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AQ: The basis of rating a NGR in electrical system

NGR stands for Neutral Grounding Resistor. When an earth fault current occurs on a plant, assuming that there is no external device presented to limit the earth fault current, the magnitude of the earth fault current is limited only by the earth impedance presented between the point of fault (to earth) and the return path (typically a star point of a transformer). If the earth impedance is low (type of soil being one of the reason amongst others), the fault current magnitude can be significantly high, and if left unchecked could damage the primary equipment. It is therefore mandatory that the earth fault current be limited to a suitable value, which is typically the rated value of the plant as a thumb rule. Why use the rated value? Because the plant has been designed to carry the rated current continuously.

Let’s take an example: say you have a transformer 60MVA, 132/33kV Star-Delta transformer. It is required to calculate the value of NGR to be connected to the zig-zag transformer on the 33kV Delta. the value of the resistor required to limit the earth fault current to the transformer’s LV rated value is (33 x 33) / 60 = 18.15 Ohms.

(Earth Fault current limited to rated value = (60 x 1000) / (1.732 x 33) = 1050A) When you go to a supplier you might find he supplies only 20 ohms resistor (as you might not get the exact value that you have calculated theoretically). No problem, use the 20 ohms and calculate what your new value of earth fault current would be (33 x 1000 / (1.732 x 20) = 952.6A, which is less than the transformer’s rated LV current. So you’re safe. This is how I would go about. In fact I would go a step further and introduce a safety factor of 20% i.e. I’ll bump up the value of the resistor from 20 ohms by an extra 20% and buy a resistor/ NGR of 1.2 x 20 = 24 ohms. So I am 100% sure that the earth fault current is way below the rated value and my transformer will be safe, even if the fault current goes undetected for any unforeseen reason say my earth fault protection has failed to pick up.

Make sure however that the earth fault setting that you choose is sensitive enough to pick up for the earth fault current calculated. I would generally put two relays a 64 or REF designed to pick up and operate instantly backed by a 51N with a sensitive setting but with a delay of a couple of seconds to pick up in case the 64 has failed to pick up.

So that’s it. I have described how I would go about calculating the earth fault current, selection of NGR value and how I would protect it.
Protection and related devices aiding protection don’t come cheap. Also I assume by your comment “this method is the most expensive option available since the cost of the transformer shall be astronomical”, you are referring to the Zig-Zag transformer and not the actual 132/33kV Star-Delta power transformer, under question.

I have taken a very generic example and tried to focus on how to arrive at a suitable value of an NGR, assuming an Star HV and Delta LV. My aim being to calculate how I could limit the fault current on the Delta LV. Being a Delta winding, I have to use a Zig-Zag transformer, for providing a low zero sequence path for the flow of earth fault current. It is really the Zig-Zag trafo. that bumps up the cost.

Note: If the above transformer is one of a kind, i.e. this is the only transformer in an isolated network, then I simply disregard the Zig-Zag transformer + NGR method and use the 3 PT broken delta method for 3Vo detection to drive a 59N. My cost here would be very low.

If the transformer is a Star-Star type with HV start solidly grounded, and LV star impedance (NGR) grounded, then I don’t need a Zig-Zag trafo. on the LV side. My cost is purely for the NGR alone.(Of course this transformer will have a Delta tertiary which may need it’s own protection depending on the whether one plans to load the tertiary or not. We could di

AQ: VFD replace mechanical gearbox to drive the load

Can an AC drive to replace the mechanical gearbox that used to decrease motor speed in conveyor application i.e to use a motor that will drive the load directly throw a coupling, belt or chain, without gearbox, motor rated up to 18.5 kw.

Theoretical is true as far the speed variation is concerned. Practically is not recommended for your application if the conveyor is required to be used with constant speed, on the other hand the gearbox also used for Torque purposes.

For light conveyors used on packing lines on which rate of production varies in accordance to some industrial parameters (Automation & PID control), direct coupled motor controlled by variable frequency drive may be feasible.

VFD is expensive (capital & running cost) its selectivity should be done carefully among the other available options.

By using a variable frequency drive we can change the speed of an AC Motor, and working for any time on any choosing speed, even in some case we can exceed the speed more than the normal one if the motor can withstand it. Noting that:
1- We should be careful when choosing the type of AC drive that should ne normally done according on the application “Conveyor, Fan, Pump, Compressor, ext ” to determine the torque’s level at running time.
2- In some special case when the motor runs at too low speed comparing by his normal one, maybe we need a forcing cooling for that motor.
3- Each VFD has a value of the Short Circuit’s level that can be withstanded, so, we should be careful of that point.

AQ: MCCB burn out in connection with 22kW motor

125A rated MCCB is connected with 22KW motor. The motor runs in normal condition, no overload. But the contacts of MCCB is burnt out. Why?

When the transition between wye and delta takes place, be very sure that that the mechanical interlocks on the contractors are properly adjusted. If one doesn’t completely open before the other closes, you have a line to line fault. That will eventually take out the upstream breaker. Be careful, this is a very dangerous starter. I have been done this road many times.

“Star/delta switching” is delicate maneuver.
* The engine has almost no force to push something more than itself at startup. When it’s time for mode switching start to delta, may not happen too quickly. The arcs that occurs when the star contactor switch off, needs a few milliseconds (minimum 20 ms). Typical of an MCCB to go off is 50 ms and on is 20 ms.
* If the load is too high during startup, the engine will get overloaded when switching from star to delta and arcs can become very powerful and devastate even the strongest Components. In case the engine does not start at idle, the start method is directly harmful to both motor and power grids. Instead of a soft and comfortable start, we get instead two powerful surges. (In that case it may be even better with only one MCCB).Should this be the case, there are two solutions: Make sure the engine starts without load or replace the Star/Delta switch to a soft starter.
3: Next step is a frequency converter but then it’s about something completely different.

AQ: How to find the KA rating of Circuit breakers?

Before breaker’s selecting for your electrical system, you need to calculate value of expected short circuit current at the place of breaker’s installation. Then you need to calculate value of heat pulse and 1s current (expected value of current during one second). After that you need to calculate power of breaker and finally, after all, you can select appropriate breaker. Values of characteristics of selected breaker need to be higher from calculated values of characteristics of your power system.

1. The fault level of the upstream NW (Source) to be known, normally 500MVA or 250MVA.
2. Upstream impedance (reactance and resistor, capacitor to be ignored for Short cct calculation) can be determined accordingly.
3. The LV System starting from the secondary of the distribution transformer.
4. Short circuit percentage voltage for Transformer is known (normally 4% for 1000kVA and 6% for 1500 kVA) and hence reactance and impedance can also determined.
5. Impedance of Cables also can be determined from manufacturer TD sheet.
6. Subtotal impedance to be determined by conventional way (Submit if are in series/ (Z1+Z2+….Zn)/(Z1XZ2X…Zn) if are in parallel.
7. divide voltage by the Impedance up to the required location, will give you the fault current at that location.
8. Determine Maximum and minimum fault current. By the former you can decide the breaking capacity of CB and by the later the setting can be achieved.
9. verify the thermal constraints of the conductors(cables). ie

I²t ≤ S²K² , I short cct current, t time( < 5 s valid), K cable material Factor and S cable section area.
I²t Known as let through energy. accordingly breaking capacity of CB should be > than Circuit Maximum fault.

The MCB, MCCB, & ACB are all Low Voltage Circuit Breakers, where SF6 is a Non-active gaze used in Medium Voltage Circuit Breakers.

Now, to determine the value of Breaking Capacity of any circuit breaker, we should, by calculation, the Maximum Short Circuit Current Value ” Isc3max ” at the installation point of that circuit breaker, where we can calculate it by assuming a ” Short Circuit between 3 phases at that point “, then after knowing ” Isc3max ” we can determine the Breaking Capacity value that should be ” equal or bigger than Isc3max “.

Further:
1- The value ” 250 … 500MVA ” is the short circuit power at Medium voltage side for up to 36kV.
2- About the Short Circuit Voltage percentage value:  we called ” Ucc or Usc ” and the value is ” 4& for up to 630kVA transformers “, and ” 6% for up to 2500kVA transformers “, but in all case, we can read it at the transformer’s name plate.
3- Sorry Mr. Omar, we can’t do, you mentioned, the sum of all Z, as these values aren’t on the same vector, so, we should first calculate ” R & X ” for each component, then do the sum of all R ” R total ” and all X ” X total “, then calculate the ” Z total “.
4- By knowing the Minimum Short Circuit Current value ” Iscmin “, we use it to determine the value of “Setting Value” of “Magnetic Protection or Short-time Protection”.

AQ: Change autotransformer to VFD or soft starter

What the parameters needed if we change from autotransformer (6.6kv/3.3kv) to VFD or Soft starter?

Since you got Auto Transformer 6.6/3.3 kV mean you have inductive load with constant speed in that case you should go for Soft starter, best way is collect all the motor data and send it to Soft Starter manufacturer along with the motor starting curve if available also you may ask for capacitor bank for PF improvement.

If you’re planning to use a Soft Starter or VFD for motor starting, you need to specify the horsepower rating, voltage rating, rated frequency, the type of motor (induction wound rotor or induction squirrel cage), the type of motor load (compressor, pump), motor load starting torque requirement and motor loading cycle. This information is important in selecting the type or model of the Variable Frequency Drive (VFD) or Soft Starter unit.

AQ: Motor fuses

Mainly Fuses are used for protection against short Circuits due its high rupurting capacity (breaking capacity) and fast response (less than 10ms).

As far the electrical drives are concerned, Fuses can be used to protect the feeders, while the Electrical Motors will be protected by Thermomagnetic CB to achieve Short Circuit as well as overload protection. At least thermal overload has to be provided for the Electrical Motors.

Accordingly, Plow of fuses depend on the type of Short Circuit, Single phase or 3 Phase fault (ie location of the fault) and the let through energy. In case one phase blown (say earth fault) -ve sequence and Zero sequence will be generated and subsequently the motor thermal overload will operate to protect the Motor.

It is worth to mention that, now a day proper protections for Electrical motors are commonly used, MCCB/MCB for overcurrent (short Circuit & overload), Single Phasing, Under voltage, Phase sequence relays… etc.
Thermal Protection can be achieved by many technique (ie Bi-metal, thermostat, resistance (NTC or PTC),,,etc.

The Fuse for Electrical Motor is efficient for O/C (Short Circuit, either L-G or L-L) or/and internal fault in the Motor windings. Taking into consideration the fuse rating considering the Starting current of the Motor. Therefore the fuse will not be effective for overload protection on the similar case.

However, I believe the motor was either subjected to an internal fault due to insulation failure (Humidity, water, bearing damages, high temperature rise, Stator/rotor gap,,etc) , subsequently the fuse blown or in prior the fuse blown due to an external factor and the thermal overload device associated with Motor Control panel not operated / out of order in the proper time -The heat rise impaired the winding accordingly or the Motor was subjected to stall current and prolong starting period.

AQ: Cable faults/fails

There are only 2 distinct types of Cable fault
1. Due to system Parameter or operating conditions – which you have to take care at the initial design stage for selection of the cable. There is a long list of checks – Design Engineers know.
For example, if 50 sq.mm cable is adequate for a particular Load, you may have to choose higher size in relation to the Fault Level. In urban Distribution system, you will find large size of cable is connected to a small size distribution Transformer.

2. Failure of Cable does not normally occur in the run of the cable unless it is damaged for external reasons. Damaged cable may not fail unless there is ingress of moisture / water through the damage. You will find cable failing during rainy season, high tide in the coastal areas.

Cable fails at the joints mainly because the (construction) characteristics of Cable are changed at the joints – joints become weak links in the run of the cable.

It is a well documented phenomenon that underground cables fail a week or so after lightning activity. Some of the can be attributed to lightning surges that enter the primary conductor and reflect off an open as you indicate. I believe the majority of the failures come from lightning strikes on adjacent structures or trees that reach the cable through ground and cause slight damages to the cable insulation. The maddening part related to customer service is the cables end up failing on a sunny day. Most customers understand outages during inclement weather but are not so understanding of outages on clear days.

AQ: Motor short circuit protection

In motor protection panel when 3 fuses are provided for short circuit protection, Is it always a condition that during short circuit minimum 2 fuses should be blown? If yes or no then why?

Because fuse is a type of low resistance resistor that acts as a sacrificial device to provide overcurrent protection, of either the load or source circuit.

Its essential component is a metal wire or strip that melts when too much current flows, which interrupts the circuit in which it is connected.
Short circuit, overloading, mismatched loads or device failure are the prime reasons for excessive current.
2 fuses are must & should blowing in motor control panel due to motor each winding sets are connected to 2 phase in delta connection (each winding set is works on 440 Volts power supply).

We need to identify the types of short circuits which can be experienced in a motor and if you are talking of 3 fuses for short circuit protection, it means you are dealing with a 3phase motor. All things being equal, a three phase motor should be balanced in operation hence the current in each phase must be the same.

If a short cct occurs, it could be a phase to frame ( L-E),or phase to phase(L-L)or even 3phase (3L) short cct. In each case, the fuse that ruptures will depend on its condition, rating, type and class. If a fuse has been subjected to various loading and abnormal conditions, the tendency to rupture faster exists. If I should view your question from the perspective that all fuses are of the same type, class and subjected to the same condition and motor windings are same and in the same healthy condition, then a L-E fault should not necessarily cause other fuses in the motor cct to rupture immediately. It should be the defaulted line. And if it happens, the motor will not be balanced which in turn causes the other fuses to rupture in turn due to increase in current. It is always better to use a circuit breaker to isolate all the lines in the event of a fault.

AQ: What causes cables to fault during weather seasonal changes?

I currently work for a small utility with a small amount of underground installations but a lot of it is aging and failing during weather changes. I am curious as to why it happens during weather changes and if there are scientific facts that can support it? Is there a way to predict when a cable will fail based on weather patterns? I’ve heard of different opinions on the matter, but is there a proven reason why? It is my goal as a young engineer and Gonzaga T&D engineering graduate student to learn more about these phenomena’s and what better way than to hear it from industry professionals in a technical discussion?

Scenario #1: Lightning strikes during summer on power cable installations can cause voltage spikes on the line, which in turn doubles back when it finds the open point on an underground cable installation. The initial voltage spike can cause the insulation of the cable to deteriorate or fail, and the reflection of the surge can cause the voltage to spike which can then finish off the already deteriorating insulation if it hadn’t faulted from the initial surge. Side note: This is why it is good practice to have transformers with load on them at the end of a cable run, or lightning arrestor at the termination points of an underground run and not just an open switch. Faults, recloser operations and other switching events can also cause a voltage spike on underground installations which can break down the cable insulation, thus making it more susceptible to failing after future events.

Scenario #2: Cables could fail more during the weather change due to the stresses that are inserted in to the cables during heavy irrigation motor start-ups and operation. Today you will see more soft-starts on your pump motors. With older cable supplying energy to older pumps you may find an across the line motor starter at the end of it. Cross-line starters rapidly heat the cables that have laid dormant over the cold winter months. If there was any sort of treeing, insulation deterioration, rodents chewing on the dormant cable, dig-ins, or any other common cable damaging scenarios during the winter, the startup will speed the deterioration process up in these locations, which in turn lead to cable faults.

Scenario #3: In areas where older open concentric cable has been installed, you are most likely experiencing many faults if it hasn’t already been changed out for newer jacketed solid-dielectric cable. As the ground dries out in the spring/summer, you will see higher resistances on the return path of the old and deteriorating open concentric neutrals. Without the cable being in wet conditions as it was throughout the winter, the electric field around the cable is no longer uniform and in some cases is a complete loss of your neutral.

Regardless of the insulation you use on cables, you most likely have faults. Maybe you’ve been “lucky” and it’s only in your joints and terminations? Regardless of which type of cable insulation, temperature has a significant impact on the dielectric withstand of the cable (i.e. higher temperatures will result in lower dielectric strength properties). Drying conditions also equates to higher insulation temperature due to poor heat transfer characteristics of your cable.

There are some common points in each of the above three scenarios but there really isn’t any scientific proof, just observations. Does it depend on your system load factor, your power factor, your installation practices, or even your cable design? Is it all of the above or is it much more simple than that? Is it different between different manufacturers of cable? Are there different scenarios that you’ve seen or heard of?

AQ: Ground fault detection in a Delta system

We have system which is connected to 16kV/2.4 utility transformer (delta on secondary) and we are using 2.kV/480V transformer for loads after 2000ft. Utility wants to protect against ground fault in the system. I am planning to select a ground over voltage relay using a broken delta PTs on secondary. I am having problem with calculating the 3Vo value, How much voltage will you set to trip the relay for SLG or LLG fault.

Let’s say you have a system 16kV/2.4kV with more than one, say 5 transformers T1, T2, T3….T5 interconnected transformers throughout your network, with the broken delta arrangement to detect the residual voltage on each of the transformer’s delta side, If you have an earth fault say on the LV of T1, the voltage displacement gets picked up on the delta side of all 5 transformers and there is a very high probability that all 5 transformers get taken out. This is because this scheme does not look for the earth fault current or where it exists, as long as it is on the interconnected system where the source is able to support the earth fault. The moment it notices a voltage displacement, bang goes your CB to clear the fault irrespective of it’s location.

A better scheme is to use the zig-zag transformer which offers a low impedance for zero sequence currents, generally used with a neutral grounding resistor to limit the current to more often than not the rated current (or lesser than that) of the transformer LV. So in a similar situation for an earth fault on T1 LV, the earth fault completes it’s path through the earthed NGR resistor and back to the fault point. A sensitive earth fault relay connected to a CT connected between the grounded resistor and the neutral point of the zig-zag transformer, designed to take out both the HV & LV CBs of T1 will do the job, without fear of taking out the other transformers.

Of course if this is the only transformer you are talking of, then the voltage displacement method should work in principle, however I would still go ahead and install the zig-zag arrangement described above. Let me know your thoughts, and then we can start discussing about the magnitude of 3Vo or 3Io as the case may be.

When we talk about detection of Earth Faults, that means we want to know it without tripping, so, we should absolutely use “IT Earthing system” for LV side, then with this system we can use “IMD – Injection Monitoring Devices” that monitor when it happen, and if wanted send the tripping order to the installed Circuit Breaker.

By the way:
1- As the transformer’s connection of secondary side is “Delta”, we use one of 3 phase to be connected via a special impedance to the earth to have “IT” system. Noting that for some of “IMD” we don’t need to use the special impedance as it’s integrated inside the IMD.
2- In the most of “IMD” we can adjust the value of “Insulation level” where above of this value an Alarm signal by auxiliary contact will be sent.
3- Some of “IMD” have 2 levels can be adjusted “1st level for Alarm” and “2nd level for tripping”.