PROTECTION AND INTERLOCK

UNIT IV
Interlock:
• An interlock is a feature that makes the state of two
mechanisms or functions mutually dependent.
• In most applications, an interlock is used to help prevent a
machine from harming its operator or damaging itself by
preventing one element from changing state due to the state
of another element, and vice versa.
– Elevators are equipped with an interlock that prevents the moving
elevator from opening its doors, and prevents the stationary
elevator (with open doors) from moving.
• An interlock should not be confused with a simple safety
switch.
• For example, in a typical household microwave oven, the switch that
disables the magnetron if the door is opened is not an interlock.
• Rather, it would be considered an interlock if the door were locked while
the magnetron is on, and the magnetron were prevented from operating
while the door is open.
Interlock: Electrical safety

• Many people use generators to supplement power to a

home or business in the event that main (municipal)
power has gone offline.
– In order to safely transfer the power source from a generator
(and back to main), a safety interlock is often employed.
– The interlock consists of one or more switches that prevent
both main power and generator power from powering the
dwelling simultaneously.
– Without this safeguard, both power sources running at once
could cause an overload condition, or generator power back-
feed onto the main could cause dangerous voltage to reach a
lineman repairing the main feed far outside the building.
Interlock: Electrical safety

• An interlock device is designed to allow a generator to

provide backup power in such a way that it
• (a) prevents main and generator power to be connected at the same
time, and
• (b) allows circuit breakers to operate normally without interference in
the event of any overload condition.

• Most interlock devices for electrical systems employ a

mechanical device to manage movement of circuit
breakers.

• Some also allow for the use of padlocks to prevent

someone from accidentally activating the main power
system without authorization.
Interlock: Applications

• Interlocks may include sophisticated elements

such as
– Curtains of infrared beams
– Photo detectors
– A computer containing an interlocking computer
program
– Digital or analogue electronics
– Simple switches and locks.
Fail safe : concept
• A fail-safe in engineering is a design feature or practice that in
the event of a specific type of failure, inherently responds in a
way that will cause no or minimal harm to other equipment,
the environment or to people.

• A system being "fail-safe" does not mean that failure is

impossible or improbable, but rather that the system's design
prevents or mitigates unsafe consequences of the system's
failure.
– That is, if and when a "fail-safe" system "fails", it is "safe" or at
least no less safe than when it was operating correctly.

• Since many types of failure are possible, failure mode and

effects analysis is used to examine failure situations and
recommend safety design and procedures.
Fail safe

• Some systems can never be made fail safe, as

continuous availability is needed.

• Redundancy, fault tolerance, or recovery

procedures are used for these situations
– (e.g. multiple independent controlled and fuel fed
engines).
– This also makes the system less sensitive for the
reliability prediction errors or quality induced
uncertainty for the separate items.
– On the other hand, failure detection & correction and
avoidance of common cause failures becomes here
increasingly important to ensure system level reliability.
Fail safe : Examples

• Many devices are protected from short circuit by fuses, circuit

breakers, or current limiting circuits. The electrical
interruption under overload conditions will prevent damage
or destruction of wiring or circuit devices due to overheating.

• The automatic protection of programs and/or processing

systems when a computer hardware or software failure is
detected in a computer system. A classic example is
a watchdog timer. See Fail-safe (computer).

• A control operation or function that prevents improper system

functioning or catastrophic degradation in the event
of circuit malfunction or operator error;
Fail safe : Examples

• Many nuclear reactor designs have neutron absorbing control rods

suspended by electromagnets. If the power fails, they drop under
gravity into the core and shut down the chain reaction in seconds by
absorbing the neutrons needed for fission to continue.

• In industrial automation, alarm circuits are usually "normally closed".

This ensures that in case of a wire break the alarm will be triggered. If
the circuit were normally open, a wire failure would go undetected,
while blocking actual alarm signals.

• Analog sensors and modulating actuators can usually be installed and

wired such that the circuit failure results in an out-of-bound reading –
see current loop. Another example – a potentiometer indicating pedal
position might only travel from 20% to 80% of its full range, such that a
cable break or short results in a 0% or 100% reading.
Fail safe : Examples
• Incontrol systems, critically important signals can be carried by a
complementary pair of wires (<signal> and <not_signal>).
– Only states where the two signals are opposite (one is high, the other low) are valid.
– If both are high or both are low the control system knows that something is wrong with the
sensor or connecting wiring.
– Simple failure modes (dead sensor, cut or unplugged wires) are thereby detected.
– An example would be a control system reading both the normally open (NO) and normally
closed (NC) poles of a SPDT selector switch against common, and checking them for
coherency before reacting to the input.

• In HVAC control systems, actuators that control dampers and valves may
be fail-safe, for example, to prevent coils from freezing or rooms from
overheating.

– Older pneumatic actuators were inherently fail-safe because if the air pressure against the
internal diaphragm failed, the built-in spring would push the actuator to its home position –
of course the home position needed to be the "safe" position.
– Newer electrical and electronic actuators need additional components (springs or
capacitors) to automatically drive the actuator to home position upon loss of electrical
power.
Fail safe : Examples
• Programmable logic controllers (PLCs).
– To make a PLC fail-safe the system does not require
energization to stop the drives associated.
– For example, usually, an emergency stop is a normally
closed contact. In the event of a power failure this would
remove the power directly from the coil and also the PLC
input. Hence, a fail-safe system.

• If a voltage regulator fails, it can destroy connected

equipment.
– A crowbar (circuit) prevents damage by short-circuiting
the power supply as soon as it detects overvoltage.
Electrical Preventive Maintenance
• Preventive maintenance is a schedule of planned maintenance actions
aimed at the prevention of breakdowns and failures.

• The primary goal of preventive maintenance is to prevent the failure of

equipment before it actually occurs.

• It is designed to preserve and enhance equipment reliability by

replacing worn components before they actually fail.

• The recommended practices and frequencies that would form the core
of a regularly scheduled electrical preventive maintenance program
are discussed here .

• All work associated with electric power systems and equipment should
be performed in accordance with accepted industry safety standards
and work practices.
Electrical Preventive Maintenance
• In general, it is recommended that a frequency of once every three
years for conducting regular preventive maintenance on electrical
equipment.

• It is recognized that individual locations may require more frequent

maintenance due to the physical environment or operational nature of
the equipment.

– For example, harsh environments where excessive moisture or dust may

be present should have a more frequent EPM program.

– Similarly, equipment that is used intermittently or equipment critical to a

key process should be considered for a more frequent program.

– Sound engineering judgment should be used in determining if more

frequent maintenance is appropriate.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• Switchgear 1.1 Enclosures
• Ensure that all enclosure panels, doors, and structures are well-
maintained in accordance with the manufacturer’s specifications.

• During de-energized maintenance, enclosures are to be vacuum

cleaned of all loose dirt and debris — use of compressed air is not
recommended since this may cause foreign particles to become
embedded in the insulation or damage insulators.

• Any buildup of dirt or other contaminates that will not come off with
vacuuming should be cleaned with lint free rags using cleaning
solvents recommended by the manufacturer.

• All vents and fan grills are to be cleaned of all dust and/or dirt
accumulations.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• Switchgear 1.1 Enclosures
• Ensure that ventilation openings are not obstructed. Where seals
and/or gaskets are installed, these should be examined and repaired or
replaced as necessary.

• All doors and access panels should be properly secured during

operation. Where heater elements are installed, these should be
cleaned, examined for damage and/or deterioration, and tested.

• Repair or replace heater elements as necessary.

• In environments where there is an extreme exposure to adverse

conditions, the frequency of maintenance for enclosures should be
increased as conditions warrant.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• Switchgear 1.1 Enclosures
• Electrical equipment rooms or vaults should be kept
cleaned of dirt and/or dust accumulations on a regular
basis.

• Doors and windows should be maintained in proper

working order and kept closed during routine operation.

• Access doors should be clearly marked to alert personnel

that live electrical equipment is in use. Where ventilation
and/or air conditioning is used, all fan motors should be
cleaned and examined for signs of wear and
deterioration.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• Switchgear 1.1 Enclosures
• Fan blades should be cleaned of dirt and dust and bearings should be properly
lubricated.

• Vent openings should be cleaned of all dust and dirt accumulations. Filters should be
cleaned and/or changed as recommended by the manufacturer, or more often if
conditions warrant.

• Electrical equipment rooms should never be used as storage areas.

• Electrical equipment rooms or vaults should be examined for evidence of water

seepage.

• The tops of electrical equipment enclosures should be examined for evidence of water
since this is a common entryway that often goes undetected until a failure occurs.

• The source of the water should be immediately identified and corrective measures
taken to permanently correct the condition.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• 1.2 Insulators, Supports, and Connectors

• Inspect insulators and conductor supports for signs of

cracking, broken pieces, and other physical damage or
deterioration. Clean all loose dirt with lint free rags.

• For contaminates that will not remove easily, solvents

approved by the manufacturer may be used. Examine for
evidence of moisture that may lead to tracking or flashover
while in operation.

• Examine surrounding areas for signs of tracking, arcing, or

overheating. Repair or replace damaged insulators and
supports as necessary.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• 1.2 Insulators, Supports, and Connectors

• Examine all bolts and connecting devices for signs of deterioration,

corrosion, or overheating. Ensure that bolts and connecting devices
are tight, according to manufacturer’s specifications.

• Be careful not to over-torque bolts and connecting devices since

insulators are easy to damage and difficult to replace. Where copper
and aluminum conductors and/or connectors are used together,
examine connections for signs of galvanic action.

• Ensure that the connectors are properly used and installed in

accordance with manufacturer’s specifications. Apply an antioxidant
compound to all aluminum-to copper connections.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• Conductors

• Examine insulation for signs of deterioration, cracking,

flaking, or overheating.

• Examine all connections for signs of overheating, cracked

or broken connectors, and signs of tracking or arcing.

• Ensure that conductors are clean and dry. Examine and

clean all connections, and torque to manufacturer’s
recommendations.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• Batteries

• Thoroughly clean all battery surfaces of dust and/or dirt accumulations

• Clean and tighten all terminal connections.

• Remove any corrosion on battery terminals with bicarbonate of soda.

• Clean battery studs and cable ends. On stranded cable, if ends are
corroded, cut off ends or separate strands and clean internally.

• Check electrolyte levels and specific gravity. Variations of more than

fifty (50) points between cells may indicate a bad cell.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• Batteries - Charger

• Clean all dust and/or dirt accumulations from charger. Clean all vent
openings and ensure that they are free from obstructions.

• Check terminals and connections for tightness. Check all relays, lights,
and other indicating devices for proper operation.

• If all cells consistently read low, check charger for proper operation.

• If electrolyte levels are low, check charger rate settings against the
manufacturer’s specifications.

• Consistently low levels may indicate the charge rate is too fast.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• Cables and Bus

• De-energize cables if they are to be touched or moved during maintenance.

• Inspect for sharp bends, physical damage, excessive tension, oil leaks, pits, cable
movement, soft spots, cracked jackets, damaged fireproofing, poor ground
connections, deteriorated and corroded or weakened cable supports.

• Inspect for wear at entrance point and at supports. Inspect manhole for spalled
concrete, proper ventilation and excessive moisture.

• Inspect potheads for oil or compound leakage and for cracked / chipped porcelain.
• Examine the manhole and cable grounding system to ensure its integrity.

• If cathodic protection has been installed in the manhole, it too should be evaluated.
Corrective action should be taken as appropriate to maintain the integrity of these
systems.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• Bus Duct

• Bus duct joint covers should be removed to allow access for a thermo graphic survey
of the energized bus under load.

• After de-energizing and grounding the bus duct, connections should be checked for
proper tightness as well as evidence of overheating, corrosion, arcing, or other forms
of deterioration.

• All loose or dirty connections should be cleaned and properly torqued — be careful
not to over-torque the bolts. Consult the manufacturer for recommended
maintenance practices and torque values.

• The tops of the bus duct enclosure should be inspected for evidence of water or other
foreign matter that may contaminate the bus duct.

• Suggested cable or bus tests include insulation resistance testing and polarization
index testing. These tests should be recorded to track trends that may indicate a
deterioration of the cable’s insulation.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• Transformers

• Transformer data (such as, voltage, current, and

temperature readings) should be recorded on a regular
basis in order to determine operating conditions of the
transformer.

• Peak, or redline, indicators should be recorded and reset.

Readings taken on a weekly basis can provide important
information about the loading of the transformer that is
needed before additional loads can be added to the
transformer.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• Surge Arrestors

• Clean and inspect porcelain for signs of damage or

deterioration. Repair or replace as necessary.

• Examine arrestor leads for damage and/or deterioration.

• Other suggested tests are 60 cycle spark over and hold tests,
watts-loss and leakage current tests, insulation resistance
tests, and grounding electrode circuit resistance tests.

• These should be conducted according to manufacturer’s

recommendations.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• Protective Relays

• Inspection, maintenance and testing of protective relays

should be done on an annual basis in order to ensure proper
and reliable operation.

• All necessary precautions should be taken while working with

protective devices to ensure personnel safety and to avoid any
unplanned interruption of service.

• In particular, when working on control circuits, all current

transformer (CT) secondaries should be shorted to ground and
never left open-circuited in order to avoid serious injury to
maintenance personnel.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• Electrical Testing

• Using an appropriate testing instrument, suitable for the relays being

tested, conduct electrical testing of the relays in accordance with
manufacturer’s recommendations and IEEE testing standards.

• For overcurrent relays, test the following functions of the relay at the
established settings specified by the system engineer or manufacturer:

• Pickup contacts should close when a current equal to the relay tap
setting is applied to the induction coil. Adjust the spring as needed to
allow for proper operation.

• Timing tests should be performed corresponding to two (2) or more

points on the relay’s time-current curves. One of the tests should be
done at the specified time dial setting.
Electrical Preventive Maintenance
Recommended Maintenance Practices
• Electrical Testing

• Instantaneous pickup test should be performed for the specified

instantaneous setting, if applicable.

• Seal-in units should be tested to ensure that the contacts hold closed with the
minimum specified current applied.

• Relay target should indicate when the relay has operated.

• If possible, the relays should be tested to ensure that operation of the relay
will in fact cause a tripping action of the respective circuit breaker.

• Relays that do not test satisfactorily or are found to be defective should be

replaced immediately to maintain the integrity of the protection systems.