Prot. & Metering Note

ABC PROTECTIVE RELAYS
AND PROTECTION SCHEME &

METERING
BY- R. SHARMA
IN ELECTRICAL SUB-STATIONS,
POWER SYSTEM & INDUSTRIES
A study based program in the fields of
400KV/220KV/132/66/33KV Substations
In power system for post graduates /graduates Diploma Engineers
working in the fields of Power systems
JBS POWER SYSTEM
TRAINING & RESEARCH
CENTER
9B2,Vindravan Society Thane(W)
(ISO 9001 certified company)
(Copy of this manual is strictly prohibited)
PROTECTIVE RELAYS &
PROTECTION SCHEMES & METERING
IN
ELECTRICAL SUB-STATIONS,
POWER SYSTEM & INDUSTRIES
A Scientifically based study program in the fields of

400KV/220KV/66KV
Substations
In power system for post
graduates/graduates/Diploma Engineer working in
the fields of
Power systems
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PREFACE
We are pleased to bring out the literature/ material on
Electrical Power System Protective Relays & Protection schemes,
Metering commonly used in substations, large industries. While
having the activities of construction, erection, testing,
commissioning, operation & maintenance of sub-stations, this
literature/ information will be certainly useful & also impart
knowledge to the Electrical Engineers doing studies in Electrical
Engineering Courses, passed out from Engineering Institutions and
working field engineers.
To overcome the errors/ omissions, additions of new subject
material and other topics, suggestions will be highly appreciated
from the readers in the interest of all Engineers. We look forward for
your valued suggestions, co-operation for the improvement in the
above book material.
This book material will fulfill the requirement of the Electrical
Engineering Students, passed out Engineers, working professional /
field Engineers for construction, erection, testing, commissioning,
operation and maintenance of power system sub-stations.
Er. R. SHARM
B.E. (ELECTRICAL) M.I.E. ( I )
CHIEF EXECUTIVE
JBS Enterprises (P),LTD.Thane
*Accredited Energy Manager &
Energy Auditor (BEE)
*Power Consultant (PFC)
*Approved S.L.A.
*Formerly Addl. Superintending
Engineer RRVPNL
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ACKNOWLEDGENMENT
Our sincere thanks specially to ER. ANURAG MAHLOTRA CMD,

expert for Manufacturing & Over hauling of all type of Power
Transformers of M/S TRAFO TECH, NEW DELHI & ER. MILIND
THEKEDAR Chairman & Managing Director, JBS Enterprises Private
Limited, for encouragement regarding subject matter & our expert &
experienced engineers of M/S JBS Enterprises Private limited
Thane for their best co-operation in preparations / compilations /
valuable suggestions for the above.
I am further thankful to ER. Vishamber Singh, Senior Project
Engineer, Electricity Department (Administration of Daman) Union
Territory for inspiring to study on above matter.
We would like to acknowledge the contribution to our Engineers &
several individuals, those who have been instrumental in successful
completion of the above task.
These papers are containing two parts:
Part-A (Protection Scheme & Relays)
Part-B (Current & Voltage Transformers & Metering) with

conservation of Energy
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CONTENTS
Sr.No. Particulars of subject material Page No.

01. Description of Protection system protection schemes & Protective 06
Relays in sub-stations
02. Various types of Relays & their function. 08
03. Relay Nomenclature 11
04. Power Equipment Nomenclature 12
05. Substation single line diagram with a feeder and associated relay 13
circuits for safety interlocking system
06. Relay Circuit with CT & Circuit breaker, Battery Set for fault 15
Tripping
07. Fault Level based Calculations for Relays in Power System 16
08 Relay & Relay Testing set 25

09. Power system Relay Circuits in general use. 26
10. Relay testing formats 45
11. Current Transformer & Relay Testing 51
12. Current Transformer/ Voltage Transformer & Energy Metering 57

13. Failure Report of Power Transformer 61
“PART-A” PROTECTION SCHEME & RELAYS

DESCRIPTION OF PROTECTION SYSTEMS/ SCHEMES &
01. PROTECTIVE RELAYS IN SUB-STATIONS
In brief so long as the operating conditions i.e. normal voltage and

current remain within permissible limits i.e. the equipment is able to
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function trouble free. But whenever a fault occurs, large fault
current starts flowing, which if allowed existing for few seconds or
long time, may damage the power lines, equipments. Hence faulty
line/ equipment must be disconnected/ isolated automatically from
the power system by protective relays/ protection schemes.
The primary function of relay is to operate during abnormal

conditions/ system disturbance/ fault and isolate faulty line /
equipment, so that damage to the costly equipments like
generators, transformers and power lines may be avoided and
power supply on healthy lines/ equipments could be maintained
without causing inconvenience to the public consumers of other
areas.
That is to say that

“Whenever there occurs a fault,
then the fault current must halt.
Otherwise the fault current will increase,
and the service continuity would decrease.
But the RELAYS act quickly & accurately,
& the circuit breaker trip.
The faulty section is isolated,
& the power system/equipments are protected.
Thanks to our RELAYS/RELAY TESTING & SWITCHGEARS,
Because of it every thing is saved.”
When fault occurs due to any short circuit/ earth of power line
conductors emanating from a sub-station, heavy current flows there
through current transformers (connected circuit breaker, isolators)
in proportional to the fault current in primary side of current
transformers flows secondary current flow through relay circuit coil,
relay operate as per its characteristic and pre set timing, thereby
relay contact when closed, energize the trip coil of the circuit
breaker to trip the circuit breaker to isolate the faulty section/
circuit.
Faults can be classified as under:

01. Over loading of equipment capacity.
02. Un-balanced loading
03. Failure of supply in power station/ prime mover/ exciter etc.
04. Loose contacts/ loose connectors
05. Over voltage surges
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06. Fault like power system-failure of insulation values, aging of
equipment/ insulation, underground overhead cables/ lines.
Fault may be single phase to ground, Two phases to ground, Phase
to phase short circuit, Three phase short circuit.
Non clearance of fault, under frequency status at any stage
results in cascade tripping in power system, thereby collapsing the
total power system in the total region.
CONSEQUENCES OF IGNORING PROTECTION SYSTEM:
Due to ignorance or taking lightly or careless working results in long,

incurable incidences like damage of Current Transformers, Power
transformers. Improper relay co-ordination and failures of D.C.
control/ relay supply also results in similar incidents resulting in
hues losses of equipment capital cost, large maintenance/
replacement cost by new spares/ production/ power transmission
revenue cost, down time etc.
There are numerous examples of burning & fire/ damage of Power

Transformers up to 400/220KV,315 MVA “BHEL”, 220/132KV
100MVA CROMPTON GREAVES”, 220/132KV, 50MVA “TELK”,
132/11KV “HHE” 220KV SF-6 NGEF Circuit Breaker, Current
Transformers fired/ damaged & thrown up of Master tripping relay,
Bulging of 66/11KV, 10MVA Transformer & cascade tripping causing
dark/ blackouts in power system unconvinced reply to utility.
VARIOUS TYPES OF RELAYS & THEIR FUNCTION.

02.
Fundamental requirement of any relay/ protective scheme are as
01. Speed of the relays

02. Selectivity
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03. Sensitivity
04. Simplicity
05. Reliability
06. Economy
CLASSIFICATION OF RELAYS:
Based on operating principles-
 Electromagnetic attraction type

 Electromagnetic Induction type
 Thermal type
 Polarized relays
 Bimetallic/ motor protection relay
 Static relays/ micro processer relay
 Gas / hydraulic/ pneumatic operated relays- Buchholz, Oil Surge relays.
 Numerical relays.
Based on application-
 Under Voltage relay

 Under Current relay
 Under power relay
 Over Voltage relay
 Over current relay
 Over power relay
 Directional current relay
 Directional power relay
 Differential relay
 Bus bar protection scheme.
 Distance, phase comparison relay
 Under frequency relay (df/dt)
 Over fluxing relay
 Current unbalance relay
Based on operation-
 Instantaneous type
 Definite time lag relay
 Inverse, very inverse, extremely inverse time lag
 Inverse Definite Minimum Time lag (IDMT) relay
Based on input-
 Primary relay-operating without instrument transformer
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 Secondary relay-operating with instrument transformer
 Shunt trip relay (D.C. operated)
 Series trip relays (A.C. operated)
TERMS RELATING TO RELAYS-
CT/ Current : / 1 or 5A
Voltage : / 110V or 110/ √3 Volts A.C.
CT CLASS :
CT BURDEN :
CT kvp :
Aux. supply : 220/110/50/24Volts D.C. or self powered.
Frequency : 50Hz
PSM : Plug Setting Multiplier
TMS : Time Multiplier Setting
Rated burden : VA
Make :
Model :
Type :
S.No. :
Operating value (time) – Setting Value (time)

%Error=-----------------------------------------------------------
Setting Value (time)
Relay coil fault current

PSM =--------------------------------
Pickup current
Relay coil fault current

=---------------------------------------------------
CT Secondary Current x Current setting
T.M.S. =T/Tm T.M.S. is Time Multiplier Setting on relay.

T is Actual time of operation of relay as found/specified
Tm Time of operation of relay when set at 1.0 i.e. TMS is 1.0
For example at 20 times current, time of operation Tm is 2.2 sec.,
then at TMS set at 0.1 minimum time of operation will be set at 2.2
x 0.1= 0.22 sec. for 3 sec. relay.
INVERSE DEFINITE MINIMUM TIME LAG (IDMTL) RELAYS:
These are the most commonly used & affordable over current &
Earth fault relays in the Power system. The operating characteristic
of these relays is such that the time of operation varies inversely
with the fault current up to twenty times the current setting on the
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relay and becomes constant at higher values of increased fault
current.
“In power system generally in case of radial feeders it is in the

interest of un interrupted supply to grade the current setting for
operating current as well as time setting within the limits imposed
by normal load conditions.”
CHARACTERISTIC CURVE:
These curves show the relationship between the operating current in

terms of Plug Setting Multiplier along the X-axis and operating time
along the Y-axis, at TMS 1.
IDMT relays are widely used as their time of operation

inversely varies with the operating current, thus providing a
scope for selective operation not only with other relays but
also with fuses.
RELAY NO. RELAY NAME

94 Bus bar protection
25 Synchronizing relay
64R Restricted earth fault
50 Instantaneous Over Current Relay
51 Non Directional Over Current Relay
64 Non Directional Earth Fault Relay
67 Directional O/C
67N Directional earth fault
21 Distance protection relay
21X Auxiliary relay
75 V.T Selection relay
30 Auxiliary relays
86, 86X Tripping relay
95 C.B Trip ckt. Supervision relay(for 33 or 11KV)
195 C.B Trip ckt. Supervision relay(for 66 or 132KV)
295 C.B Trip ckt. Supervision relay(for 220KV)
97 Bus bar protection
27/98 Fuse failure
87 Differential protection relay
99 Over flux relay
50Z LBB Protection
2/50Z Timer
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RELAYS NOMINCLATURE
03.
POWER EQUIPMENT NOMINCLATURE

04.
SYMBOLS MEANINGS
29 Isolator(in de-energized condition)
89 Isolator auxiliary contacts
52 Circuit breaker
a, b Normally open, Normally closed contacts or terminals of coil of a contactor
63 Transformer auxiliary contacts
FC Alarm/ annunciation fascia
F Frequency meter
FT Frequency meter transducer
V Voltmeter
VT Voltmeter transducer
A Ammeter
AT Ammeter transducer
S Semaphore indicator
SL Signal lamp/Indication lamp
AS Ammeter selector switch
VS Voltmeter selector switch
VR Voltage recorder
SS Synchronizing socket
TTS Trip Transfer Switch
NIT Normal Inter Transfer
A CT PS core A11,A31,A51,A71 for Dist./ Differential protection scheme
B CT PS core B11,B31,B51,B71 for Bus bar protection scheme
C CT 5P20 core C11,C31,C51,C71 for O/C & E/F protection
D CT 0.5 class metering core D11,D31,D51,D71
E PT/ VT core E11,E31,E51,E71 for Dist. / Directional O/C, E/F, Indication & metering
1111111111111111111111111111111111
H AC supply 1-ф H1-H2 ……., 3-ф & Neutral H1,H2,H3,H4
J Main DC supply J1-J2
K DC control supply K1-K2 or K51-K52………….
L DC indication supply L1-L2 C.B./ Isolator OFF/ON
M AC supply to Motor 1-ф M1-M2, 3-ф M1,M2,M3
N Tap position numbers
P CT primary connection marks P1-P2-P3-P4
S CT secondary connections S1-S2-S3-S4-S5
U Spare terminals in C.B./ Isolator auxiliary switch/ Relays Ui-U2,U3-U4…..
SUBSTATION SINGLE LINE DIAGRAM WITH A FEEDER AND

05. ASSOCIATED RELAY CIRCUITS FOR SAFETY INTERLOCKING
SYSTEM
 Single line diagram of bus system in switch yard comprising of main bus A & main bus B with
associated isolators & transfer bus isolator.
 Position of auxiliary switches of the all isolators in switch yard normally isolators in open mode
associated drawings related to above i & ii are mentioned here under
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From above figure, we can see that whenever Line Isolator Earth
Switch-1 is open, 29E-1 b is NC & also when Line Isolator Earth
Switch-2 is open, 29E-2 b is NC & when LINE ISOLATOR SWITCH is
closed, 29a will be closed, Main Bus-1 or Main Bus-2 Isolator are
closed one of the isolator auxiliary contact will be closed,
simultaneously tripping relay 86-1/ 86-2 both are reset, relay circuit
contact will be closed. Thus under above ideal conditions circuit is
ready for remote closing from control panel, to Circuit breaker. By
such interlocking of isolator auxiliary contacts & Tripping relay circuit
safely supply can be made to closing coil of the circuit breaker.
More-ever in some of the panel board wiring circuit comprises in
series addition to above, Bus bar protection scheme reset contacts
(NC) & SF-6 gas pressure maintained (NC) connections, Hydraulic
pressure (in case of hydraulic pressure drive system) or pneumatic
pressure maintained (NC) connections (in case of air pressure drive)
or springs charged ready (NC) connections for successful closing
command to closing coil of the circuit breaker by remote control
panel.
RELAY CIRCUIT WITH CT & CIRCUIT BREAKER, BATTERY

06. FOR FAULT TRIPPING
1414141414141414141414141414141414
Power Supply Bus
Battery Set Set

Off Load Isolator
TC
Circuit Breaker TC
C.T.
Off Load Isolator
Fault Occurance
FAULT LEVEL BASED CALCULATIONS FOR RELAYS

07 SETTINGS IN POWER SYSTEM
Calculated/ analyzed fault level assumed as = 572 MVA at 132 KV BUS of Grid Station.
1515151515151515151515151515151515
3 Phase short circuit current = 572x4.4 =2517 Amp.
Phase to Phase S.C.CURRENT=2517x0.866 =2180Amp.
Phase to Earth S.C.CURRENT=2517x0.54 =1359Amp
FAULT LEVEL OF THE AREA =572 MVA at 132 KV base
(a) P.U. IMPEDENCE up to EHV system voltage on

Bus at 100MVA base-100/a= 100/572 =0.175 ohm.
(b) P.U. IMPEDENCE Of 10/12.5 MVA transformer

= (10.24/100)x(100/12.5) =0.82 ohm.
(10.24% impedance, 12.5MVA capacity)
Hence (a) + (b) = Total P.U. IMPEDENCE =0.175+0.82 =0.995 ohm.
FOR EHV i.e. 132KV SYSTEM:

3 phase short circuit current = 572x4.4 =2517 Amp.
Phase to phase S.C.CURRENT=2517x0.866 =2180Amp.
Phase to Earth S.C.CURRENT=2517x0.54 =1359Amp.
FOR HV i.e. 33KV SYSTEM
3 phase short circuit current = (100/0.995) x 17.5 =1759 Amp. (1MVA= 17.5A)
Phase to phase S.C.CURRENT=1759x0.866 =1523Amp.
Phase to Earth S.C.CURRENT= 1759x0.54 =950Amp.
Reflected fault current on 132KV side, when fault recd. On 33KV system:-
(Voltage on HV/ EHV side 33/132= 0.25)
i. Phase to phase= 1523x 0.25 =380.75A say 381A

ii. Phase to Earth= 950x 0.25 =237.50A say 238A
IDMT RELAYS IN POWER SYSTEM:
RELAY SETTING CALCULATION

(A) 33KV OUT GOING FEEDERS SYSTEM:
Now 4 nos. of 33KV feeders (no.1 to 4) having CT ratio 120/5
1616161616161616161616161616161616
Relay make U/E, type 10c, PS-5 for O/C &
PS-0.5 for E/F
(a) O/C RELAY TIMINGS
C.T. Times of fault current = 1523/120 = 12.725

= say 13 times
At 13 times current the operating time as per Relay Characteristics is

(Tm = 2.8 sec) at TMS = 1
T = Time obtained
TMS = T/TM
T = the required time operation
TM = the time obtained from the relay characteristics curve at TMS = 1 & using
the PSM equivalent to max fault current.
T = TMS * Tm
= 0.075*2.8
= .21 sec
(b) E/F Relay Timings (120 x 10% = 12 A)

C.T. times of fault current = 950/12 = 79 times which is greater than 20.
At 79 times current for operating time as per relay chart eristic is 2.2 sec(Max at 20 times) on
TMS = 1.
T = TMS * TM
= 0.075* 2.2
= .165sec
B) 33K.V. INCOMER SYSTEM:
C.T. Ratio = 300/5

Relay Make = CDG
P.S. = 5 for 0/C, 1 for E/F
(a) O/C RELAY TIMING:
C.T. Times of fault current = 1527/300 = 5 Times
At 5 times current operating time as per relay characteristics at TMS = 1 is 4.3 sec.
1717171717171717171717171717171717
Actual time required = 0.21 + 0.5 = 0.71sec.,
TMS = 0.71/4.3
= 0.165
(b) E/F RELAY TIMING:
C.T. Times of fault current = 950/60 = 15.84 say 16 times

At 5 times current operating time as per relay characteristics atTMS = 1 is 2.6sec.
Actual time required = 0.165 + 0.5 = 0.665sec. ,
TMS = 0.665/2.6
= 0.256.
(C) FOR 132 KV SYSTEM:
C.T. Ratio = 60/5
Relay Make: CDG
PS = 5 O/C
PS= 1 E/F
(a) O/C RELAY TIMING:
C.T. Times of fault current = 2180/16 = 36.34times

At 36.34 Times current for operating time as per
Relay characteristics at TMS = 1 is 2.2(Max).
Actual time required for operation = 0.71 + 0.5 = 1.21sec
TMS = 1.21/2.2 = 0.55
(b) E/F RELAY TIMING:
C.T. Times of fault current = 1359/12

(Which more than 20 times)
Operating time as per relay characteristics 2.2 sec at TMS = 1.
Actual operating time required = 0.665 + 0.5 = 1.165 sec
TMS = 1.165/2.2
= 0.53
------------------------------------------------------------------------------------------------------------
PARTICULARS O/C E/F
OF FEEDERS PS TMS PS TMS
------------------------------------------------------------------------------------------------------------
1818181818181818181818181818181818
132 KV Incoming 5 0.55 1 0.53
33 KV Incoming 3.75 0.165 1 0.256
33 KV O/G 1 to 4 2.5 0.075 0.5 0.075

------------------------------------------------------------------------------------------------------------
INSTANTANEOUS SETTING OF BACK UP RELAYS

IN POWER SYSTEM
In case of any fault phase to phase or phase to earth, as per time –current
characteristics, relay operate within time pre-set on the relays, but in case of any
seviour short circuit or earth fault it is dangerous to power equipment like current
carrying conductor, clamps/ connectors (fasteners), CTs, Circuit breakers,
transformers in cascade manner, if not cleared just at the instant of the fault.
Relays clearing / signaling the fault at instant are termed as instantaneous relays.
Such relays are very useful/ helpful particularly in the areas near between grid
sub-station or lines & tacking grounds of army/cantonment or city slaughter
house. Because vultures/ big birds gather in such ground to eat the waste
material & sit & rest on the conductors or peak of tower or cross arm top or on top
of pin insulators and drop/ derail their waste material on the lines or flew at any
time at that time fault is created and lines/ feeders/ transformers trip making total
power zero & essential supply to water works/ hospitals/urban areas are affected
badly. Such problems have been faced in many states/ districts in rural/ urban
areas. More ever vultures / big birds are dead thus diminishing in numbers, thus
making unbalance in nature from envoi mental point of view as well as loss of
power & cause of interruption. Remedial action is to be taken to increase the
clearance/ providing bird guards on tower/ line top, cross arms.
To protect the interruption due to the reasons as above, instantaneous relays are
required to be installed & their proper setting is carried out. If proper setting is
not carried out their will be the same problem as it was prior to installation of inst.
Relays & will cause system disturbance at the time of tripping depending upon
fault intensity on lines.
Normally on power transformers instantaneous relays are installed on EHV & LV

side both. Both side settings are co-coordinated because improper setting will
cause fault current & its stresses subjected to the transformer windings. More
ever such relays can be installed on lines/ out going feeders also. But settings are
carried out in proper & correct way.
SETTINGS (HIGH SET)
In power transformers on primary side instantaneous relays are set for 6-8 times
of normal maximum current in case of any fault. On secondary side in LV side it is
kept 6 times.
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For EHV side CTs are of Ratio: 200/5 Amps.
Primary fault current can be 6 x 200=1200A
Correspond fault current in secondary will be= 6 x 5=30A
In old English Electric/ ALSTOM relays settings will be K1 x K2=30
K1 x K2=30, we may keep K1=10, K2=3 or K1=20, K1=1.5 whichever is possible for
Setting result as K1 x K2=30.
Similarly setting can be carried out 6 times fault current as above but not exceeding the
transformed (primary) fault current.
In some of the relays Links are provided as Link-1, Link-2, Link-3 & K values on a dial
type pot. In front panel of the relay on left side.
ILLUSTRATIONS OF CALCULATION, TESTING & SETTINGS

Example-1:
EHV side CTs: 400/1A for 220KV side of 50MVA Transformer (O/C PS is= 0.4)
O/C Set is 2.4 times fault current in primary= 2.4 x 400=960A, LV transformed fault
current= 960x (220/66) =3200 A on 66KV side.
Correspond fault current in secondary will be= 2.4 x 1=4A
E/F Set is 2x1=2A, primary E/F current is 2x400=800A
For OVER CURRENT Inst. For EARTH FAULT Inst

(960A, 2.4A) (800A, 2A)
LINK LINK x K SETTING
LINK-1 4 x K value
LINK- 2 x K* 2 x
2* value 1.2*=2.4A
LINK-3 1 x K value
LINK-1 4 x K value
LINK- 2 x K* 2 x 1*=2A
2* value
LINK-3 1 x K value
LV side CTs: 600/1A for 66 KV side of 50MVA Transformer (O/C PS is=1)

O/C Set is5 times fault current in primary= 5 x 600=3000A, 220 KV side fault current
will be=3000/ (220/66) =900 A
Correspond fault current in secondary will be= 5 x 1=5A
E/F Set is 2x1A, primary E/F current is 2x600=1200A
For OVER CURRENT Inst. For EARTH FAULT Inst
(3000A, 5A) EHV (900A) (1200A, 2A) EHV (360A)

LINK-1 10 x K value
LINK-2* 5 x K* value 5 x 1*=5A
LINK-3 2.5 x K value
LINK x K SETTING
LINK-1 LINK
LINK-2* 2 x K* value 2 x 1*=2A
LINK-3 1 x K value
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Example-2:
HV side CTs: 100/1A for 66 KV side of 10MVA Transformer (O/C PS is=1)
O/C set is 10 times fault current in primary= 10 x 100=1000A, 11 KV side fault
Current will be=1000/ (66/11) =6000 A
For O/C Relays Correspond fault current in secondary will be=10 x 1=10A
E/F Set is =4 x 1=4A, primary E/F current is 4x100=400A
OVER CURRENT RELAYS Inst. EARTH FAULT RELAY Inst.

(10x1000=1000A, 10A) (4x100=400A, 4A)

LINK-1 4 xK value 4 x 1*=4A
LINK-2 2 x K value
LINK-3 1 x K value
LINK-1 10 x K value 10 x 1*=10A
LINK-2 5 x K value
LV side CTs: 800/1A for 11KV side of Transformer (O/C PS is=0.5)
O/C set is 5.5 times fault current in primary= 5.5 x 800=4400A, 220 KV side fault
current will be=4400/(66/11)=733.33 A
Correspond fault current in secondary in LV will be=5. 5 x 1=5.5A
E/F set is 4.8x1=4.8A, primary E/F current is 4.8x800=3840A

(5.5x800=4400A, 5.5A) HV (733A) (4.8x800=3840A, 4.8A) HV (640A)
LINK-1 4 x K value 4 x 1.2*=4.8A
LINK-2 2 x K value
LINK-3 1 x K value

LINK-1 10 x K value
LINK-2* 5 x K value* 5x1.1*=5.5A
Example-3:
CTs: 400/1A for 11KV FEEDER (O/C PS is=1)
O/C set is 2.5 times fault current in primary= 2.5 x 400=1000A,
Correspond fault current in secondary in LV will be=2.5 x 1=2.5A
E/F set is 1x1=1A, primary E/F current is 1x400=400A
2121212121212121212121212121212121
(2.5x400=1000A, 2.5A) (1x400=400A, 1A)
LINK-1 10 x K value
LINK-2 5 x K value
LINK-3* 2.5 x K value* 2.5x1*=2.5A
LINK-1 4 x K value
LINK-2 2 x K value
LINK-3* 1 x K value* 1x1*=1A
Example-4:
CTs: 40/1A for 11KV side of Station Transformer (O/C PS is=0.5)

O/C set is 5 times fault current in primary= 5 x 40=200A, Correspond fault current in
secondary will be=5 x 1=5A
(5.5x40=200A, 5A) (2x40=80A, 2A)

LINK-1 4 x K value
LINK-3 1 x K value

LINK-1 10 x K value
Example-5:
CTs: 200/1A for 11KV side feeder of Transformer (O/C PS is=0.75)

O/C set is 5 times fault current in primary= 5 x 200=1000A, Correspond fault current in
secondary will be=5 x 1=5A
(5.5x200=1000A, 5A) (2x200=400A, 2A)

LINK-1 10 x K value
2222222222222222222222222222222222
LINK-1 4 x K value
LINK-3 1 x K value
RELAY TESTING FORMAT FOR 220/66KV, 50MVA TRANSFORMERS ( EHV CT 400/1)
DIRECTIONAL OVER CURRENT RELAY R-ф

TYPE CDD MAKE: ALSTOM/……………..
SR. NO. ………………………………………….
MODEL NO. …………………………………….
Time Plug Inst. K Inst. Link

Original Setting Setting Value Connection
Setting 0.3 0.4 1.00* Link: 2
K Value*2
INSTANTANEOUS RELAY INVERSE TIME RELAY R-ф

LINK-1 LINK-2 LINK-3
K*4A K*2A K*1A
K=1.0 3.85 1.97 0.95
K=1.2 4.70 2.38 1.18
K=1.4 5.50 2.83 1.42
PLUG PICK UP Operating Time for Second. Current
SETTING CURRENT 2 Times 4 Times 10 Times
0.20 0.21 11.84 6.25 3.34
0.30 O.32 11.67 5.90 3.24
0.40 0.43 11.07 5.62 3.19
DIRECTIONAL OVER CURRENT RELAY Y-ф

SR. NO. ………………………………………….
MODEL NO. …………………………………….
2323232323232323232323232323232323
Time Setting Plug Inst. K Inst. Link
Original Setting Value Connection
Setting 0.30 0.40 1.20* Link: 2
K Value*2
INSTANTANEOUS RELAY INVERSE TIME RELAY R-ф

Setting 0.3 0.4 1.00* Link: 2
K Value*2

K*4A K*2A K*1A
K=1.0 3.70 1.80 0.95
K=1.2 4.40 2.20 1.15
K=1.4 5.30 2.60 1.34
0.20 0.22 13.06 6.49 3.48
0.30 O.33 12.65 6.14 3.33
0.40 0.44 12.01 5.86 3.27

Setting 0.3 0.4 1.00* Link: 2
K Value*2
DIRECTIONAL OVER CURRENT RELAY B-ф

SR. NO. ………………………………………….
MODEL NO. …………………………………….

Setting 0.30 0.40 1.20* Link: 2
K Value*2
INSTANTANEOUS RELAY INVERSE TIME RELAY B-ф
0.20 0.21 11.91 6.23 3.40
0.30 O.32 11.51 5.94 3.32
0.40 0.43 11.22 5.72 3.26
K*4A K*2A K*1A
K=1.0 3.65 1.80 0.94
K=1.2 4.35 2.15 1.12
K=1.4 5.20 2.60 1.34

Setting 0.3 0.2 1.00* Link: 2
K Value*2
2424242424242424242424242424242424
DIRECTIONAL EARTH FAULT RELAY
SR. NO. ………………………………………….
MODEL NO. …………………………………….
INSTANTANEOUS RELAY INVERSE TIME RELAY E/F

0.20 0.21 11.69 6.11 3.42
0.30 O.33 11.38 5.83 3.28
0.40 0.44 10.76 5.61 3.20
K*4A K*2A K*1A
K=1.0 4.00 2.05 1.03
K=1.2 4.70 2.35 1.20
K=1.4 5.45 2.75 1.41
RELAY TESTIMG FOR FEEDER INVERSE TIME RELAYS (C.T. RATIO-800/1)

Time Plug
Setting Setting
Original Setting 0.3 0.5
DIRECTIONAL OVER CURRENT RELAY R-ф

SR. NO. ………………………………………….
MODEL NO. …………………………………….
INVERSE TIME RELAY R-ф

0.50 0.53 10.22 4.38 *
1.00 1.07 9.51 4.01 *
1.50 1.60 9.55 3.39 *

SR. NO. ………………………………………….
MODEL NO. …………………………………….
Time Plug
Setting Setting
NVERSE TIME RELAY Y-ф

2525252525252525252525252525252525
0.50 0.55 10.52 4.51 *
1.00 1.28 10.22 4.13 *
1.50 1.65 9.81 4.04 *
DIRECTIONAL OVER CURRENT RELAY B-ф

SR. NO. ………………………………………….
MODEL NO. …………………………………….
Time Plug
Setting Setting
NVERSE TIME RELAY B-ф

0.50 0.53 11.15 4.51 *
1.00 1.06 10.33 5.26 *
1.50 1.66 10.13 4.00 *

SR. NO. ………………………………………….
MODEL NO. …………………………………….
Time Plug
Setting Setting
NVERSE TIME RELAY Y-ф

0.50 0.53 10.22 4.38 *
1.00 1.07 9.51 4.01 *
1.50 1.60 9.55 3.39 *
2626262626262626262626262626262626
RELAY TESTING & RELAY TEST SETS
08
GENERAL ITEMS FOR RELAY TESTING WORK WITH OTHER REQUIRED
TESTING:
1. PRIMARY LOADING TRANSFORMER

(Input: 0-230Volts, Out put: 10Volt, 500A)
(Manufactured by Amar Electricals
Factory-36, Dena Industrial Estate, Thane-400 601,
Ph. 5364256)
2. DIMMERSTAT: Continuously variable auto transformer
Type: 20, D-1P, no. 4051090974164 Max. Load: 20Amp.
Max KVA: 5.4 Input: 0-240V, 50/60 Hz, Out put at E &
C: 0-240 Volts or 0-270Volts for Input at A & C or B & C
respectively. Manufactured by Automatic Electric Ltd.,
Bombay-31.
3. Secondary Injection Test Set.
4. Digital Tong Tester (20 mA-20-200A)
5. Digital Multi Meter.
6. CT Polarity Tester.
7. D.C. source for testing Relays
Inverse time characteristic may be 3 sec. for 10 times current or 1.3 sec. for
10 times current as per field requirement in EHV/ HV or LV system
respectively.
TABLE (Showing permissible deviation in test results)
Sr. Injected Time of operation Time of

No. current as operation
As that of Per IS:3231/1965 at TMS 0.1
plug setting TMS 1.0
multiplier
(PSM)
01 2 times 10.0 sec. + 1.0 sec. +
12.5% 12.5%
02 5 times 4.3 sec. + 7.5% 0.43 sec. 100
m.s.
03 10 times 3.0 sec. + 7.5% 0.3 sec. +
100 m.s.
2727272727272727272727272727272727
RELAYS TESTING
1. GENERAL CHECKING
(a) FOR LOOSE CONNECTION,

(b) AUTOMATIC CT SHORTING LINKS,
(c) DC ISOLATION SWITCH,
(d) CONTACT CLEANING,
(e) CONTACT GAP,
(f) RELAY CONTACT GAP SPACER POSITION/ CONDITION,
(g) RELAY CASE ASSEMBLY EARTH CONNECTION.
(h) RECORD OF EXISTING PLUG SETTING, TIME MULTIPLIER SETTING,
(FOR TIME & INSTANTANEOUS SETTING) ON RELAY UNDER TEST.
2. INSULATION TEST/ MEASUREMENT WITH 500V MEGGER (keeping all secondary

connections shorted together).
3. SECONDARY CURRENT INJECTION
(a) STARTING CURRENT,

(b) CONTACT CLOSING CURRENT,
(c) RELAY ALARM/TRIP CONTACT CLOSING TIME AS PER RELAY CHARACTERSTIC
CURVE,
(d) CORRECT OPERATION OF RELAY/ FLAG/ INDICATION.
04. PLUG SETTING & TIME MULTIPLIER SETTING AS PER FIELD REQUIREMENT.
2828282828282828282828282828282828
POWER SYSTEM RELAY CIRCUITS GENERAL IN USE.
09.
Various type of power system relays are used at EHV sub-stations,
manufactured by various companies like English Electric
(ALSTOM/AREVA), ASHIDA/ Universal Electric/ E.R. (Easun
Reyolee) /ABB/JVS/JYOTI/L&T/SIEMENS etc. Some of the relays
are electromagnetic type & others are microprocessor based.
Numerical relays are the latest one. Relay characteristics & circuits
are as per the manufacturers, but useful in the field as per
requirement of power system engineers.
Some relays circuits are produced here to get introduce the power
engineers for the purpose of understanding the relays & its function.
2929292929292929292929292929292929
CDG 11 O/C or Earth Fault Relays. (51/ 64)
SELF POWERED CDG-11 E/F RELAY CIRCUIT
To Alarm
R
2
S2
S1
Y S1
S2
B S1 S2
Automatic C.T. shorting contacts
To Trip
IS: Isolating Switch
3 4 5 6 7 8 9 10
O/C Plug Settings
IS
% 50% 75% 100% 125% 150% 175% 200%
Rated
PS 5A 2.5 3.75 5.0 6.25 7.5 8.75 10.0
Rated
PS 1A 0.5 0.75 1.0 1.25 1.5 1.75 2.0
3030303030303030303030303030303030
b) 2 Over Current + 1 Earth Fault Relay i.e. CDG-31 type Relay Circuit
3131313131313131313131313131313131
c) CDD 21 Relays (67) Directional Earth Fault Relay
Function of the CDD relays is the same as that of CDG 11 except that CDD relays are
3232323232323232323232323232323232
connected With V.T. phases like A phase CT with VT of B & C phase in directional over
current relay & B phase CT with VT of C & A phase in directional over current relay C phase
CT with VT of A & B phase in directional over current relay. For directional earth fault
relay, it is connected with open delta of V.T. cores.
d) Differential Relays for transformer protection system. (87)
Detail about differential relays mentioned in the topic on transformers. Relay generally
used are DDT, DMH. DTH, MBCH, MICOM, SIPROTECH, REL, MIT, MIB, ALSTOM,
SIEMENS /ABB/ ER EASUN etc.
Diagram of the arrangement of main and interposing/ matching transformers with wiring /
connections is as under.
e) DISTANCE PROTECTION FOR TRANSMISSION LINES. (21)

SSRR3V, QUDROMHO, PDS521, PYTS, PYTC, MICOM, REL, SIPROTECH,
3333333333333333333333333333333333
THR- 3PE1(ER make). For the operation of the distance protection scheme,
most important factors are the impedance of line, CT current & PT voltage in the
system. In case of fault any of the parameters when vary, the distance protection
scheme gives signal for tripping the connected circuit breaker in the circuit/
feeder. Various types of distance protection scheme are available like SSRR3V,
PYTS, QUDROMHO, MM 1T, MM 3T etc. Relays manufactured by ABB & E.R. are
also in use by some utility department of Electricity, Departments, / State
Electricity Boards etc... But now a days the micro processors relay MICOM
manufactured by M/S ALSTOM (AREVA), SIPROTEC by M/S SIEMENS are
popular and best suited in power system which reveals the occurrence of fault
sequence in systematic way including the time of flow of fault currents, circuit
breaker operation and indicating the probable exact distance in km i.e. the
location of the fault & phase wise indication at the time of fault with date & time of
operation with no. of other information’s.
Article I. (Moreover all electromagnetic relays for Differential & Distance are now
obsolete & out of use now a days) Example of calculations for commissioning:-
Example-1. Distance Protection Scheme type QUDROMHO-21:- 220KV GSS PHULERA:
Article II.
TYPE OF SCHEME: Qudromho-21

CTR: 800/5
PTR: 220KV/110V
CTR/PTR = .08
3434343434343434343434343434343434
Z1=0.079+J0.4Ω/KM = 0.41∟78.6.
Z2=0.27+J0.27Ω/KM =1.30∟78.6.
ZONE 1=90% PHULERA-AJMER
=0.9 x 75.2 x 0.41 x 0.08.
=2.219Ω
K1 = 4, K2 =0.8
Zph = (K1+K2)/In = 4.8/5 =0.96
(K1+K2+K3)K14= (Z1/Zph) = (2.3/0.96)
k11=2.0
k12=0.3
k13=0.00
k14=1
Z1= (k11+k12+k13) k14 x Zph= (2.3) x 1 x 0.96=2.217Ω
ZONE 2=100% PHULERA-AJMER+50% AJMER-BEAWER

= (75.2+0.5 x 69.31) x 0.41 x 0.08
=3.603Ω
Z2= (K21+K22) x K14 x Zph
Z2/Zph = (3.8/0.98)= K21=3, K14=1, K22=0.8
Z2=3.8 x 0.98=3.564Ω
ZONE3=100% PHULERA-AJMER+AJMER-BEAWER
= (75.2+69.31) x 0.41 x 0.08
=4.739Ω
Z3 = (K31+K32) x K33 x Zph
(K31+K32) x K33= (Z3/Zph) = (3.4/0.96)
K31=3
K32=0.4
K33=1
Z3 = (3+0.4) x 1 x 0.96
=3.264Ω
Z3 reverseZ3' = 0.25 x 13.169
3535353535353535353535353535353535
Z3'= (K35+K36) x K33 x K37 x Zph
(k35+k36) x k33 x k37= Z3'/Zph=3.291/0.36=9.142
K35=1, K36=0.8, K33=5, K37=1
Z3'= (1+0.8) x 5 x 1 x 0.36=3.24
NEUTRAL IMPEDENCE SETTING ZN
K4+K5+K6=1/3((Z0/Z1)-1) (KI+K2))
=1/3((1.3/0.41)-1) (1+0.8)
=1.303
RESIDUAL COMPANSATION FACTOR =ZN/Zph= (0.262/0.36) =0.73
PSB Z6 (FORWARD) =1.3 x 23=
Z6 (REVERSE) = Z3'+0.3 x Z3
Example-2: COMISSIONING OF DISTANCE PROTECTION SCHEME PYTS-204

AT 66KV SUB-STATION VARKUND, CONSIDERING 66KV V, M, K, AND D LINE
Length of the lines
1. 66 KV V to M 3.75 Km.
2. 66 KV M to K 2.65Km.
3. 66 KV K to D 9.25Km
C.T. Ratio 1200/1 Amp 1200 x 110
----------------------------- = ---------------- = 2.0
PT Ratio 66KV/110V 66000
S/S K
S/S V S/S M S/S D
3.75KM 2.65KM 9.25KM
PRIMARY:-
Positive sequence impedance=0.042+j0.187
=0.191<77°
3636363636363636363636363636363636
Zero sequence impedance=0.0786+j0.276
=0.286<74
SECONDARY:-
PTR=66000/110
CTR=1200/1
Trans. Ratio= CTR/PTR= (1200x110)/66000=2.0
Positive sequence Impedance= o.191< 77°/ x 2 =0. 382<77°/KM
Zero sequence Impedance= o.286< 74 °/ x 2 =0. 572<74°/KM
Z1 Setting=80% of 3.75KM
=0.8x3.75x0.382
=1.15Ω
(Zone I)
Z2 Setting= Positive sequence impedance x (100% of first line +50% of next line)
= (3.75x0.382) + (0.5x2.65x0.382)
=1.43+0.50
=1.93Ω
(Zone II)
Z3 Setting=Positive sequ. imped. X (100% of first line+ 100% of 2nd line+20% of 3rd
line)
= 0.382 (3.75 + 2.65 + 0.2 x 9.25)
=1.43+ (2.65x0.382) + (0.2x9.25x0.382)
=1.43+3.03+0.7067
=5.1667Ω
(Zone III)
SETTINGS IN RELAY:-
Z1=K1 x Kz x KD
Select, KZ=2.0,KD=1.0
K1=Z1/ (KZ x KD)
=1.15/ (2.0x1.0
K1=0.58
3737373737373737373737373737373737
SETTING VALUES:
Now say, K1=0.6 & fixed value selected KZ=2.0,KD=1.0
K1=0.6
Z1=0.6x2.0x1.0 KZ=2.0
=1.2Ω KD=1.0
SETTING VALUES:
Z2=K2 x Z1
K2=1.6
K2=Z2/Z1
K3=4.30
=1.93/1.2
K2=1.6
Z3=K3 x Z1
K3=Z3/Z1 =5.1667/1.2 K3=4.30
STARTER SETTING: -
ZA=ZB=ZC=25 ohms.
(a) 63.5 ZP=35 ohms.
1.1x (125/100) x1.0 110/1.732=63.5Volts.
=46Ω
Full load Current=1.0A, 125%
Zo-(+Z1) (0.572-0.382)
(b) Z3 setting x (1+K), K=------------ ---------------=0.166
=5.1667x (1+0.166) 3 x (+Z1) 3 x 0.382
=6.024 say=6Ω
So. Select 25Ω as starter setting
ZPH=ZA=ZB=ZC=25 ohms.
PSB SETTING: - =35Ω
E/F Compensation K= (0.572-0.382) /3x0.382
=0.166
(K1NxKZN)/K1xKZ=0.166
3838383838383838383838383838383838
K1NxKZN= 0.166 x (0.6 x 2.0) =0.1992
Say K1NxKZN= 0.2
Minimum setting available=0.5x1=0.5
Article III.
Article IV. Example-III: Setting Calculations for PYTS 204 Relay IN VARKUND
66KV S/S
Section IV.1 FEEDER: DALWADA Feeder 66KV
DALWADA VARKUND KACHIGAM

DABHEL
3.49km 9.25km
2.65km
PRIMARY:-
Positive sequence Impedance= 0.042+j0.187 =0.191<77°
Zero sequence Impedance=0.0786+j0.276 =0.286<74°
SECONDARY:-
PTR=66000/110
CTR=1200/1
Turn Ratio=CTR/PTR=2.0
Positive sequence Impedance=0.382<77°/km
Zero sequence Impedance=0.572<74°/km
Z1 setting=80% of 3.49 km
=0.8 x 3.49 x 0.382 =1.07Ω
Z2 setting=150% of (100% of 1st line + 50% 0f 2nd line)
= (3.49x0.382) + (0.5x9.25x0.382)
=1.33+1.77 =3.1Ω
3939393939393939393939393939393939
Z3 setting=220% of (100% of 1st line + 100% of 2nd line + 20% of 3rd line)
=1.33+(9.25x0.382)+(0.2x2.65x0.382)
=0.202+1.33+3.5 =5.06Ω
SETTINGS IN RELAY
Z1=K1xKDxKZ
K1=Z1/KDxKZ
=1.07/2x1 =0.55
Z1=K2x Z2
K2=Z1/Z2=3.1/1.1=2.8 Ω
Z3 =K3x Z1
K3=Z3/Z1=5.06/1.1 =4.6Ω
STARTER SETTING-:
(a) With Full Load Current = 1.0
Starter =46Ω
(b) Z3 Setting (1+k) = 5.8Ω
Starter setting= 25Ω
PSB SETTING:-
Tp=40ms
P= C position, ZP = 35Ω
E/F COMPENSATION:-
K=Z0-Z1/3Z1=0.572-0.382/ (3x0.382)
=0.166
(K1NxK2N)/ (K1xK2) =0.166
K1NxKZN=0.166x1.1=0.18
Minimum setting available=0.5x1= 0.5
f) TRIP CIRCUIT SUPERVISION RELAYS (Pre-close & post close) (95 / 195 / 295)
95 denotes for trip circuit supervision of trip coil of breaker of 33KV or 11KV or any
Breaker having one trip coil only.
195 denotes for the trip circuit supervision of trip coil no.1
295 denotes for the trip circuit supervision of trip coil no.2
In pre close trip circuit supervision 95/ 195/ 295 A & B both coils are charged as
4040404040404040404040404040404040
shown in drawing, where as only A coil is charged while at the time of post close
trip circuit supervision. It is clear from the circuit shown that C coil is charged
when A or B, or A & B both are charged (after close or pre close) & contacts of coil
A & B are closed for giving alarm contact or signal. Please refer the drawing:-
Whenever the trip circuit is faulty indication is appeared on the enunciator
panel for trip circuit faulty, the relay position must be checked like relay flag is
for pre close trip circuit supervision or after close trip circuit supervision, looking
to the position of circuit breaker open or closed respectively. More ever it is to be
seen which phase/ pole of circuit breaker & trip circuit-1 or trip circuit-2 is
operated on the relay panel. Operation of trip circuit supervision indicates/ gives
the signal/ alarm for the fail / missing of
i. D.C. + ive or
2. D.C, - ve or
3. Burning of trip coil-1 or trip coil-2 or its resistance in series with it.
Now the TC-1 or TC-2, D.C. fuses/ links or healthy ness of the resistance in series
with the trip coils can Be checked & defective fuses, coils, resistance can be
replaced as required. It may happen sometimes due to defects in the NO, NC
contacts of auxiliary switch or non-operation of auxiliary switch of the circuit
breaker. Careful examination of the above noted points will certainly help in
tracing the reasons of the trip circuit faulty and its easy rectification.
Please refer the drawing at next below for the trip circuit supervision relay
generally used in power system.
4141414141414141414141414141414141
g) AUXILIARY RELAYS for transformer protection (Oil/ Winding/ Buchholz/ Oil Surge/PRV) (30)
h) MASTER TRIP RELAYS. (86)

Any over current/ earth fault/ or fault actuating relay like Buchholz, OT trip/
winding temp. trip Over flux relay etc., signal is initiated through to the master trip
relay to finally trip the circuit Breaker & isolate the faulty system/ section from the
healthy system immediately in power system or at a sub-station. Its circuit is shown
here in drawing:-
4242424242424242424242424242424242
MASTER TRIP RELAY 86
Rear View of Terminals
8L31 L31 7 L29
9 K47 3 K1 1 K11
10 K2 4 K3 2 K11A
6L7
5L1
6L7
Contact Function
K1 K3 To Tripping Coil of C.B.

3 4
K11 K11A Ready for Closing Command to C.B.

1 2
L1 L7 For Alarm ckt. / Indication ckt.

5 6
L29 L31 Spare or Remote Panel

7 8
K2 K47 For Trip Signal from O/C, E/F Relay or Any Other Relay
10 9
K1 K3 To Tripping C.B. as at 1
3 4
i) LBB Protection (50 Z), 2/50Z Timer for LBB Protection Relay
j) Bus-Bar protection.(96)
k) VOLTAGE SELECTION RELAYS (75)

Voltage selection is used in a sub-station having two Bus system & P.T. or CVT are
mounted on both Bus-1, Bus-2,. Voltage selection have five elements of coils like
75A&75B; 75C&75D; & 75E&75F coils charged through isolators for Bus-1 V.T.
selection & Bus-2 V.T. is selected. A or B coil contacts arrange V.T. supply to
4343434343434343434343434343434343
distance protection scheme where C or D coil contacts arrange VT supply for the
Directional over current relays & E or F coil arrange VT for synchronizing, Energy
Meter, W.M., VAR meters.
l) OVER FLUX RELAY (99)
Power Transformers are designed to function at or to level of a maximum
magnetic flux density in transformer core i.e. flux linkage thereby limiting the
eddy currents in CRGO core, causing heating/ over heating of core in very short
time, may damage the core insulation & nearest winding. Magnetic flux in core is
proportional to the voltage applied to the winding divided by the impedance of
transformer winding. Thus flux in core increases/ decreases with proportional to
increase/ decrease in voltage during initial charging after shutdown or sudden load
reduction on Generator Transformer or Power Transformer can subjected to
excessive Voltage to Frequency ratio and core is over excited , operating in non
leaner magnetic characteristic i.e. odd 5th/ 7th/ 9th harmonic components in
exciting current are created, responsible for damage of core & its nearest winding.
Some of the manufacturers provide nearest winding in open delta i.e. is called
tertiary winding. Tertiary winding is of two types Loaded tertiary or un loaded
tertiary. In un loaded tertiary winding (nearest to core) open delta terminals are
brought through bushing on top of transformer & shorted through copper plate &
further earthed to a good earthing pit to pass the odd harmonics generated to
earth.
Over flux relays are used on EHV power transformer on EHV side, some times on
LV side also on relay panels for its protection from over voltage due to sudden
load thrown off on feeders fed from power transformer.
Normally OLTC system is on HV side in two winding transformer or

Autotransformer of rating 220/132KV or 220/66KV, 132/33KV, 132/11KV,
66/11KV. Here in this case VT supply is connected to over flux relay from
respective EHV side VT & LV side VT only.
If separate VT is installed on transformer, the same VT is to be used for over flux
relay in place of Bus V.T.
Also in case of 132/33KV or 66/11 KV transformers, tap changers are provided on

EHV side only, here the VT supply from main Bus EHV PT or VT is not advised
4444444444444444444444444444444444
because in case load thrown off suddenly on LV side & LV side capacitor banks
switched on, the LV side voltage will boost up along with the capacitor banks in
circuit (if over voltage setting is higher it will not trip) & LV side winding will be
subjected to abnormal higher voltage, such LV side high voltage can damage the
bushings, winding insulation. Hence, in such transformer only LV side VT must be
used for connecting over flux relays.
Hence VT supply of LV side should be used in over fluxing relay of transformer
having OLTC on EHV windings.
OVERFLUX RELAY SETTING CALCULATIONS IN POWER SYSTEM:
Over flux relays are generally installed on generators at generating station & on
power transformer at EHV sub-stations. It is very difficult to understand or create
setting because it is not clearly mentioned any where in books or in manuals of
relays. There are chances of failure of windings of power equipment like power
transformer if over flux relay not operating properly i.e. safe guarding against
abnormal rise in system voltage & frequency at any time due to any reason. It is
explained here with easy calculations as under:-
Take example of English Electric /Alstom/ Areva relays generally in use at sub-
stations..
A. RELAY INVERSE CHARACTERISTICS FOR ALARM OF OVER FLUXING:
V/f=K1 x Vn/Fn
V= Actual system Voltage available
F= Actual system frequency available
Vn= Normal Voltage for relay 110 V
Fn= Normal frequency for relay i.e. 50Hz.
Hence K1= (V x fn ) / ( Vn x f )
Suppose voltage are increased by 10% on 66KV side (LV winding of transformer),
actual voltage available will be= 66 + (66 x 10%)= 66+6.6=72.6 KV
Corresponding secondary voltage in PT/ VT circuit will be around 121 Volts.
Also suppose power system frequency is suddenly raised to 50.5Hz.
So V=121 V, f=50.5 & Vn =110 V, fn =50Hz
So value of K1= (121x 50) / (110x 50.5) =1.089 say 1.0
Thus K1=1
B. SIMILARLY FOR INST. SETTING (TRIP)

V/f=K1 x K2 (Vn/Fn)
4545454545454545454545454545454545
Hence K1 x K2= (V x fn ) / ( Vn x f )
So value of K1x K2= (121 x 50) / (110 x 50.5) =1.089
So K2= 1.089/ 1.0= 1.1
Thus K1 is set on dial as 1.0 & K2 is set as 1.1 for safe guarding against sudden
rise in Voltage by 10% i.e. up to 72.6 KV instead of normal voltage 66 KV
C. Also E=4.44 f ф N
E= system voltage
Ф=flux in core/ in further winding may be tertiary or LV
F=system frequency
N= Number of turns in winding in LV (constant)
So ф= E / (K x f)
If voltage is increased by 72.6 KV, system frequency becomes=50.5 Hz Ф
(flux) will be increased more in core & correspondingly induced in nearest winding
tertiary or HV winding, then to LV winding, as such winding can get damaged due
to heating of core.
Hence care is to be taken for carrying out setting to protect from over voltages to
power equipments.
m) CIRCUIT BREAKER TROUBLE SUPER VISION RELAY. (VAA 21)

This circuit is useful for the interlocking of any system like low SF-6 blocking etc.
with the circuit breaker or any other interlocking, deemed proper.
4646464646464646464646464646464646
AUXILIARY RELAY FOR TRANSFORMERS FAULTS:
(30A&B, 30C&D,30E&F etc.
These relays are used to get signal from mechanical operation of the Buchholz /
OSR/ Oil temperature/ winding temperature/ PRV operation etc. at the time of
any abnormal happening in the power transformer & switching action from
transformer mounted above element at any time to so normally called 30
auxiliary relay, when energized give trip juice to the master trip relay so as to
trip the circuit breaker & isolate the transformer instantly.
This relay will reset only when cause of operation is attended/ rectification done/
rectified i.e. the 30 relay is de-energized. The generally adopted relay circuit
diagram is produced here to understand the function of the relay for alarm &
tripping purpose.
4747474747474747474747474747474747
9(K563) 5
13(K201)
G
3(K201)
1
10(K202)
4(K203(T)) 2 14(K203)
6(L301)
8 1999919999921199999
18 17 16
19(K565)
H
18 17(L231) 16(L301)
20(K202)
G 10
(K563)9 5 20(K565)
19 H
2
15
1
11 12
14(203)(T)
(K201)3 (K201)13
4(203)(T)
17(L231)(ALARM)
(L301)6 (L301)16
7(L231)
999999999999999
4848484848484848484848484848484848
n) D.C FAILS CIRCUIT SUPER VISION:
D.C. fail circuit super provision is made in control & relay panels to ascertain the
availability of D. C. supply continuous to the relay panels to trip/ close/alarm &
other signals at the time of any operation. As seen in following circuit D.C. & A.C
both are connected with relay as per provision. When ever D.C. +ive or D.C. –ive
fails or push button in D.C. control circuit is pushed for test, D.C. circuit is broken,
simultaneously, two contacts with incorporated D.C. coil become NC, A.C. supply
is connected to lamp giving indication for D.C. fail, also the A.C. hooter also gives
alarm through NC contact of A.C. coil de energized now. To silence the hooter
Push button is pressed to energized its A.C. coil and its NC contact causing hooter
alarm is NO. Whenever D.C. supply is restored, the A.C. contactor is energized by
opening the contacts NC to NO position (of DC coil) in circuit.
4949494949494949494949494949494949
RELAY TESTING FORMAT GENERALLY IN USE
10.
e)
(i) CUSTOMER SUPPORT DEPARTMENT f)
g)
a) QUALITY PLAN FOR h)
Form No.:
b) RELAY TESTING AT SITE i)
c) Commissioning Test Schedule for Inverse time
JBSEPL/07
non-directional & directional
d) j)
over current and earth fault relays type CDG/CDD/,
Sheet 01
…………………
REFERENCE OF CALL FOR RELAY TESTING WORK : ……………………………………………

WORK ORDER NO.: ………………………………………………………………………………….…
1. LOCATION : …………………………………………………………….
2. OWNING AUTHORITIES : ……………………………………………………………
3. SYSTEM VOLTAGE : ……………………………………………………………
4. CIRCUIT DESIGNATION : ……………………………………………………………
5. AUXILIARY SUPPLY VOLTAGE : ……………………………………………………………
6. DATE OF TEST : ……………………………………………………………
7. TESTED BY : ……………………………………………………………
8. ACCEPTED BY. : ……………………………………………………………
(1) RELAY DETAIL:
Phase Relay type Serial No. Setting Range Type of operation MTA(CDD
Indicator relays)
A
B
C
E/fault
(2) a) CURRENT TRANSFORMER DETAILS:
Phase Type and Serial No. CT Ratio Accuracy Rated Burden Rated
make Class accuracy
limit factor.
A
B
C
Neutral
5050505050505050505050505050505050
(2) b) POTENTIAL TRANSFORMER DETAILS (For CDD relays):
Phase Type & Serial No. V.T. Ratio Accuracy Rated Burden Rated voltage
make(single Class factor and
phase or three time.
phase)
A
B
C
(2) (c) RESIDUAL VOLTAGE WINDING:
Type & Make Serial No. VT Ratio Accuracy Class Rated Burden
(3) GENERAL INSPECTION:
A B C E/Fault
(4) WIRING CHECK:
Wiring checked to (a) Wiring diagram No. ……………………………………………

(b) Schematic diagram No. ……………………………………
(5) INSULATION TEST:
Measure and record the insulation resistance at 1000V.
(a) to earth and between poles on all D.C. circuits with all links and fuses in, where possible.
(b) to earth of CT and VT wiring. All earth links to be in position except on circuit being tested.
(c) Between as many of the CT, VT and D.C. circuits as possible.
Circui DC DC DC CT to CT to VT to CT VT
t positive negative positive earth DC earth to to
to earth to earth to DC supply VT DC
negative
5151515151515151515151515151515151
(6) CURRENT/ VOLTAGE TRANSFORMER CHECKS:
(a) POLARITY :
A B C N
(b) RATIO TEST:
Phase Primary Secondary Measuring point Remarks

injected current current and phases
measured
A
B
C
N
(7) VOLTAGE TRANSFORMER CHECKS:
(a) POLARITY:
A B C
(b) RATIO TEST:
Phase Remarks
A
B
C
(c ) (i ) PHASING:
A-B B-C C-A A-N B-N C-N Broken

Delta
5252525252525252525252525252525252
(ii ) PHASE SEQUENCE CHECK: ………………………………………
(iii) OPERATION INDICATONRS CHECK:
Phase Minimum Operating Volts/ Amps.

A
B
C
E/F
(8) SECONDARY INJECTION TEST:
Phas Relay Current Time Starting Closing Operating time at

e Setting Multiplier Current Current Times current setting
Setting 2 5 10 20
A ……………%
(Rated tap) 1……..
…….%
(Service setting) 0.5……
B ……………%
…….%
C ……………%
(Rated tap) 1………
…….%
E/F ……………%
…….%
CONTINUITY OF ALL TAPPING:
A B C E/Fault
Plug bridge shorting contact satisfactory
A B C E/Fault
5353535353535353535353535353535353
Cup units: MTA of the relay: …………………………………………………………..
(9) TRIP AND ALARM CIRCUIT CHECK:
S.No. Particulars A B C E/Fault

a Prove manual operation of
relays results in correct
operation of appropriate
indicators and aux. relays.
b Alarm correctly Initiated.
c Correct circuit breaker
tripped.
(10) LOAD TEST:
Particulars A B C E/Fault
Load current (Circuit breaker)
Equivalent CT secondary current
Over current relay current
Earth fault current
Directional unit Polarity check
(for CDD relays)
SIGNATURE OF TESTING PERSONNEL TESTING & TEST RESULT

WITTNESSED BY
NOTE: Testing of all types of relays is essential for calibration check once year or two
times a year in dusty / polluted / humidity area /sea shore or costal area.
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CURRENT TRANSFORMERS & RELAY TESTING
11
11KV RESIN CORED CTs: INDOOR TYPE
Ratio may be 800-400/ 1-1-1 A
CT RATIO BURDEN CLASS CORE PURPOSE

800-400/ 1 15 VA 5 P 10 Core 1 For Over current, E/F Prot.
800-400/ 1 15 VA 0.5 Core 2 For Metering
800-400/ 1 PS (1.9/5 ohm) Core 3 For Differential Prot.
*5P10 means CT with 5% composite (Phase Angle & Ratio ) Error and 10VA burden in
Protection Core.
*0.5 means CT of accuracy class=0.5 for metering core.
*PS means CT with highest burden & knee point voltage used for Distance or Differential
or Bus-Bar Protection.
EHV/ HV CTs (OUT DOOR) may be up to 4 cores, 5 cores as per requirement

in the field/ power system
Purpose is for
1. Distance Protection in case of lines Main-I or Differential protection in
transformers.
2. Over current & Earth Fault Protection ( may be directional or non
directional)
3. Metering ( May be for energy account class 0.5or. commercial accounting
class 0.2)
4. Bus bar Protection scheme.
5. Distance Protection in case of lines Main-II
DISTANCE PROTECTION SCHEME:
In EHV lines for prompt & assured protection two distance protection schemes are
incorporated as Main-1 & Main-2 with two different cores of CT of class PS. Now a
days numerical distance protection relays are most preferred than other
microprocessor relays like as SIPROTEC 7SA52 (SIEMENS), REL 670 (ABB),
MICOM (AREVA/ALSTOM) showing almost exact distance of fault location.
Old obsolete relays like PYTS, QUDRMOHO SHPM 101, MM1T, MM3T, SSRR3V are
changed/ replaced in phased manner under renovation programmed by placing
RETROFITTING orders to the manufacturer of the relays.
DIFFERENTIAL PROTECTION SCHEME:
5555555555555555555555555555555555
Similarly micro processer based Differential Relays are preferred than traditional
old/ obsolete electromagnetic/ electronic relay like DDT/ D m h/ DTH31/ DTH32/
MBCH (E.E./ ALSTOM). ALIND relay, RADS (ABB). Now a day MIB 202 of ER is
also used in field for differential protection purpose.
OVER CURRENT & EARTH FAULT RELAYS:
In EHV system where numerical distance protection relays are used separate
Directional Over current & Earth fault relays are not required as the same feature
is incorporated in the scheme with all features of instantaneous / time etc.
Old relays of ASEA, JYOTI & CDD/ CDG of E.E./ALSTOM/AREVA were used but now
a days comparatively cheap & other relays are MIT of ER, JVS are prompt in
application in field having directional/ non directional/ inverse or very inverse
characteristics/feature in option.
RELAY SETTINGS:
INSTANTENEOUS SETTING:
In case of power transformers on EHV side settings is 6-8 times of normal rated
current but on LV side it is kept as 6 times because instantaneous element of LV
side must operate first than EHV side to clear the fault. The fault current reaching
to EHV winding should be interrupted first by isolation of LV winding from fault.
Improper setting of instantaneous relays results in the damage of LV winding or
EHV winding System in power transformers/ transformer i.e. the main cause of
damages in transformers.
For safety point of view such setting can be kept 2.5 times in EHV & 2 times in LV
relays. In case of any nearest bus duct fault or cable fault or any short circuit in
power or distribution cables will be cleared within no time.
TIME MULTIPLIER SETTING & PLUG SETTING MULTIPLIER:
TSM & PSM are important setting in IDMT relays. According to present maximum
loading plug setting are kept. In English Electric Relays it is minimum 50% & then
in steps of 25% increasing trend like 2.5-3.75-5-6.25-7.5-8.75-10 for 5Amp relay
& 0.5-.75-1-1.25-1.5-1.75-2 for 1 Amp relay, also relays with % of current setting
are also available & can be used for prompt protection of the power system in
case of any minor or major fault after the transformer or Incomer or feeder at
required setting of 20%, 30% 40% etc.
Time multiplier setting is also kept in consideration to relay characteristics & in

gradient way for cascade tripping only.
UTTERMOST CARE IN TESTING OF RELAYS:
Normally the testing party simply issues the test certificate & plays the game of
testing the relays in routine, after withdrawal out the relay from the relay case,
inject the current, and see the operating time. After such testing party see that
their responsibilities over or thinking it to be the job of other field officers. This
5656565656565656565656565656565656
procedure is sufficient for only issuing the test certificate but note in favor of the
power system.
EQUIPMENT FAILURES DUE TO IMPROPER WORKING:
At many places power transformers up to 50MVA damaged, CTs exploded/

saturated system, collapsed by above practice. The test certificates issued for
testing but it resulted in lot of damages/ break downs in power system.
As observed in the field, testing personnel do not bother or
 Do not pay attention after its required setting for PSM, TMS, before & after
relay testing.
 Do not check any loose connections of CTs or DC supply
 Do not check whether automatic shorting terminals in relay case are
correctly operating or not
 Do not check even DC trip terminal on relay is healthy
 Do not check whether the controlling circuit breaker trips with fault current
stimulation in relay.
It is definite that in above all cases no alarm or relay signal will be there to warn
for unhealthy power protection system like DC trip circuit fail/ trip circuit faulty/
trip coil not functioning etc except the failure of the equipment with power
interruption only. Hence nobody will try to look on these problems prior to any
occurrences which are not at all desired any time.
At some of the places in field that DC supply was intact, relay was operating on
fault, giving the annunciation of fault on facia window on panel but the circuit
breaker did not trip, the same caused the clearance of fault by next incomer
breaker, resulted in the damage of LV side winding of the power transformer. It
causes
01. Long Power Interruption due to damage of power handling equipments,

02. Financial implications out of Budget Provision,
03. In conveyance caused to consumers,
04. Loading/ Transportation/ unloading.
05. Wastage of time in further testing/ analysis/ decision/ approval for repair
services & financial implications and other activities etc.
There are numerous examples of burning & fire/ damage of

Power Transformers 400/220/33KV, 315 MVA “BHEL”,
Power Transformers 220/132KV, 100 MVA “CGL”,
Power Transformers 220/132KV, 50 MVA “TELK”,
Power Transformers 132/11KV, 10/12.5MVA TELK”,
Power Transformers 132/11KV, 6MVA“HHE”,
220KV SF-6 Circuit Breaker, “NGEF”
Current Transformers etc.
Damage & thrown up of Master Trip Relay with explosion
Bulging of 66/11KV, 10MVA Transformer.
Consequently causing cascade tripping causing dark/ blackouts in power system

unconvinced reply to utility.
5757575757575757575757575757575757
It is mentioned that along with damage of power transformer burnt to ashes,
nearby equipment were also damaged i.e. 390 KV L.A. 3 nos. on 400KV side of
Transformer, 216KV L.A. 3nos. on 220KV side of Transformer, 400KV Isolator one
no. Power equipment worth Crores of rupees burnt to ashes & heavy expenditure
incurred for removal of existing system & providing new equipment.
CASE STUDY: REPORT OF FAILURE OF 400/220/33KV, 315 MVA TR.
To avoid such situation, uttermost care is to be taken to identify the problems

before they lead to failures. During all testing stress should be given for
1. Tan delta value yearly as per CBIP, (may be done twice a year as per DTL)
2. SFRA once in two years.
3. DGA once a year (twice a year as per CBIP)
for which on line portable DGA EQUIPMENT is suggested because same
equipment can be used for many power transformers in a station & results
can be compared easily with same type of DGA test equipment for the
same transformer.
4. Furan & polymerization test
5. Circuit breaker opening time test
6. Relay trip test (Buchholz, OSR, PRD, and REF) is required at the time of
maintenance during shut down. All test should be confirmed by actuating
the relays only not by external shorting the switching contacts.
7. Normally Construction Agency charged the Power Transformer at
no load & declares “Transformer commissioned” as their
achievement only but the outgoing feeder/ bays are not ready or
connected/ commissioned for load out lets. This practice is not at all
acceptable in power system because when Transformer is not 70% or
100% loaded, its performance is not established.
At the time of first charging at no load, it should not be left as it is but load
should be released as early as possible, gradually up to 75%, 80%, 90%,
100% then to 110%, further to 120% by (increasing relay current setting), so
that system equipment performance is watched by rise in oil temperature,
winding temperature, automatic start of cooling fans, cooling pumps in cooling
bank, further observing oil temperature Alarm, winding temperature alarm,
then winding temperature trip. After such rigid testing after cooling the entire
system by cooling fans & pumps to normal temp., transformer should be
charged again for service.
By adopting above practice, actual performance of the Power Transformer & its
Associated Equipments, connected relays & metering system can be tested &
well established for its future satisfactory working.
5858585858585858585858585858585858
DELTA-STAR 2 WINDING TRANSFORMER CONFIGURATION
1U 2U
1V 2V
2W
1W
2N
STAR- STAR 2
1U 2U
1V 2V
2W
1W
2N
1N
NOTE: TAP WINDINGS ARE PROVIDED IN EHV/ HV SIDE WINDINGS ONLY.
5959595959595959595959595959595959
THREE PHASE OVERCURRENT & EARTH FAULT RELAY CIRCUIT
S2
P2 P1
S1
9 9 9 10
O/C R O/C Y O/C B E/F
10 10 10 9
6060606060606060606060606060606060
DISTRIBUTIONS SYSTEM:
a) Use of ABC (Arial bunched conductors) for L.T. distribution / Urban / Rural area to
prevent theft of energy.
b) Use of Single phase Transformers 11KV/230V for rural supply distribution for lighting,
for correct energy accountable.
c)Installation of theft prone meters with retrofit acrylic cover push fit meter boxes to
prevent theft of energy, energy meters available now a days with having record of past
six months and other features should be used for accurate energy accountable for
domestic and commercial ( non domestic) consumers.
d) Installation of capacitors for p.f. improvement by the consumers at the agriculture and
small industrial installations.
e) Periodical / Sudden checking of energy meters by reviewing the energy consumption
sudden fall by M.R.I. or aqua check of all consumers meters and industrial meters on
three phase system to locate the defaulter consumers, instance have been noticed that
many industrial units with the help of culprits successes in stopping the secure meters
on one phase by removing potential supply or making it slow by inserting resistances in
circuit after seal tempering with the help of few departmental staff or them selves. In
case MRI of industrial energy meters is not done by 100 %, there are chances of theft
like above. Particularly the MRI of the HT or large load medium load consumers is must
if there is variation in the energy consumption or in maximum demand, the records of
production, working shifts be considered to prove the less energy consumption in
factory. Installation of computerized energy meters at EHV Sub-stations for all feeders
and recording of energy data’s to evaluate energy losses, energy transmitted in the
system with GPS system.
g) The monthly (fixed numbers for each category consumers) regular vigilance checking
reports containing theft / excessive connected load, male practices with energy meters/
service lines are to be submitted by the respective Junior Engineers, Assistant Engineers
and Executive Engineers, including the meter site testing engineers in their jurisdiction
and related revenue accountants should assess the revenue realization on behalf of
such V.C.Rs (visilence checking reports )& effective recovery should be done.
h) For consumers with doubt of theft/ un fair practices for power consumption by passing
the energy meters, pole mounted (at height) energy meter as check meter should be
immediately installed & billing readings should be taken through it, in the last all energy
meters of all the category should be installed at the entry of main gate and in no case
meter should be installed in side the building or house or in a industrial unit.
6161616161616161616161616161616161
I) For overhead lines always use “D” loops on conductor for lifting jumper switch the
appropriate connector/ clamps to avoided the damage of main conductor while
disconnecting the jumpers at the time of dis-connection of T off lines/ connection.
j) Always use pointed spike or sharp teeth type bird guards on pin insulators in the area
if vulture-sitting faults occurred frequently on distribution lines.
k) Attend the sub-station battery set for correct D.C. voltage for C.B.tripping, if at the
time of faults the desnapping of conductor is observed.
l) Ensure the continuous earth wire along the HT or LT lines for the sense of fault for
tripping the lines through relays for the safety of all lives.
CLEARANCES:
1. The utility company shall adopt its standards of line construction taking in to
consideration of all relevant factors as per IEC/ IS for structures type, conductor type,
Line type, conductor configuration, and span etc.
2. All clearance will be based on 75 degree centigrade temperature to take into account
3. The horizontal clearance between guarding and any portion of a building or structure
shall be as decided by the direct solar heating.
4. Guarding shall will be provided wherever required to maintain electrical
clearance.
5. Minimum vertical clearance between ground and guarding of lines across or along the
road or shall not be less than minimum clearance for low and medium voltage lines.
6. The horizontal clearance between guarding & any portion of building or structure shall
be decided by the Electrical Inspector in each case but shall not be less than that for high
voltage line. Clearance between guard and lower line shall be as mutually agreed by the
electricity department.
DISTRIBUTION SYSTEM & ENERGY CONSERVATION / LOSS

REDUCTION:
a) Use of ABC Conductors for L.T. distribution / Urban / Rural area to prevent theft of
energy.
b) Use of Single phase Transformers 11/230V for rural supply distribution for lighting /
domestic single phase supply round the clock as per new reforms.
6262626262626262626262626262626262
c) Installation of theft prone meters with retrofit acrylic push-fit meter boxes to
prevent theft of energy.
d) Installation of capacitors for p.f. improvement by the utility company at their 11/ o.4 KV
sub-station or by the industrial, agriculture consumers at the installations.
e) Periodical / Sudden checking of energy meters by M.R.I. or aqua check of all industrial
meters on three phase system to locket the defaulter consumers.
f) Installation of computerized energy meters at EHV Sub-stations for all feeders
and recording of energy data to evaluate energy losses, energy transmitted in the system
with GPS system.
“PART-B” CURRENT & VOLTAGE TRANSFORMERS, METERING SECTION
6363636363636363636363636363636363
CURRENT & VOLTAGE TRANSFORMERS & ENERGY
12 METERING.
ENERGY METERING IN POWER STATIONS & LARGE

INDUSTRIES
It is surprised that metering of Energy transmitted from power stations & to

receiving stations/ utilities specially large Industrial consumers pay no attention
over the correctness of the consumption recorded by the traditional metering
equipment consisting of EHV Current Transformers, Voltage Transformers,
Recording static/ microprocessor based Energy Meters. It is all left upon the
certified testing results from their manufacturers or mostly upon the mercy of test
results with +/-, percentage error mentioned as permissible by the Engineers of
Energy Supply Company. It is fact that metering equipments are not tested
accurately as should be done for correctness of metering equipments
It is well established fact that latest test equipments with accuracy or comparator
standard CT/ VT are normally not available having latest actual calibration
certificate.
CURRENT & VOLTAGE TRANSFORMERS:
Contribution in error by each and every component of power system, play

important role.
Due to unawareness & non availability of suitable & reliable instruments/ methods
for the testing at site, these components are not tested or very rarely tested and
as such it contributes in continued as source of potential errors.
Errors caused due to CTs/ PTs contributes heavily in energy metering and tus
losses to utility. Looking to the heavy consumption & higher tariff , it is not
worthwhile to ignore this area.
CTs & PTs used in Energy metering are for scaling down high current & Voltage to
the acceptable ratio & phaseor relationship.
Ideal CTs & PTs should not have leakage impedance, losses, excitation current,
which is not practically not possible.
Above leads to Ratio error & Phase angle error. When Current & Voltage
transformers are energized, its magnetic circuit i.e. leakage impedance comes in
to roll. These exciting or magnetizing currents produces some voltage drop &
same contributes errors. It is to say that Primary and Secondary currents are
never apart 180 0 in phase difference, is contributing phase angle errors.
NECESSACITY OF TESTING OF ACCURATE ENERGY

CONSUMPTION
Now a days cost of production is rising on heavy consumption of units & cost of
base material both, hence it strokes in the mind of every individual to have break
up the cost of energy unit consumption & cost of base material separately.
Due to higher tariffs of Electricity, it is necessary to have 100% accurate metering
equipments.
6464646464646464646464646464646464
Presently Energy Bills are watched & traced at every stage from Boiler/ Turbine
Hall to Energy Supply Company and Consumer of every category (including bulk
consumer like CEMENT, Fertilizer, Petro chemicals, Textile, Aluminum/ caustic
Soda plants, Zinc smelters, Steel Furnaces & Rerolling Mills, Railways) as unit
consumption involves major cost.
It is mentioned that Looking to heavy cost of energy unit consumptions utility

consumers assessed & achieved some standards for production like Electricity
units per kg of yarn production in textile industries, units per kgof Caustic Soda
production, 15 units per kg of Alumina in Aluminum production plant, 80 units per
ton of Cement in Cement Plants (30% of cost of production)
By Energy Supply Company & Consumers it is preferred to haveload above 60
Amp. supply is metered to
EXAMPLE:
For example in a CT of rating 200/1 or 200/5, secondary current obtained is .975

to 5.025 Amps. This is because of Ratio & Phase angle error.
Hence to test CTs/ PTs standard CT/PT as comparator (duly calibrated from a
accredited laboratory) is to be used.
(a) In normal case of a 0.5 class of accuracy CT Ratio error at 100% load to 120%
load accounts as (+/-) 0.5% at 30’ at 0.8 Power factor (at 5% load accounts as
(+/-) 1.5% ), but over all error in first consideration can be as high as (+/-) 1.2%
.
(b) Also with consideration of PT Ratio error as (+/-) 5%, Phase angle error as 20’
at 0.8 Power factor, error can be as high as (+/-) 1%
So combined error effect will be (a) + (b) = (+/-) 1.2% + (+/-) 1% = (+/-) 2.2%
At 20% load, error is increased by 50%, at 5% load, it is three times. Thus error
is tremendous in fact as combined error effect.
Hence correct size of CT ratio & PT with class of Accuracy is to be selected for
utility as per loading pattern. In EHV system 0.2 class of accuracy CT/PT are
essential.
Actually at manufacturers’ works or in a laboratory CT/ PT are tested in a

particular environment & temperature condition in a laboratory at works of
manufacturers at rated burden but truly speaking accuracy is depreciated/ drifted
in field due to
1. Temperature cycle at field site of installation.

2. Humidity in enjoinment in field
3. Time/ Aging of the CT/ PT
4. Imposing of transient faults in power system connected
to CT/ PT.
5. Faults occurring in system
6. Switching surges on equipments.
7. Burden on Instrument transformers.
Due to partial or very less burden in field connected to CT/PT in field, errors will
be on higher side.
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Due to conditions mentioned at 01 to 06, also CRGO related drifts in Ratio & Phase
angle error and accuracy is affected when CTs get saturated. No one can not
predict about CT saturation for long time if readings are not watched daily
(carefully) and CTs are tested at site in field periodically.
Errors in Instrument transformers meters reflected in the Billing amount of Energy
consumption for Energy Supply Company & Consumers both.
Hence in field at site CT/ PT should be tested for its specified/ declared accuracy
at multiple burdens & loads to establish the complete behavioral range.
As per some experts for a load of 1MVA at 0.9 power factor & 75% load factor,
1% error cause revenue dent of Rs2.35 lacks per year with rate considered as @
Rs.4.00 per unit.
Current Transformer having (a) Primary current applied (b) Ideal secondary
current, Degree apart from primary (c ) Actual secondary current obtained with
phase angle Error.
(a) Primary current
Phase Angle Error
(c)Actual secondary Current available
(b) Ideal Secondary current Error due to phase angle
Magnetizing current
causing phase angle error
ENERGY CONSERVATION/ ENERGY MANAGEMENT & ENERGY
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AUDIT:
Energy conservation, Energy Management and Energy Audit are the demands for power
generating / transmitting / distributing & utility sector. Looking to the abnormal growth of
load / excess demand and less availability, load shadings is imposed, power tariff is also
increased, and quality of power available is not as per requirement, less power to rural /
agricultural sector. On one side the non renewable source of energy like coal, oil, natural
gases are depleting with time , may get exhausted rapidly looking to its increased
utilization, on other side it may spoil the envoi mental condition, may cause green house
effect due to pollutant gases evolved by the above fuels.
It is the requirement of to day to look forward towards renewal sources of Energy sources
like Wind power, Solar power, Hydro power, tidal power which are non exhaustive , do not
pollutant the atmosphere & keep the environmental balance.
ENERGY CONSERVATION:
When energy consumption in measured terms is reduced after certain process change,
development & production is not affected or production increased, is called Energy
conservation , may be as the result of several considerations The promotional activities of
Energy Efficiency will result in energy conservation. Energy conservation Act-2001 has
been declared by the Govt. of India and also has enacted Electricity Act 2003 Energy
conservation requires frame work of Energy Management & Energy Audit For best
implementation i.e. institutional & instrumental activities in a unit. The Energy
Conservation Act explains for:
STANDARDS & LABELLING i.e. energy consuming equipment shall be notified on

it with the minimum energy consumption it will consume, means its performance to the
customers under clause (a) of section14.
DESIGNATED CONSUMERS specified under clause (e) of section 14.The Govt.

shall notify the energy consuming establishment/ units and describe as designated
consumers basically Railways, Transport sector, Power Stations, TRANSCO, DISCOM,
CEMENT, SUGAR, PETRO CHEMICAL,CHEMICAL/REFINERIES, COMMERCIAL
BUILDING/ESTABLISHMENT having connected load of 500KW or contract demand of
600KVA (Energy Conservation Building Code clause(a) of section15 of clause of sub
section(2) of section56).Development & appointment of Energy Managers and Energy
Auditors for specific designated consumers. Energy Audit will be compulsory for
designated consumers implement the methods suggested by the Energy Auditors.
ENFORCEMENT THROUGH SELF REGULATION by the designated Consumers

for certification of energy consumption norms & follow of energy performance standards.
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PENALTIES Penalty of Rs10, 000/- for each offence & Rs1000/- per day for continued
non-compliance under the Act. Initial period of 5 years is for the Promotional activities for
creating infra structure for implementation of the Act. POWER TO ADJUDICATE for the
penalty is vested with Electricity Regulatory Commission for holding enquiry in the matter
of penalty.
ENERGY MANAGER
Any individual qualified/ accredited under clause (m) of section 14.
ENERGY AUDITOR
Qualified/ accredited specified under clause (p) of sub section (2) of section 13
APPELATE TRIBUNAL FOR ENERGY CONSERVATION

Central Govt. by notification, shall establish the APPELATE TRIBUNAL to hear the appeals
against the orders of the adjudicating officer or central government or the state
government or any authority under the Act under section 30.
ENERGY MANAGEMENT
Energy Management provides the services for the use of energy and maximize profits
maximum production/ utility with least cost and least environmental effect create
competitive position for unit. The results from good energy manager/ energy management
are adjusting, optimizing energy to reduce energy consumption per unit production using
procedures & system without affection production & quality out put.
ENERGY MANAGEMENT INVOLVES

Energy purchase/ arrangement at lowest possible price. Manage energy efficiently at
highest stage at every level i.e. energy transmission/ fuel transportation, distribution
system etc.Reusing / recycling of energy by heat recovery methods, reduce avoidable
losses i.e. least wastage in handling & use without affecting the environmental conditions.
Energy Management is continuous process having direct corporate approach, appointment
of energy manager to set up energy reporting & monitoring system, conduct energy audit
describing how energy is used, potential for energy saving areas, preparation of energy
budget. This audit can be carried out by the employee of organization or by energy
auditors. Energy audit reports includes recommendations in priority for action which may
result in energy cost saving. Senior Management of the organization should declare the
Energy Management Policy & its commitment to save energy with specific targets like
Senior Executive in top management should demonstrate their strong personal
commitment to the new policy not alone through words but by their energy action plan.
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They should participate in organization planning for Energy Management campaign.
What needs to be done?
Who will do it?
When it will be carried out?
What resources are required?
How much finance is required?
What are the barriers for it?
What are negative forces for it?
What are the priorities for it?
ROLE OF ENERGY MANAGER: Role is

As organizer
As planner
As decision maker
As a facilitators
As a team leader.
a. Train & create awareness among the employees/ residents/consumers to reduce

energy by switching off light and machines when not required.
b. Carry internal & external Energy Audi to identify the areas of improvement.
c. Bench marks the consumption to declared level. for best performance in the financial
year.
ENERGY AUDIT
Energy Audit is the translation of energy conservation ideas in to realities by adopting
feasible solutions with economic considerations within a specified period.
In past normally financial audit were being carried out in which management declares its
profits/ gains and future prospectus but no proper attention is paid to wards the units of
energy consumed. Energy audit provides areas of energy cost reduction, scope of
improvement electrical/ thermal, positive orientation to cost reduction, minimize break
downs by good preventive maintenance, quality control, environmental up keeping,

reliability of supply.
Energy audit reports gives light on energy efficient equipment/ retrofit technology for
energy conservation measures. Energy audit is done in two stages:-
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1. PRELIMINIARY ENERGY AUDIT: (with easily available data)
 Evaluate & establish the current/existing energy consumption
 Estimate scope of saving
 Identify the easiest areas for attention for energy conservation
 Area identification with no cost/least cost improvement & savings.
 Set a bench mark or reference point for reduce energy consumption immediately
 Identify the areas of detailed survey, study & measurement.
2. DETAILED ENERGY AUDIT: It comprises of Pre audit phase, Audit phase &
Post audit phase for an organization or any designated consumer.
TSM (Ten Steps Methodology)

For detailed energy audit is as under:
STEP ACTION PLAN PURPOSE/ RESULTS
1 Phase-I Pre Audit Phase * Planning & frame, organize
*Planning & organizing Energy Audit team
*Go through Audit * Arrange Instruments & time bound
*Informal meeting with programmed
Energy Manager, * Data Collection relating to audit work
Plant Manager & others *Scope in process/plant activities at
first hand observation & current level
operations and practices
2 * Organize meetings/ * Build up confidence & cooperation
awareness programmers * Issue guide lines, questionnaire for each
with all department/ all sections/ department
section head & staff head, *Orientation, awareness creation for
persons concerned (2- profitable
hrs.) results.
3 Phase II- Audit Phase * Past data analysis, Baseline data collection
* Energy data collection, * Prepare process flow charts, all service
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Process Flow & Energy Utilities system diagram.
flow Utility Diagram. (Example: Single line power distribution
diagram, compressed air & water, steam
distribution.
*Design, operation standard data and
schedule of operation & present results.
*Annual Energy Bills and energy consumption
pattern (Refer manual, log sheet, name plat,
interview), tariff pattern.
4 * Conduct survey and * Measurements:
monitoring for power Motor survey-insulation values, r.p.m, load
consuming equipments & current, Insulation, and Lighting survey with
running period. portable instruments for collection of data.
Also compare data with design data &
operating data
5 * Carry out detailed study, * Recording data for 1 hr, per shift, 24 hours
trials, / data recording for power monitoring (KWH, PF, MD etc.)
selected energy - Load Variations trends in compressors,
consuming equipment pump, fan, air condition plants, lighting load
area / sections. etc.
- Boiler/Efficiency trials Performance
evaluation.
6 * Analysis of energy use * Energy and Material balance evaluation &
energy loss / waste analysis.
7 * Identification of Energy * Identification & confirmation of Energy
Conservation opportunities conservation measures
* Conceive, develop, and refine ideas
* Review the previous ideas suggested by
unit persons in section & suggested by
energy audit if any
*Use brainstorming and value analysis
techniques to convince all.
*Contact vendors for new/efficient equipment
& technology.
8 * Cost benefit analysis * Assess technical feasibility, financial
viability and priority to Energy conservation
options for implementation.
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* Select the most result oriented & promising
projects/ methodology.
* Priorities by low, medium, long term
measures
9. Presentation/ reporting to *Documentation, presentation to Top
Top Management Management for profit oriented, time bound
results.
10. Phase-III Post Audit Phase *Implement the Energy conservation
Implementation & follow measures & recommendations.
up *Action plan, schedule of work
*Follow up & periodic review of schedule &
slippage.
For Detailed Energy Audit various instruments/ appliances are required to

be arranged or hired from other places or energy audit keeps with them:-
1. Lux meters
2. Gas leak detectors
3. Tachometer/ stroboscope: Stroboscope is non-contact instrument.
4. Infra red thermo meter
5. Contact thermo meter
6. Electrical Measuring instruments for Ampere, Voltage, KW, P.F., KVA, KVAR
7. Combustion analyzer: In built chemical cells which measures various gases such as
Oxygen, carbon die oxide, nitrogen per oxide & Sulphur die oxide.
8. Fuel Efficiency Monitor: to measure Oxygen & temp. of flue gas, C.V. of common fuels
is fed in to microprocessor which calculate combustion efficiency.
9. Fyrite: A hand bellow pump draws flue gas sample in to solution in side the fyrite, the
chemical reaction changes volume of liquid, reveals the amount of gas. A separate fyrite
can be used for Oxygen & Carbon die oxide measurement.
10. Water flow meter: Non contact flow measuring device using Doppler effect/ Ultrasonic
principle. There is a transmitter and receiver which are positioned on opposite sides of
pipe. The meter directly gives the flow. Water and other fluids flow can be easily
measured with this meter.
11. Pilot tube and Manometer: Air velocity in ducts can be measured using a pilot tube
and inclined manometer for the calculation of airflow.
PROSPECTUS OF ENERGY CONSERVATION IN POWER SECTOR:
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1. Phase load Balancing: Load on any feeder in power system should be equally
distributed so as to reduce the losses as under R is the resistance of current carrying
conductor.
In one feeder if load on R phase is 50 Amps.B phase is 75 Amps.Y phase is 100 Amps
Power consumption will be sum of I x Ix R= (2500+5625+10000) R=18125 x R
Load when equally distributed as 75 Amps on each R, Y, B phases
Power consumption in this case will be = 3 x (75 x75) R =16875 x R
Hence saving in consumption will be = 18125 R – 16875 R = 1250 R WATT
=1.25 R KW
2. Feeder load balancing: Load on five feeders at a sub-station is as under

Feeder no.1 20A
Feeder no.2 30A
Feeder no.3 40A
Feeder no.4 50A
Feeder no.5 60A
Power consumption will be (20x20+30x30+40x40+50x50+60x60) x R
=9000R
When load on feeder is balanced as 40 A on each feeder no.1, 2, 3, 4 & 5
Power consumption will be= 5 x 40 x 40 x R= 8000R
Hence saving will be = 9000 R- 8000 R= 100R Watt
= 1 R KW
3. POWER FACTOR IMPROVEMENT: will cause reduction in maximum demand

by reactive power compensation, use of H.T. Capacitor units of rating 220KVAR, 7.29KV,
1-ф, 50Hz two bushings as fix capacitor bank in power system.
4. ENERGY EFFICIENT MOTORS: By use of energy efficient motors operating at

good power factor, less no load losses, correct/ notified RPM according to loading will give
Energy Efficiency i.e. least load losses in the system.
5. EFFICIENT MAINTENANCE : The use of best lubricant, bearings, oiling can

avoided the break down & losses in system.
6. ENERGY EFFICIENT LIGHTING: Maximum use of day light transparent or

opaque sheets on roof top & windows do not require artificial lighting in system. More ever
the Energy Efficient luminaries, lamps like CFL, FTL must be used to reduce the lighting
consumptions in any system, use of T5 batten luminaries 1x28 watt in large nos., CFT 36
watt, use of transparent FRP sheets on roof for natural day light refraction.
a. In side building wall color should have light reflection properties.
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b. Use only optimum lighting essential as per requirement only.
Control of lighting by
 Timer operated
 Photo cell operated
 Occupancy sensors
 Group control light switching
 Remote control of light switches.
Lighting lamp selected with complete fixture should be suitable for low loss of power,
improved power factor, operative on low voltage system and having long working hours
life. Electronic ballast are most suitable to be used in the lighting fixtures.
TABLE SHOWING VARIOUS TYPES OF LAMPS/BALLAST WITH

DETAIL
s. Type Lamp Lumens Lumens Life in hours Capacito C.R.I.

No. Watt Per watt Choke r rating
watt
1. FTL 36 3250 90 5 14000 .8-.89 3.2-3.8

2 FTL 40 2400 60 15 4400 -do- 3.2-3.8
3 Metal 70 4200 84 26 1000 .9-.93 --
Halide
4 HPSV 70 5600 80 13 15000- .2-.39 12
20000
5 HPMV 80 3400 43 9 4000-5000 .6-.69 8
6 HPMV super 100 9500 95 18 15000-20000 .2-.39 --
7 HPMV 125 6300 50 12 4000-5000 .6-.69 10
8 HPSV 150 14000 93 20 15000-20000 .2-.39 20
9 HPSV super 150 15500 103 20 15000-20000 .2-.39 --
10 Metal halide 150 10500 70 20 10000 .9-.93 --
11 HPSV 250 25000 100 20 15000-20000 .2-.39 32
12 HPSV super 250 30000 120 25 15000-20000 .2-.39 --
13 HPMV 250 13000 52 16 4000-5000 .6-.69 18
14 Metal halide 250 19000 76 25 10000 .9-.93 --
15 HPSV 400 47000 118 40 15000-20000 ..2-.39 45
16 HPSV super 400 54000 129 40 15000-20000 .2-.39 --
17 HPMV 400 22000 55 25 4000-5000 .6-.69 18
18 Metal halide 400 31000 76 60 10000 9-.93 --
19 Metal halide 1000 80000 80 65 10000 .9-.93 --
CRI means the lighting fixture lamp will emit the same coloring light to be compared with
standard light color i.e. CRI is 100%.
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Also the use of GLS (General Lighting Service) lamp i.e. indicandiscent lamp should be
totally stopped because a 60 watt lamp have emission of 65 gm per hour carbon die oxide
and a 15 compact fluorescent lamp emits 16 gm per hour carbon die oxide, due to which
green house gas is less generated from environmental point of view.
7. AIR CONDITIONING TEMPERATURE SETTING: By setting the temp.

Setting at 24 degree cent grade, energy can be saved. More ever the use of flora carbon
gases like Freon-12/22 should be discarded and should be replaced by R-134a gases in
refrigerators, air conditioning plants.
Also use of SF-6 gas is also if released due to leakage or intentionally in atmosphere,
deplete the Ozone layer and heating of earth surface due to trapping of long wavelength
infra-red (reflected from earth surface) by the carbon die oxide layer in the atmosphere
i.e. is called greenhouse effect.
8. SYSTEM AWARENESS:
1. Maintain high load factor
2. Shift loads to off peak time, if possible
3. Minimize the maximum demand by isolating loads in sequence order by
demand controller
4. Stand by generation for high peak, high loads
5. Correct the power factor from 0.9 to 0.995, under rated load conditions.
6. Set transformer tap position to optimum setting as per transformer
manufacturer design
7. Disconnect the of primary of transformer, when do not serve active load
8. Consideration co-generation or waste heat recovery system for
Utilization in industry.
9. Export surplus power in generation to grid system with captive
generation, if feasible
10. Use best accuracy class meter with your own energy meter
11. Shut off un-necessary computers, photocopiers, printers, air
conditioning system when not in use at night hours
12. Have metering of un-metered loads in various departments/ sections of
the organization
13. Use high power factor motors with high energy efficiency
14. Use synchronous motors to improve power factor
15. Check motor alignment & proper ventilation
16. In case of rewinding of motors due to improper attention, efficiency
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decreases by 5 %to 8%, hence compare data with standard similar
motor.
17. Use SPRS (Slip Power Recovery System) for power saving on large slip
ring motors
18. Use variable drive in large variable loads
19. Use high efficiency gear boxes for geared motors or gear drives
20. Eliminate variable pitch pulleys in drives
21. Eliminate eddy current couplings in couplings with motors
22. Use the best quality & tested lubricants / greases/ bearings etc. to
minimize the break downs & interruption in production, lubricants/
greases should not freeze at low temp & should not evaporate at high
temp. or become viscous due to aging.
23. Change air filters & Diesel filters in DG set periodically, air filters in
compressors.
24. Use Flat belts in place of V belts & maintain proper tension of belts with
Motors.
25.Avioiding the over sizing of motors & compressors Reduction of 1 kg per
cm square ( fro 8 to 7) , results in 9% saving in input energy 1 mm
hole like leakage at 7 kg per cm square give power loss of 0.5KW 5
degree in take air temperature results in decrease 1% reduction of
power consumption
26. Drain moisture through drain valve periodically from air receivers
27. Use Heat less Air driers for compressed air, which should remain off
when compressors are off
28. Replacement of adjusting transformer with silicon, ferrous core by
amorphous metal Core transformer which are available up to 1000 KVA
in distribution system to have reduced iron loses around the clock.
29. For monitoring purpose daily, monthly, yearly production curve, energy
involved curve, energy cost curve should be plotted with respect to the
day, month/ year. Similarly curve should be plotted between
production and energy parameters to know the status of working of
organization for the scope of further improvement.
AUTOMATIC POWER FACTOR CORRECTION RELAYS:

APFC System are available with relay/microprocessor logic, two are most common
a. Voltage control and
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b. KVAR control
Voltage control – Switched capacitors are installed at a point where circuit voltage
decreases as load increase; (it should be 4-5% with increase load). For substations where
voltage maintaining is important, voltage control is important. It can also lead the power
factor to be noted here for substations. KVAR control – Switching of capacitor is put
responding to decrease of power factor ,as a result of system loading in unit , capacitor
can be added in steps to improve the power factor and thus low power factor penalty can
be avoided and rebate for maintaining high power factor like 0.995 can be obtained from
DISCOM. Power factor controller requires parameters of voltage and current in a system
for power factor correction relay/microprocessor system. Power factor out put parameter
fed to transducers which measures and converts to digital data compare with reference
voltage (can be set by calibrated knob/switch),when power factor falls capacitors are
switched on in sequence with first in first out and first in last out.
For a system in the industry having harmonics, special designed capacitors should be used
with harmonics suppressor circuits to improve power factor.
Shunt capacitors are useful for industry where as series capacitors are useful for voltage
Boost up in distribution network. KVAR ratings can be calculated as under
KVAR Rating = KW (tan φ1-tan φ2) And Voltage effects, when Vr is the rated voltage and
Vs is the supplied voltage then KVAR produced will be= ( Vs/ Vr )2 x KVAR rated
FINANCE OPTION FOR SYSTEM IMPROVEMENT

Always consider deeply financial analysis i.e. simple pay back system ,net present value or
future value , Returned on investment on the basis of initial cost, yearly benefits, Interest
rates etc., after that for profitable project system improvement can be carried out. In that
case finance option will be
1) Amount of budget from specific section of industry or engg. Department / self-
financing.
2) Retaining a portion of the savings achieved by the reduction of energy by energy
conservation methods.
3) Bank loans (subsidy is given by the govt in taxes etc.)
4) Raising funds from the stock market by the companies.
5) Award system improvement project to any reputed energy service company for which
contract should be done with energy performance contracting organization.
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EXAMPLE OF BREAK DOWN/ FAILURE
Report on failure of 400/220kV/33kV, 315MVA
Transformer (BHEL make) at BAMNAULI
Substation of Delhi Transco On 11-02-2008
------------------------------------------------------------------------------
1.0 INTRODUCTION
The 400/220kV Bamnauli substation of DTL has been commissioned sometimes
during 1998. The substation is operating with 1260 MVA total transformation
capacity
01. 3x315MVA, 400/ 220kV/33 (KV (BHEL)
02. 1x315 MVA 400/220/33 KV (TELK MAKE)]
The 400/220kV/33kV, 315MVA transformer no 1 (BHEL make)

FAILED ON 11-02-2008 at 20:40 Hrs at Bamnauli substation.
A Standing Committee has been constituted to assess the cause of failure and rate
of failure of various substation equipment of 220kV and above voltage class and to
suggest remedial measures so as to minimize / avert such failures in future, As
part of such activity, Shri T.P.Singh Chief Engineer, Shri K.K. Arya, Director, Shri
M.S .Satija and Shri Avinash Chander, Dy. Director of SE&TD Division of CEA
visited the site of failure of transformer at Bamnauli on February 19, 2008.
During the visit, the team had meetings with DTL officials and discussed in detail
with the operation and maintenance staff of substation about the sequence of
events leading to failure of transformer. The results of various tests conducted on
transformer before and after failure including DGA and other relevant information
were also collected. The assessment / analysis of failure of transformers is
discussed below.
1.1 FAILURE OF TRANSFORMER AT 400/220kV/33kV

BAMNAULI S/S
Transformer Particulars/ Detail
NAME OF SUB-STATION: Bamnauli

MAKE: BHEL, YEAR OF MANUFACTURE: 1993.
RATING: 315 MVA, 400/ 220kV/33kV/ 3phase (Transformer No. I)
VECTOR GROUP – YNaoD II
Sr.No. 6005262
TYPE: Three winding Transformer with unloaded tertiary
YEAR OF COMMISSIONING: 2000 (Year of manufacture 1993)
LAST ROUTINE MAINTENANCE CARRIED OUT ON: 03-11-2007 (planned)
DATE OF FAILURE: 11-02-2008 at 20:40 Hrs
INSULATION LEVEL HV (400kV): 1300 kVp,

INSULATION LEVEL (220kV): 950 kVp,
INSULATION LEVEL NEUTRAL: 95kVp
INSULATION LEVEL LV (33kV): 250kVp,
% IMPEDENCE HV-LV: 71.41%, HV-IV: 11.60%, IV-LV: 57.04%
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1.2 SEQUENCE OF EVENTS
OPERATING LOAD ON TRANSFORMER: 85MW on 09.02.2008.

INDICATION NOTICED: BUCHHOLZ ALARM at 09.30AM
SHUT DOWN OF TRANSFORMER: At 10.30
TESTING OF TRANSFORMER TESTING:
CAPACITANCE & TAN DELTA test

INSULATION RESISTANCE VALUE
DC RESISTANCE OF WINDING
TURN RATIO TEST
MAGNETIC BALANCE TEST
MAGNETISING CURRENT MEASUREMENT
FOR DGA: Simultaneously oil sample was sent to CPRI for DGA Analysis. After
Examining the report and the test results found to be normal. The Transformer was
charged at no load at 05.0PM on 11.02.2008.
FURTHER TRIPPING: At 8.40 PM, on 11.02.2008, it suddenly tripped off.

INDICATIONS NOTICED: BUCHHOLZ RELAY, OLTC-OSR, DIFF. TRIP, REF TRIP, this
was followed by heavy fire in the transformer. Simultaneously tripping of all the 400 kV
feeders.
The sprinkler system installed at the substation could not control the fire. With explosion of
main tank and spillage of transformer oil; fire spread heavily and at the same time fire tenders
were called from the different fire stations of the city. Fire tenders were put in the service and
the fire could be brought down only at 3.00 AM on 12.02.2208.
1.3 CONSEQUENTAL DAMAGES:
The blasting of the transformer caused damage to the following equipment:
a. 400KV SURGE ARRESTERS-390KV 3Nos.
b. 220KV SURGE ARRESTERS-216KV 3 nos.
c. 400KV OFF LOAD ISOLATOR 1 no.
d. CABLES-All associated power & control cables.
e. COOLING TOWER OF A.C. Plant
1.4 HISTORY OF TRANSFORMER:
Transformer manufactured by BHEL in 1993 and was commissioned in 2000 at Bamnauli station. The
transformer was lying for 7 years. It was observed that transformer
1. NO RECORD FOUND WHETHER THE TRANSFORMER WAS STORED WITH N 2

FILLED OR OIL FILLED/ AND N2 PRESSURE MAINTAINED AT THE PRESSURE
AS PER THE MANUFACTURER’S RECOMMENDATION.
2. OIL TEST /DGA TEST were conducted by CPRI in 2005, 2006 and 2007,
3. TAN DELTA AND CAPACITANCE tests on Windings and Bushing were conducted on 10-
02-08 & 09-12-2006 & 16-12-06 by (POWERGRID) & on 14-05-04 by (CPRI).
4. THERMOVISION SCANNING done on 30-10-07 & 04-02-08.
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As could be seen from the event of occurrence on 09-02-08, at about 9.30 AM when Buchholz alarm
appeared in the transformer panel and transformer was shut down on 09-02-08 and 10-02-08. All the
required tests such as
Tan delta & Capacitance tests on Windings and Bushing, Magnetizing, Voltage balance, D.C. resistance,
IR were conducted on 10-02-08 found to be normal.
Oil sample was also sent to CPRI for DGA of oil. The DGA report was also normal.
The insulation resistance (IR) measurement, magnetizing current, magnetic balance test,
turns ratio tests, measurement of BDV & other parameters (water content, neutralization value, % of
sediment & sludge, dielectric dissipation factor, specific resistance, interfacial tension, and flash point)
of oil, cleaning of bushings, tightness of clamps, connectors, nuts and bolts, thermal scanning using
infrared cameras, checking of oil leakage were being carried out as part of the routine maintenance
checks.
The failed autotransformer is of BHEL make with unloaded tertiary winding and was
Commissioned in October 2000 and after 4 years of commissioning i.e. on 14.05.2004.
tan delta & capacitance of 220 kV and 400 kV bushing were measured by M/s CPRI.
The measurement of capacitance and tan delta of bushings and windings was again
carried out on 09.12.2006.
One 52 kV bushing of B phase was replaced on 14-12-2006
No other major repair work of transformer was carried out since commissioning.
1.5 ANALYSIS OF FAILURE OF TRANSFORMER:-
It is observed that the transformer was stored at site for seven years from 1993 to
October 2000, the ingress of moisture might have damaged the insulation of the winding. The
transformer after receiving at site is generally kept N2 filled under certain pressure for a maximum
period of 5-6 months and it is not advisable to store the transformer beyond such a long period.
In such case, it is recommended that transformer should be filled with oil and oil to be filtered at regular
interval. During that period regular testing like Capacitance and Tan Delta, Break Down value of oil,
DGA of oil, Furan test and degree of polymerization should have been conducted. This is the only
reason which possibly attributed to the failure of the transformer due to insulation failure. The
transformer has served useful life for 8 years only i.e. from the year 2000 to 2008.
The 315 MVA 400/220/33 KV Transformer burst into flames and was totally damaged.
1.6 OBSERVATIONS
(a) Periodicity of test conducted should be in accordance with the recommendations made in the CBIP
Manual on EHV sub-station Equipment Maintenance.
(i) DGA TEST: CBIP manual on recommends this test half yearly basis but it is conducted on yearly
basis.
(ii) CAPCITANCE & TAN DELTA TEST: For bushing and winding as per CBIP
manual be conducted yearly basis, more ever test to be conducted twice in a year
keeping in view the higher rate of failure of bushings now a days.
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(b) TEST DATA should be available in records, it has been observed that the data
relating to testing are not maintained/ available since transformer commissioning.
(c) SFRA test should be conducted.
(d) IR measurement of winding/ testing PRV, Buchholz and OLTC surge relay are
to be tested. In addition to above test for BDV, PPM, DGA of oil of main tank and
OLTC tank,
(e) THERMOVISION: The thermo scanning is to be conducted on found
abnormalities, action should be taken immediately.
(f) The Operation or Tripping on Differential protection / REF further supports
internal fault, failure was due to failure of winding insulation.
(g) RESULT Thus as per site inspection, transformer got damaged completely and
was beyond repair. This damage might have been caused due to the sudden jerk
on the winding/core. This is evident from the photographs of the windings.
(h) POSSIBILITY OF OTHER CAUSES Possibility of transient surge from the grid
cannot be ruled out which damaged the winding insulation leading to bursting and fire in
the transformer.
NOTE:
It is surprised to note from the DGA results conducted on the transformer by
CPRI, it
appears that the results of the DGA are not consistent and indicates increasing
trend. Specially, there is variation of results conducted by CPRI on 09.02.2008
and previous test conducted by CPRI on 23.08.2007. The test reports of DGA
conducted on 23.08.2007 indicated that Acetylene (PPM) in the range of 6 was
present whereas the DGA report of 09.02.2008 indicated as not detected.
This requires reconciliation.
1.7 RESTORATION OF FAILED TRANSFORMER:
As explained Transformer got burnt completely and got burst and it is beyond
repair and has to be replaced.
As such there is no question of restoration of the transformer.
2.0 RECOMMENDATIONS
2.1 The transformer should not be stored at site for more than 5 to 6 months that
too with
N2 filled at a prescribed pressure with proper monitoring. In case it becomes
unavoidable to store the transformer for a year or so, in that case the transformer
should be oil filled and all the routine tests should be conducted at regular
intervals.
2.2 Factory test report and pre-commissioning test reports of each transformer,
which are considered to be the base results, should be made available to the
operation and maintenance staff of the substation so that subsequent measured
results can be compared with the base values to find out any abnormal change.
The trend analysis (relative change in test result and rate of change) will provide
valuable information to O&M staff for taking early action so that any major failure
can be avoided.
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2.3 In addition to other tests being conducted by DTL, it is recommended to
conduct core to Ground Insulation Resistance measurement, DC resistance
measurement and determination of Polarization Index (PI) corresponding to
60secs. & 600 secs. Recovery Voltage measurement, SFRA etc. may also form
part of maintenance activity.
2.4 Complete data base of previous test results starting from factory test, pre-
commissioning tests etc. and history of the transformer may be maintained
properly which would help in proper evaluation of results. Periodicity of tests to be
conducted on transformer needs to be decided based on condition assessment and
relative change in test results with respect to time (trend analysis).
2.5 PHYSICAL CHACTERSTICS & DGA OF TRANSFORMER OIL was being

carried out by DTL since 2005. But the rising trend of various fault gases need to
be monitored to plan future action. It is suggested that DTL may procure on line
portable DGA equipment which can cater to number of substations for condition
monitoring of transformers. DGA based on the results of same equipment used at
different times would provide better information for analysis / interpretation.
2.6 NON-OPERATION OF PRESSURE RELIEVE DEVICE (PRD) may cause serious

damages to Transformers in number of cases as in recent past in DTL’s system
also. So far no site tests are being conducted to assess healthiness of PRD whose
operation is very much required to save transformer from serious damages.
Therefore, it is required to check healthiness of PRD at site at regular interval of
time. The manufacturer may be consulted to find out the method of checking
healthiness of PRD of transformer at site.
NOTE: “Actual testing procedure is to inject dry N 2 gas in to transformer tank with
closed Buchholz cock & slowly increase in pressure will certainly operate the PRV
mechanism with flow of pressurized gas verses oil coming out from valve of PRV &
simultaneous tripping of the controlling circuit breaker, tripped operated signal
received on Anuciator Panel, PRV trip aux. relay operated. Now after releasing N 2,
refilling oil in transformer, bleeding of internal N2 or air, transformer can be taken
in service.”
2.7 Considering the failure rate of transformers due to bushing failure as reported
elsewhere in the country, it is recommended to conduct capacitance and Tan delta
measurement for bushings as well as winding twice in a year to have fairly close
monitoring of bushings.
2.8 Field test results (conducted after failure) may be verified during major repair
work at
manufacturer works / at site for which the concerned person associated with
operation & maintenance activities may be deputed to manufacturer’s works for
the purpose to have better insight and understanding of cause of failure which
would help in future.
2.9 In the above case, failure of transformer is attributed to insulation failure

(inter-turn insulation failure) and / deformation in windings. The deformation in
winding indicates flow of high short circuit current for longer duration.
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There is no Disturbance Recorder at 400kV substations to record such system
faults and its duration.
The replacement of conventional Electro-mechanical / static relay by modern

numerical relay could help in getting such valuable information.
As such the short circuit withstand level of transformer is being verified by

empirical calculations. No short circuit test has been conducted on the transformer
due to non-availability of indigenous testing facility. Therefore, such failures raise
doubts about the short circuit withstand capability of transformers being
manufactured in the country. The fault clearing time of protective system needs to
be reviewed. Adequate measures need to be taken to protect the transformer
from severe short circuit condition.
2.10 It is advisable to conduct SFRA for healthy transformers also as and when
required, may be at least once in two years.
2.11 Following tests should be conducted strictly as per recommendation of CBIP

Manual on EHV Substation Equipment Maintenance.
a) Capacitance and Tan Delta

b) DGA
c) In addition to above Furan and Degree of Polymerization tests should also be
conducted to know the healthiness of the winding and insulation of various 400
kV, 315 MVA Power Transformers installed in DTL.
2.12 It was observed that there was no oil collecting pit, it is recommended that oil
collecting pit of adequate size should be provided to minimize the oil spillage and
fire hazard.
2.13 Nitrogen Injection Fire Prevention and Extinguishing System is also available
today and be suitably considered by DTL over conventional fire protection
systems.
It is further stated that
1. “OPENING TIME OF C.B. : Checking of OPENING TIME of a Circuit Breaker.

2. “RELAY TRIP”: Checking of RELAY TRIP signal to Master Trip relay to trip
3. Circuit breaker.
4. “DC SYSTEM”: Healthiness of DC Battery Set & DC circuits (DC FAIL
5. ALARM) on individual EHV Panel.
6. “TRIP CIRCUIT SUPERVISION”: Healthiness of Trip Circuit Supervision.
7. “RELAYS CO-ORDINATION”: Relay testing & Relay co-ordination.
8. “DGA ANALYSIS”: DGA of Transformer Oil (within Limits) including ppm.
9. “TAN DELTA OF BUSHINGS”: Tan Delta of Bushings (Value within limits)
10. “LEAK PROOF JOINTS”: No oil leak joints (May be beyond control due to
poor manufacturing & workman ship during construction) causing in grace
of moisture to be rectified.
11. On Line Filtration can give perfect information about oil characteristics.
If all testing from S.No. 01 to 08 are within performance limit, no transformer can
damage any time. Above ensures best performance, no failures.
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LIST OF TESTING & ANALYSIS EQUIPMENTS:
1. C & Tan Delta Tester-preferred CDF-6000

2. Turn Ratio Meter-TRM-1
3. DC WINDING RESISTANCE METER- preferred TRT-27
4. Dissolve Gas Analyzer-portable-IDD/ DGA TRANSPORT X
5. SFRA-M500/ M5300
6. Moisture in oil & Dew point probe measurement-Domininouss
7. Digital 15KV Insulation Tester
8. BDV Tester- CU series.
9. C.B. Test System-TDR-900/ TDR-100
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Prot. &amp; Metering Note

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ABC PROTECTIVE RELAYS

AND PROTECTION SCHEME &

A Scientifically based study program in the fields of

Our sincere thanks specially to ER. ANURAG MAHLOTRA CMD,

Part-A (Protection Scheme & Relays)

Part-B (Current & Voltage Transformers & Metering) with

Sr.No. Particulars of subject material Page No.

08 Relay & Relay Testing set 25

11. Current Transformer & Relay Testing 51

12. Current Transformer/ Voltage Transformer & Energy Metering 57

“PART-A” PROTECTION SCHEME & RELAYS

In brief so long as the operating conditions i.e. normal voltage and

The primary function of relay is to operate during abnormal

That is to say that

Faults can be classified as under:

CONSEQUENCES OF IGNORING PROTECTION SYSTEM:

Due to ignorance or taking lightly or careless working results in long,

There are numerous examples of burning & fire/ damage of Power

VARIOUS TYPES OF RELAYS & THEIR FUNCTION.

01. Speed of the relays

Based on operating principles-

 Electromagnetic attraction type

 Under Voltage relay

 Primary relay-operating without instrument transformer

TERMS RELATING TO RELAYS-

Operating value (time) – Setting Value (time)

Relay coil fault current

Relay coil fault current

T.M.S. =T/Tm T.M.S. is Time Multiplier Setting on relay.

“In power system generally in case of radial feeders it is in the

These curves show the relationship between the operating current in

IDMT relays are widely used as their time of operation

RELAY NO. RELAY NAME

POWER EQUIPMENT NOMINCLATURE

SUBSTATION SINGLE LINE DIAGRAM WITH A FEEDER AND

RELAY CIRCUIT WITH CT & CIRCUIT BREAKER, BATTERY

Battery Set Set

Off Load Isolator

FAULT LEVEL BASED CALCULATIONS FOR RELAYS

Phase to Phase S.C.CURRENT=2517x0.866 =2180Amp.

Phase to Earth S.C.CURRENT=2517x0.54 =1359Amp

FAULT LEVEL OF THE AREA =572 MVA at 132 KV base

(a) P.U. IMPEDENCE up to EHV system voltage on

(b) P.U. IMPEDENCE Of 10/12.5 MVA transformer

FOR EHV i.e. 132KV SYSTEM:

FOR HV i.e. 33KV SYSTEM

Phase to phase S.C.CURRENT=1759x0.866 =1523Amp.

Phase to Earth S.C.CURRENT= 1759x0.54 =950Amp.

(Voltage on HV/ EHV side 33/132= 0.25)

i. Phase to phase= 1523x 0.25 =380.75A say 381A

IDMT RELAYS IN POWER SYSTEM:

RELAY SETTING CALCULATION

(a) O/C RELAY TIMINGS

C.T. Times of fault current = 1523/120 = 12.725

At 13 times current the operating time as per Relay Characteristics is

T = the required time operation

(b) E/F Relay Timings (120 x 10% = 12 A)

B) 33K.V. INCOMER SYSTEM:

C.T. Ratio = 300/5

(a) O/C RELAY TIMING:

C.T. Times of fault current = 1527/300 = 5 Times

(b) E/F RELAY TIMING:

C.T. Times of fault current = 950/60 = 15.84 say 16 times

Prot. & Metering Note

Prot. & Metering Note