB326

CB336CB339

42- EP-901131. 5 MVA

42-EP-901231. 5 MVA

C/ 42- ES-9001 A

XC/42-

ES-

001A

0 A

C/ 42- ES-9001 B

XC/42-

ES-

001B

0 A

CB337

42- EP-9031

42-EP-903242- EP- 9231 42- EP- 9233

42-

XK-

402-

KM-

402

2300kW

CB17

47-ECC

-500

01

1-3/

C18

5

47-

XK-

921-

KM-

921

3300kW

CB40

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-Line Diagram - SCMAX (Star Sequence-of-Operation)

12:03:46 Oct 31, 2014 Project File: ETAP-3583-PO

45- ES- 9001 A

47-

XK-

931-

KM-

931

2650kW

47-ECC

-500

02

1-3/

C18

5

R

CB38

45- ES- 9001 A

47-ECC

-500

02

1-3/

C18

5

CB38

47-

XK-

931-

KM-

931

2650kW

45- ES-9001 B

C/45-ES-9001

B

XC/4

5-

ES-

9001B

0 A

CB571

45- EP- 9031

R

CB577

C/45-

ES-

9001A

XC/45-

ES-

9001A

0 A

R

CB580

CB583 Open

R

80- ES-1803 A

I>

R

45- EP- 901131. 5 MVA

CB581

R

45- EP- 9231

R

CB582

45-

XK-

401-

KM-

401

3150kW

R

CB28 CB579

R R

CB586

45- EP- 9032

CB572

45-

XE-

705-

NM-

701

2 1 0 0

k W

80- ES- 1803 B

I>

R

45- EP- 901231. 5 MVA

CB584

R

45- EP- 9232

CB585

45-

XE-

705-

NM-

701

2 1 0 0

k W

XC/45-

ES-

9001A

0 A

45- ES-9001 B

XC/4

5-

ES-

9001B

0 A

C/45-ES-9001

B

C/45-

ES-

9001A

45- EP- 901131. 5 MVA

45- EP- 901231. 5 MVA

CB586CB571

CB572

CB583 Open

CB577 CB579 CB580

CB581

CB582

CB584

CB585

80- ES- 1803 A 80- ES- 1803 B

45- EP- 9031

45- EP- 9032

45- EP- 9231

45- EP- 9232

45-

XK-

401-

KM-

401

3150kW

CB28

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PROTECTION COORDINATION STUDYETAP REPORT

ATTACHMENT B

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Project: BOROUGE #3 ETAP

Location: LHR PAK

Contract: 6502

Engineer: DIPL

Filename: ETAP-3583-PO

Page: 1

Date: 29-10-2014

Revision: Base

12.5.0C

Overcurrent Relay Settings

OCR: R_42-ES-9001-A1

MFR: ABB

Model: RE_630

Tag #:

GND:

If (kA)Base kVCT

2500/1

24.70

0.40

2500/1Phase:

LG, (User-Defin

3 ph, (User-Defi

OC Level: OC1

SettingRange

Phase TOC IEC - Normal Inverse

Pickup (Tap) 0.3 - 5 xCT Sec 0.790

Time Dial 0.150

Phase INST Pickup 0.01 - 35 xCT Sec 6.300

Time Delay 0.04 - 30 Sec 0.400

Ground INST Pickup 0.01 - 400 xCT Sec 0.100

Time Delay 0.01 - 300 Sec 0.600

OCR: R_42-ES-9001-KM-921

MFR: ABB

Model: RE_630

Tag #:

GND:

If (kA)Base kVCT

100/1

24.70

0.40

250/1Phase:

LG, (User-Defin

3 ph, (User-Defi

OC Level: OC1

SettingRange

Phase TOC IEC - Extremely Inverse


Time Dial 3.500




Time Delay 0.01 - 300 Sec 0.050

ATTACHMENT B

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Project: BOROUGE #3 ETAP

Location: LHR PAK

Contract: 6502

Engineer: DIPL

Filename: ETAP-3583-PO

Page: 2

Date: 29-10-2014

Revision: Base

12.5.0C

Overcurrent Relay Settings

OCR: R_45-ES-9001-A1

MFR: ABB

Model: RE_630

Tag #:

GND:

If (kA)Base kVCT

2500/1

23.90

0.40

2500/1Phase:

LG, (User-Defin

3 ph, (User-Defi

OC Level: OC1

SettingRange

Phase TOC IEC - Normal Inverse


Time Dial 0.150




Time Delay 0.01 - 300 Sec 0.600

OCR: R_45-ES-9001-KM-931

MFR: ABB

Model: RE_630

Tag #:

GND:

If (kA)Base kVCT

100/1

23.90

0.40

200/1Phase:

LG, (User-Defin

3 ph, (User-Defi

OC Level: OC1

SettingRange

Phase TOC IEC - Extremely Inverse


Time Dial 2.110




Time Delay 0.01 - 300 Sec 0.050

Documents

FR-EE-403-00003-L