Test Plan Automation for Power Transformer Protective Relay Commissioning

Author: Mark Allen

Milton QuinterosHussain Al Marhoon

Nagendrakumar Beeravolu

Agenda

• Objectives• Background• Power Transformer Standard

– General Design– Relay I/O – Test Switches

• Test-Tool– Program– Examples

• Conclusions• Questions

Objectives• Implementation of a computer automated

Test-Tool program to reduce cost, increase efficiency, improve quality.

• Integration Services to provide for User Interface and Data Transfer capability.

• Reporting Services to ensure Auditability and meet Regulatory Requirements.

• Learning Tool for Users.

Background• Electric Utilities often create numerous multi-

option standard relay designs and associated relay setting templates for various relay protection schemes, which include:– Transmission Line Protection– Breaker Control including Breaker Failure Protection,

Reclosing, and Synchronism Check – Bus Protection– Autotransformer Protection– Power Transformer Protection– Capacitor Bank Protection– MV Breaker Protection

Background• Standard relay designs and associated relay setting

templates schemes can be complicated involving numerous microprocessor based relay functions, and relay inputs and outputs.

• As such, to properly test these multifunction relay schemes detailed knowledge of the design and in particular relay setting functionality is required.

• This results in a requirement for a sophisticated relay test plan to ensure that all applicable relay functions are properly tested.

Objectives of Substation Relay Testing• Ensure relays meet the requirements of the intended relay

function within manufacturer’s published tolerances based on initial conditions and input logic. – Operate (Trip) inside the relay function protection zone .– Not Operate (Not Trip) outside of the relay function protection zone.

• Gain familiarity with the relay functionality, and applications, and associated settings.

• The test procedures are not necessarily focused on relay performance as a lab test might be.

• Instead they are focused on a simple pass or fail test to determine whether or not the relay should be placed into service.

• Relay testing is a regulatory requirement.• The test results need to be auditable.

Motivation to Create an Excel Test Tool

• Relay settings are the basis for the Test Plan.

• With standardized relay settings, standardized relay test plans are logically required.

• Manually transferring numerous multifunction relay settings to a relay test plan are time consuming and can lead to errors.

• As such, it would be beneficial to automate the transfer of data.

Relay Standard Design to be Tested• Power Transformer schemes with a low side.

main breaker.• Power Transformer schemes with no low side

main breaker.• Description of I/O in the design.• Application of Test Switches.• List of possible tests based on the Standard.

Standard Transformer Protection Scheme One-line

GXXXX1 XXXXA

J XX1 XXXXA C A B

J XX2 XXXXA

HV HHHkV OPERATING BUS #W

HV HHHkV TRANSFER BUS #X

M M

XXXF3

XXXF3B XXXXA

XXXF3S XXXXA

XXXF3L XXXXA

XXXF1

XXXF1B XXXXA

XXXF1S XXXXA

XXXF1L XXXXA

C A B

FEEDER #1

XXXF2

XXXF2B XXXXA

XXXF2S XXXXA

XXXF2L XXXXA

XXXF6

XXXF6B XXXXA

XXXF6S XXXXA

XXXF6L XXXXA

XXXF4

XXXF4B XXXXA

XXXF4S XXXXA

XXXF4L XXXXA

XXXF5

XXXF5B XXXXA

XXXF5S XXXXA

XXXF5L XXXXA

XX

BT2

XBT2T3 XXXXAX

XB

T1

XBT1T2 XXXXA

(NOTE 7) (NOTE 7) (NOTE 7) (NOTE 7) (NOTE 7)

(NOTE 9)

3∅ MV XX.XkV OPERATING BUS #Y

MV XX.XkV TRANSFER BUS #Z

(NOTE 8)

REMOVABLE LINK REMOVABLE LINK

XBT1T1 XXXXA

XBT2T1 XXXXA

TXX1

STATIONSERVICE

3∅3∅

IW2

87 Relay 1

IW1

VA,VB,VC

IBW3

C A B

FEEDER #2

C A B

FEEDER #3

C A B

FEEDER #4

C A B

FEEDER #5

C A B

FEEDER #6

DXX1 XXXXA

(NOTE 7)

VA,VB,VC I4

87 Relay 2

I2I5B I3I1

Transformer Protection with No-Main Circuit Breaker

H2H1 H3

G G G

F1X1

X5

X1

F2X1

F3X1

F3X5

F2X5

F1X5

X1 X1

X5X5

G1Y1

X5

X1

G2Y1

G3Y1

G3Y5

G2Y5

G1Y5

X1 X1

X5X5

X5

X1X1 X1

X5X5

G

R

W

BK

X2X1 X3

X5

X1

J 8X5

J 8X1

W

BK

D

F

IH

G

E

C B301300

303

305

302

304

16

14

10

6 5

9

13

15 17

11

7

3 4

8

12

18

2CA2

2CB2

2CC2

2CN2

LD1

LD2

LD3

LD4

LC10

LC11

LC12

2CA1

2CB1

2CC1

2CN1

D

F

IH

G

E

C BZ02Z01

Z04

Z06

Z03

Z05ICW1

IBW1

IAW1

16

14

10

6 5

9

13

15 17

11

7

3 4

8

12

18

1CA2

1CB2

1CC2

1CN2

LC5

LC6

LC7

LC8

LC1

LC2

LC3

LC4

1CA1

1CB1

1CC1

1CN1

G

R

W

BK

W

R

G

BK

D

F

IH

G

E

C BZ08Z07

Z10

Z12

Z09

Z11ICW2

IBW2

IAW2

16

14

10

6 5

9

13

15 17

11

7

3 4

8

12

18

3CA2

3CB2

3CC2

3CN2

LD9

LD10

LD11

LD12

LD5

LD6

LD7

LD8

3CA1

3CB1

3CC1

3CN1

LE12

LE10

Z15

Z16

1817

1615

IBW

3

LE11

IH

CTA CTB CTC

CTD CTE CTF

X5

X1 G2Z1

G3Z1

G3Z5

G2Z5

G1Z5

X1 X1

X5X5

G1Z1

H4Y3

X3

X1

H5Y3

H6Y3

H6Y1

H5Y1

H4Y1

X1 X1

X3X3

CTP CTQ CTR

CTG CTH CTJ

CTL CTM CTN

H4X5

H5X5

H6X5

H6X1

H5X1

H4X1

CTK 2 1

4 3

6 5

2 1

4 3

6 5

Z19VA

Z20VB

Z21VC

VA

VB

VC

VNN

Z22

RB1

RB2

RB3

RB4

3 4

B

6

C

8

D

E10

LC9

5

7

9

RB5

RB6

RB7

RB8

2 1

4 3

6 5

2 1

4 3

6 5

VA

VB

VC

3903P

RA∅

WB∅

GC∅

BKN

3701C

3702C

3703C

3704C

GND4

GND3

GND2

(NOTE 8)

(NOTE 8)

GND5

I326

1817

H327

I5B15

16

330VA

331VB

332VC

N

333

3 4

B

6

C

8

D

E10

5

7

9

D

F

IH

G

E

C B307306

309

311

308

310

16

14

10

6 5

9

13

15 17

11

7

3 4

8

12

18

4CA2

4CB2

4CC2

4CN2

LE5

LE6

LE7

LE8

LE2

LE3

LE4

4CA1

4CB1

4CC1

4CN1

LE1

I2C

I2A

I2B

I1C

I1A

I1B

VN

DA87T1B1

Manufacture 2

87 Relay 2

DA87T1B1

Manufacture 2

87 Relay 2EB

TSI-B1-XEB

TSI-B1-X

ECTSV-B1-X

DA87T1B1

87 Relay 2

ECTSV-B1-X

ECTSV-B1-X

(DWG. PMWD69A0)

(DWG. PMWD69A0)

ZBFU2

(5 AMP)

BA87T1P1

87 Relay 1

BA87T1P1

TO HHHkV HV BUS #WDIFFERENTIAL PROTECTION

(IF USED)

CCTSV-P1-X

ZAFU1

(5 AMP)

BA87T1P187 Relay 1

CCTSV-P1-X

CCTSV-P1-X

CBTSI-P1-X

CBTSI-P1-X

CATSI-P1-H

CATSI-P1-H

EATSI-B1-H

EATSI-B1-H

XFMR TXX1YARD CABINET

(DWG. GXXXXCD1)

CT KXXXX/5 MRXXXX/5 TAP

X0

CT'S L, M, N

XXXX/5 MR

XXXX/5 TAP

CT'S P, Q, R

(METERING)

XXXX/5 DRSHORTED & GROUNDED

CT'S D, E, F

XXXX/5 MR

XXXX/5 TAP

XFMR TXX1XX/YY/ZZ MVA @ XX°

ONAN/ONAF/ONAF RATINGHHH/XX.XkV XX%Z

XFMR TXX1YARD CABINET

(DWG. GXXXXCD1)

CT'S A, B, C

XXXX/5 MR

XXXX/5 TAP

CT'S G, H, J

XXXX/5 MR

XXXX/5 TAPSHORTED & GROUNDED

CKT SW.XXXX1XXXXA

87 Relay 1

Example of Relay Analog Inputs

Winding 13 Phase AC Currents

3 Phase AC Voltages

Winding 23 Phase AC Currents

DC Power Supply

DC Input/Output & Relay Contacts

Relay DC INPUTSInput Definitions:        

IN101  XFMR 63 SPR OPERATE EVENT TRIGGR

IN102  DIFFERENTIAL ENABLE, 87CO1 NORMAL

IN103  XFMR 63 SUDDEN PRESSURE RELAY #1 OPERATION

IN104  XFMR 63 SUDDEN PRESSURE RELAY #2 OPERATION

IN105  BFI CIRCUIT SWITCHER XXXX1

IN106  CLOSED STATUS CIRCUIT SWITCHER XXXX1

IN201  CLOSED STATUS MOS JXXX

IN202  OPEN STATUS MOS JXXX

IN203  CLOSED STATUS MAIN BREAKER GXXX

IN204  TRIP MONITOR CIRCUIT SWITCHER XXXX1

IN205  DC MONITOR C.S. XXXX1 SUPV. TRIP

IN206  DC MONITOR C.S. XXXX1 PROT. TRIP

IN207  TRIP MONITOR MOS JXXX

IN208  DC MONITOR MOS JXXX

Relay DC OUTPUTSOutput logic:      

   

OUT101  TRIP1

   TRANSFORMER DIFFERENTIAL TRIP

OUT102  TRIP2

   TRANSFORMER O/C TRIP

OUT103  S1LT1 + S1LT2

   TRANSFORMER DIFFERENTIAL TRIP ALARM (RTU)

OUT104  S1LT3

   TRANSFORMER O/C TRIP ALARM (RTU)

OUT105  0

   TRANSFORMER DIFF RELAY TEST CONTACT

OUT106  S1LT4 + S3LT7 + !SG1 + ISQTAL + RB14 + RB16

   PRI. XFMR DIFF RELAY SYSTEM ALARM (RTU)

OUT107  IN102 * !RB16

   PRI. XFMR DIFF PROT. ENABLED STATUS (RTU)

OUT201  TRIP1 + TRIP2

   TRIP MOS JXXX

OUT202  TRIP1 + TRIP2

   TRIP CIRCUIT SWITCHER XXXX1

OUT203  TRIP1 + TRIP2

   TRIP MAIN BREAKER GXXX

OUT204  S3V4T * 50P13

   CIRCUIT SW. FAILURE BUS DIFFERENTIAL TRIP

OUT205  S3LT4

   CIRCUIT SWITCHER FAILURE ALARM (RTU)

OUT206  !IN206 + !IN208 + S3V2T + !IN205 + S3LT6 + S3LT3

   RELAY EXT. SYSTEM FAILURE ALARM (RTU)

OUT207  0

   Spare

OUT208  0

   Spare

OUT209  0

   Spare

OUT210  0

   Spare

OUT211  0

   Spare

OUT212  0

   Spare

Test Switch Connections

OUTXX

J

20

19 EBTSI-B1-

X AMPS

J

20 EATSI-B1-

H AMPS

202

203

19

Computer-operatedTest Set

G

13

14

229

228

OUTXX

?

Sensing Operation: 15V OFF->ON

RTU COMMON (-)

Computer-operatedTest Set

RL1

H

15

16

RL2

MATS-B1-

1 TRIPS

223

222

OUTXXSensing Operation: 15V OFF->ON

Computer-operatedTest Set

Two Test SwitchesOne Test Switch

Substation Relay Panels

List of Relay Test Routines • Calibration Test• V-I Winding Test• Restrained Differential Trip/Alarm Test (87R Pickup)• Differential Slope Test (87R Pickup) • Differential Harmonic Restraint Test (87R Pickup) • Circuit Switcher Fail Test• High Speed Bus Trip/Block Test (No-main breaker schemes) • Unrestrained Differential Pickup Level Test (87U Pickup) • High Side Time-OC Plot Test (51P) • High Side Time-OC Trip/Alarm Test• Instantaneous OC Trip/Alarm Test• Double Circuit Feeder Fault Time-OC Plot Test (No-main breaker schemes)• Ground Time-Overcurrent (51N)• Ground Time-OC Trip/Alarm Test (51N) • Restricted Earth Fault (If available) • Feeder Breaker Failure (No-main breaker schemes) • Alarm SPR and OIL Level Test• Differential Protection Enable Test• Differential System Fail Alarm Test• Relay Ext. System Failure Alarm Test (No-main breaker schemes).

Excel Relay Test-Tool

Excel Relay Test-Tool • It is an Excel Macro-enabled file that contains

subroutines and excel functions that allow for user interface and data transfer functionality.

• The Excel file imports the relay settings from the viewable document.

• The calculations of the variables needed for each test are based on the Relay Manual and the Calc-Sheet.

• Each of the test options allows for different test configurations.

Relay Test-Tool Process DiagramRelay Settings

Manufacturer x

Utility WorkerUtility WorkerWorkstationWorkstation

Excel Macro to Format Settings

Test-Set Software

Test Set

Logic Inputs

Logic Outputs

AC DC

AC/DC sources

Differential Protection Panel

87/50/51 Relay Primary

87/50/51 Relay Backup

Test Switches

Viewable Document

Test-Tool Program

Various Look up TablesFrom

Standard Design

Report from TestingReport from Testing

Relay Setting Viewable Document

Test-Tool EnvironmentDisplay

Calculations (Source)

Visual Basic

Forms

Test-Tool Display ExampleTitle of the Test

Test Menu Orange Area for Data to be copied

I/O Information

Relay settings used in the test Important

Calculations

Purpose of the Test

Operational Graph

Test-Tool Calculation Example

Navigation Button

Calculation and Formulas Table

Table with some Excel Functions

Some Information used in the Drop Down boxes for the Test Menu Display

Test-Tool Visual Basic• Visual basic code is needed for certain

discrimination functions and to obtain some graphical user interface.

Test-Tool Main Form Example

Example Program

Example of Test Report

Example of Test Report (2)

Conclusions• Relay Test Fundamental Objectives

– Determines whether the relay in question is operationally functional as intended, and

– Within the manufacturer’s published accuracy, – To allow it to be safely placed into service.

• Increase Training/Awareness – To ensure that personnel understand how the relay functions and

operates.• Achieve Cost and Time Savings• Allow for Database Management• Improve Quality• Improve Reliability• Ensure Auditability• Ensure Regulatory requirements are met.

Thanks for your attention

Questions?