The Relay Testing Handbook-A Practical Guide from the Field

This book was created for relay test technicians and provides the knowledge and skills necessary to test most of the modern protective relays installed over a wide variety of industries. Basic electrical fundamentals, detailed descriptions of protective elements, and generic test plans are combined with examples from real life applications to increase your confidence in any relay testing situation. A wide variety of relay manufacturers and models are used in the examples to help you realize that once you conquer the sometimes confusing and frustrating man-machine interfaces created by the different manufacturers, all digital relays use the same basic fundamentals and most relays can be tested by applying these fundamentals.

 By the end of this book, you will have the information you need to:

• Evaluate relay applications

• Review, understand, and compare the relay settings to the application

• Create a test plan

• Test the relay

• Evaluate the test results

• Provide comprehensive test results and documentation

Each chapter is a self contained unit and the chapters are organized in a logical progression of knowledge to allow readers from different skill sets to focus on or skip to the sections they need without wasting time reading through information they already know.

We also provide packages for technicians who are looking for specific information only.  These packages can be downloaded in pdf format for easy viewing and printing as they become available.  Soft cover copies are available for order through our partnership with lulu.com.  Go to Lulu.com for more information.

Package #1: Electrical Fundamentals (On Sale Now)

Package #2:  Relay Testing Fundamentals (On Sale Now)

Package #3: Understanding Digital Logic (On Sale Now)

Package #4: Creating and Implementing Test Plans (On Sale Now)

Compilation #1: Principles of Relay Testing  (On Sale Now)

	This download includes all of the Relay Testing Handbook Packages 1-4 in one file. Modern protective relays are becoming increasingly powerful and complex, but many relay testers use test procedures and philosophies that are based on previous generations of relays and their limitations.  Modern relays have very different characteristics which require a different testing philosophy to ensure they will operate correctly when required. This compilation includes all of the previously released packages from The Relay Testing Handbook that discuss the generic principals of relay testing for modern digital relays.  Step-by-step instructions for individual elements will be discussed in upcoming packages and compiled together in a future compilation. This compilation describes: Electrical fundamentals that all relay testers should understand including phasors, transformer connections and operation, symmetrical components, and grounding. A brief introduction to protective relays and how relays have evolved over the years. Relay testing fundamentals including different test philosophies and test techniques. Test sheets and documentation that should be included in every relay testing report The most commonly applied digital logic interfaces with detailed instructions and plenty of examples to help the tester convert and understand the different logic so that they understand what functions the relay is programmed to perform. A step-by-step procedure that will allow the reader to create and implement a protective relay test plan. The procedure follows a logical progression that can be applied to nearly every application and ensures accurate and efficient relay testing that includes the following steps. This download includes all of the Relay Testing Handbook Packages 1-4 in one file.
Package #5: Testing Voltage Protection (59/27/81) (On Sale Now)
	This package provides a step-by-step procedure for testing the most common voltage protection applications: Undervoltage (27) Overvoltage (59) Frequency (81) Each chapter follows a logical progression to help understand why voltage protection is used and how it is applied. Testing procedures are described in detail to ensure that the voltage protection has been correctly applied. Each chapter uses the following outline to best describe the element and the test procedures. Application Settings Pickup Testing Timing Tests Tips and Trick to Overcome Common Obstacles Real world examples are used to describe each test with detailed instructions to determine what test parameters to use and how to determine if the results are acceptable.
Package 6: Testing Overcurrent Relays (50/51) (On Sale Now)
	This package provides a step-by-step procedure for testing the most common overcurrent protection applications: Instantaneous Overcurrent (50), Time Overcurrent (51), and Directional Overcurrent (67). Each chapter follows a logical progression to help understand why overcurrent protection is used and how it is applied. Testing procedures are described in detail to ensure that the overcurrent protection has been correctly applied. Each chapter uses the following outline to best describe the element and the test procedures. Application Settings Pickup Testing Timing Tests Tips and Tricks to Overcome Common Obstacles Real world examples are used to describe each test with detailed instructions to determine what test parameters to use and how to determine if the results are acceptable.

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Chapter 1 – Electrical Fundamentals (Included in Package #1: Electrical Fundamentals  and Compilation #1: Principles of Relay Testing)

Chapter 2 – Introduction to Protective Relays (Included in  Package #1: Electrical Fundamentals and Compilation #1: Principles of Relay Testing)

Chapter 3 – A Brief History of Protective Relays (Included in Package #2:  Relay Testing Fundamentals and Compilation #1: Principles of Relay Testing)

Chapter 4 – Relay Testing Fundamentals (Included in Package #2:  Relay Testing Fundamentals and Compilation #1: Principles of Relay Testing)

Chapter 5 – Test Sheets (Included in Package #2:  Relay Testing Fundamentals and Compilation #1: Principles of Relay Testing)

Chapter 6– Instantaneous Overcurrent (50) Protection Testing (Included in Package #6:  Testing Overcurrent Protection (50/51/67))

Chapter 7– Time Overcurrent (51) Protection Testing (Included in Package #6:  - Testing Overcurrent Protection (50/51/67))

Chapter 8– Directional Overcurrent (67) Protection Testing (Included in Package #6:  Testing Overcurrent Protection (50/51/67))

Chapter 9– Overvoltage (59) Protection Testing (Included in Package #5: Testing Voltage Protection (59/27/81))

Chapter 10– Undervoltage (27) Protection Testing (Included in Package #5: Testing Voltage Protection (59/27/81))

Chapter 11– Over/Under Frequency (81) Protection Testing (Included in Package #5: Testing Voltage Protection (59/27/81))

Chapter 12 – Differential (87) Protection Testing

Chapter 13– Transformer Differential (87) Protection Testing

Chapter 14– Impedance (21) Protection Testing

Chapter 15– Understanding Digital Logic (Included in Package #3: Understanding Digital Logic and Compilation #1: Principles of Relay Testing)

Chapter 16– The Test Plan – Part I – Review the Application (Included in Package #4: Creating and Implementing Test Plans and Compilation #1: Principles of Relay Testing)

Chapter 17– The Test Plan – Part II – Preparing to Test (Included in Package #4: Creating and Implementing Test Plans and Compilation #1: Principles of Relay Testing)

Chapter 18– The Test Plan – Part III – Testing (Included in Package #4: Creating and Implementing Test Plans and Compilation #1: Principles of Relay Testing)

Chapter 1 – Electrical Fundamentals

1. The Three-Phase Electrical System

    A) Generation

    B) Phasor Diagrams

    C) Watts

    D) Inductive VARS

    E) Capacitive VARS

    F) The Power Triangle

    G) Power Factor

    H) Three Phase Connections

2. Transformers

3. Instrument Transformers

    A) Current Transformers (CTs)

         i)  Ratio

         ii) Polarity

         iii) Burden / Accuracy Class

    B) Potential Transformers (PTs) or Voltage Transformers (VTs)

         i)  PT Ratio

         ii) PT Connection

4. Grounding

    A) Solid Ground

    B) Resistor Ground

    C) Impedance Grounded Systems

    D) Ungrounded Systems

5. Sequence Components

    A) Positive Sequence

    B) Negative Sequence

    C)  Zero Sequence  

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Chapter 2 – Introduction to Protective Relays

1. What are Protective Relays?

    A) Protect Equipment from Damage

    B) Be Selective

         i)  Protective Relay Elements

         ii) Zones of Protection

         iii) Zone Overlap

    C) Coordinate with Other Protective Devices

    D) Compensate for Normal System Fluctuations

2. Time Coordination Curves (TCC) and Coordination

    A) Fault Study or Short Circuit Study

    B) Coordination Studies

         i)  Time Coordination Curves

         ii) Damage Curves

         iii) Protective Device Curves

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Chapter 3 – A Brief History of Protective Relays

1. Electro-Mechanical Relays

2. Solid State Relays

3. Microprocessor Based Relays

    A) Simple Digital Relays

    B) Multi-Function Digital Relays

    C) The Future of Protective Relays

4. The Digital Relay Rant

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Chapter 4 – Relay Testing Fundamentals

 1. Reasons for Relay Testing

    A) Type Testing

    B) Acceptance Testing

    C) Commissioning

    D) Maintenance Testing

    E) Troubleshooting

2. Relay Testing Equipment

    A) Test Set

    B) Test Leads

    C) Communication Supplies

3. Relay Testing Methods

    A) Steady State

    B) Dynamic On/Off Testing

    C) Simple Dynamic State Testing

    D) Complex Dynamic State Testing

    E) Dynamic System Model Based Testing

    F) End to End Testing

    G) Computer vs. Manual Testing Rant

4. Determine Pick Up

    A) Choose a Method to Detect Pickup

         i)  Front Display LEDs

         ii) Front Display Timer Indication

         iii) Output Contact

         iv) Status Display via Communication

    B) Pick-Up Test Procedure

5. Timing Tests

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Chapter 5 – Test Sheets

1. Your Company Name and Logo

2. Project Details

3. Nameplate Data

4. CT and PT Ratios

5. Comments and Notes

6. Metering Test Data

7. Input / Output Tests

8. Element Test Results

9. Element Characteristics

10.   Final Output Checks

11.   Test Sheet Template

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Chapter 6 – Instantaneous Overcurrent (50) Protection Testing

1. Application

2. Settings

    A) Enable Setting

    B) Pickup

    C) Time Delay

    D) Reset Delay

    E) Required Phases

3. Pick Up Testing

    A) Test Set Connections

    B) Pickup Test Procedure if Pickup is Less Than 10 Amps

    C) Pickup Test Procedure if Pickup is Greater Than 10 Amps

    D) Test Procedure to Avoid Setting Changes and Interference

4. Timing Tests

    A) Timing Test Procedure

5. Reset Tests

    A) Reset test Procedure

6. Residual Instantaneous Overcurrent Protection

7. Tips and Tricks to Overcome Common Obstacles

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Chapter 7 – Time Overcurrent (51) Protection Testing

1. Application

2. Settings

    A) Enable Setting

    B) Pickup

    C) Curve

    D) Time Dial

    E) Reset

3. Pick Up Testing

    A) Test Set Connections

    B) Pickup Test Procedure

4. Timing Tests

    A) Using Formulas to Determine Time Delay

    B) Using Graphs to Determine Time Delay

    C) Using Tables to Determine Time Delay

    D) Timing Test Procedure

5. Reset Tests

    A) Reset test Procedure

6. Residual Neutral Instantaneous Overcurrent Protection

7. Tips and Tricks to Overcome Common Obstacles

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Chapter 8 – Directional Overcurrent (67) Protection Testing

1. Application

2. Settings

3. Pick Up Testing

4. Timing Tests

5. Tips and Tricks to Overcome Common Obstacles

Chapter 9 – Overvoltage (59) Protection Testing

1. Application

2. Settings

    A) Enable Setting

    B) Pickup

    C) Time Curve Selection

    D) Time Delay

    E) Reset

    F) Required Phases

3. Pick Up Testing

    A) Test Set Connections

    B) Pickup Test Procedure if Relay Requires Three Phase Voltage to Operate

    C) Pickup Test Procedure if Relay Requires More Than One Phase Voltage to Operate

    D) Pickup Test Procedure for Any Phase Pickup (Example #2)

    E) Evaluate Results

4. Timing Tests

    A) Timing Test Procedure with Definite Time Delay and All Three Phases Required

    B) Timing Test Procedure with Definite Time Delay and Two Phases Required

    C) Timing Test Procedure with Definite Time Delay and Any Phases Required

    D) Timing Test Procedure with Inverse Time Delay and All Three Phases Required

    E) Timing Test Procedure with Definite Time Delay and Two Phases Required

    F) Timing Test Procedure with Definite Time Delay and Any Phases Required

    G) Evaluate Test Results

5. Tips and Tricks to Overcome Common Obstacles

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Chapter 10 – Undervoltage (27) Protection Testing

1. Application

2. Settings

    A) Enable Setting

    B) Pickup

    C) Time Curve Selection

    D) Time Delay

    E) Reset

    F) Required Phases

    G) Mode

    H) Minimum Voltage

I)  Blocking Signal

3. Pick Up Testing

    A) Test Set Connections

    B) Pickup Test Procedure if the Relay Requires Three Phase Voltage to Operate  

    C) Pickup Test Procedure if Relay Requires More Than One Phase Voltage to Operate

    D) Pickup Test Procedure for Any Phase Pickup

    E) Evaluate Results

4. Timing Tests

    A) Timing Test Procedure with Definite Time Delay and All Three Phases Required   

    B) Timing Test Procedure with Definite Time Delay and Two Phases Required  

    C) Timing Test Procedure with Definite Time Delay and Any Phases Required

    D) Timing Test Procedure with Inverse Time Delay and All Three Phases Required   

    E) Timing Test Procedure with Definite Time Delay and Two Phases Required  

    F) Timing Test Procedure with Definite Time Delay and Any Phases Required

    G) Evaluate Test Results

5. Tips and Tricks to Overcome Common Obstacles

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Chapter 11 – Over/Under Frequency (81) Protection Testing

1. Application

2. Settings

3. Pick Up Testing

4. Timing Tests

5. Tips and Tricks to Overcome Common Obstacles

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Chapter 12 – Differential (87) Protection Testing

1. Application

2. Settings

3. Pick Up Testing

4. Timing Tests

5. Tips and Tricks to Overcome Common Obstacles

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Chapter 13 – Transformer Differential (87) Protection Testing

1. Application

2. Settings

3. Pick Up Testing

4. Timing Tests

5. Tips and Tricks to Overcome Common Obstacles

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Chapter 14 – Impedance (21) Protection Testing

1. Application

2. Settings

3. Pick Up Testing

4. Timing Tests

5. Tips and Tricks to Overcome Common Obstacles

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Chapter 15 – Understanding Digital Logic

1. Understanding Logic

    A) OR

    B) AND

    C) NOT

    D) Comparator

    E) TIMER

    F) NOR

    G) NAND

    H) XOR

    I)  XNOR

    J)  Summary of Logic

2. Relay Labels

3. Internal Relay Control Schemes

    A) SEL-311C Undervoltage Element

         i)  SEL-311C Undervoltage (27) Logic Scenario #1

         ii) SEL-311C Undervoltage (27) Logic Scenario #2

    B) GE D-60 Undervoltage (27) Logic

         i)  GE-D60 Undervoltage (27)Logic Scenario Example #1

         ii) GE-D60 Undervoltage (27)Logic Scenario Example #2

4. Individual Element Schemes

5. Binary Relays

6. Arithmetic (Mat    H) Scheme

    A) Example #1 Parameters

    B) NOT (!)

    C) OR (+)

    D) Parentheses [()]

    E) AND (*)

    F) Example #1, Scenario #1

    G) Example #1, Scenario #2

    H) Example #1, Scenario #3

    I)  Example #2

    J)  Example #2, Scenario #1

    K) Example #2, Scenario #2

    L) Latch Control Switches

    M) Rising Edge (/)and Falling Edge (\)

7. General Electric FlexLogic™

    A) FlexLogic™ Example – The Situation

    B) FlexLogic™ Example – CB999 Trip Logic

    C) FlexLogic™ Example – Reclose Initiate

    D) FlexLogic™ Example – Reclose Block

    E) FlexLogic™ Example – SCADA Logic

    F) FlexLogic™ Example – Naming Logic

    G) FlexLogic™ Example – Assigning Output Functions

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Chapter 16 – The Test Plan – Part I – Review the Application

1. Introduction

2. Collecting Information

    A) Single Line Drawings

    B) 3-Line Drawings

    C) Test Switches

    D) Schematic Drawings

    E) Settings

    F) Co-ordination Studies

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Chapter 17 – The Test Plan – Part II – Preparing to Test

1. Establish Communication

    A) Port

    B) Port Configuration

    C) Protocol

    D) Baud Rate

2. Apply Settings

3. Connect Test Set

    A) AC Connections

    B) Relay Output Connections

    C) Relay Input Connections

4. Creating the Test Plan

    A) Pickup and Timing Tests

    B) Feeder Protection Test Plan

i)  Test Plan #1 – Setting Changes

ii) Test Plan #1 – No Setting Changes

    C) Generator Protective Relay Test Plans

    D) Line Distance Protective Relay Test Plans

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Chapter 18 – The Test Plan – Part III – Testing

1. Perform Relay Self-checks

2. Verify Digital Inputs and Outputs

    A) Input Testing

    B) Output Testing

3. Verify Current and Voltage Inputs

4. Element Testing

5. Final Output Tests

    A) Example Output logic

    B) Complex Relay logic

    C) Output Logic Testing Methods

6. Final Report

    A) Cover Letter

    B) Test Sheet

    C) Final Settings

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