ABB Relion 670 PCD231B101 Generator Protection Device

Description

Application Scenarios:

In a 200MW combined-cycle power plant, the generator is the single most valuable rotating asset. A stator winding fault, if not isolated within milliseconds, can cause catastrophic damage leading to months of downtime and millions in losses. The ABB PCD231B101 3BHE025541R0101​ is deployed as the primary protection device for this generator. It continuously monitors currents, voltages, and frequency. Its high-speed differential protection (87G) function can detect an internal phase-to-phase fault within one cycle and send a trip signal to the circuit breaker, isolating the generator before significant damage occurs. Simultaneously, its loss-of-excitation (40) and reverse power (32) functions protect against abnormal grid conditions that could mechanically stress the turbine-generator set. The PCD231B101​ doesn’t just protect; it also provides detailed oscillography and event recording, giving engineers precise data for post-fault analysis, drastically reducing mean time to repair. Its key value is transforming generator protection from a simple safety function into a source of operational intelligence and asset preservation.

Technical Principles and Innovative Values:

Innovation Point 1: Integrated, High-Speed Protection Algorithms.​ The ABB PCD231B101​ is built on a powerful hardware platform running advanced, validated protection algorithms. It performs complex calculations, like percentage-restrained differential protection, in real-time. This allows it to distinguish between a true internal fault and an external fault with through-current, providing both speed for severe faults and stability during external disturbances, which is critical to avoid nuisance tripping.

Innovation Point 2: Advanced Stator Earth Fault Protection.​ A key innovation is its implementation of multiple stator earth fault protection methods (e.g., fundamental frequency and 3rd harmonic voltage-based). This ensures sensitive detection of earth faults throughout the entire stator winding, including close to the neutral point—a traditional blind spot. This comprehensive coverage provided by the PCD231B101​ significantly reduces the risk of progressive damage from undetected ground faults.

Innovation Point 3: Synchrophasor Measurement & IEC 61850 Integration.​ Beyond basic protection, the relay can act as a Phasor Measurement Unit (PMU), providing synchronized vector (synchrophasor) data for system-wide monitoring. Its native support for IEC 61850. including GOOSE messaging, allows for fast, peer-to-peer communication with other bay-level devices (like breaker controllers) for advanced, distributed protection schemes and seamless integration into modern digital substations.

Application Cases and Industry Value:

A large hydroelectric facility was experiencing intermittent, unexplained generator trips that led to lost production and grid instability. The existing legacy protection relays provided minimal diagnostic data. The plant upgraded its critical units with the ABB PCD231B101 3BHE025541R0101. Soon after, another event occurred. This time, the PCD231B101’s detailed event log and high-resolution oscillography clearly showed a developing inter-turn fault that was detected by the sensitive differential protection. The relay tripped precisely, preventing a winding burnout. The recorded data allowed engineers to pinpoint the exact failing coil in the stator. This enabled a targeted, minimal repair during a short planned outage instead of a full, months-long rewind. The head of maintenance stated the ABB PCD231B101​ paid for itself by preventing a single major failure, highlighting its value in predictive maintenance and asset management, not just fault protection.

Related Product Combination Solutions:

REC670:​ A bay controller/recloser control IED from the same Relion 670 family. It can be used in the same substation to control the generator circuit breaker, communicating seamlessly with the PCD231B101​ via IEC 61850 GOOSE for integrated protection and control.

Current Transformers (CTs) & Voltage Transformers (VTs):​ High-accuracy, low-burden instrument transformers are required to provide the input signals to the PCD231B101. Proper selection is critical for protection performance.

RER670:​ A line differential protection relay. For generator-transformer block protection schemes, the RER670​ can protect the connecting transformer and transmission line, while the PCD231B101​ protects the generator, with both relays communicating for a coordinated overall scheme.

SMT Series Test Equipment:​ Specialized secondary injection test sets from ABB (or other brands like Omicron) are used to comprehensively test and commission all the protection functions of the ABB PCD231B101​ relay.

Disturbance Recorder:​ A dedicated, system-wide recorder that can gather and synchronize fault data from multiple relays, including the PCD231B101. for complex system event analysis.

IEC 61850 Engineering Tool (e.g., PCM600):​ ABB’s protection and control IED manager software, PCM600. is used to configure, set, monitor, and retrieve fault records from the PCD231B101.

TRIO-VIDEO Module:​ An optional video module that can be added to the relay to enable remote access and support via a secure, real-time video link for expert assistance.

Installation, Maintenance, and Full-Cycle Support:

Installation of the ABB PCD231B101 3BHE025541R0101​ involves mounting it in a standard 19-inch rack or cabinet, followed by careful wiring of its current, voltage, binary input, and output circuits. Special attention must be paid to CT circuit integrity to avoid open circuits. The relay is configured and set using ABB’s PCM600 software, where all protection functions are enabled, parameters are set (pick-ups, time delays, curves), and the communication protocols (like IEC 61850) are mapped. A comprehensive functional test using a secondary injection test set is mandatory before commissioning to verify every protection element responds correctly.

Routine maintenance primarily involves periodic visual inspections, verifying health LEDs, and checking the clock synchronization. The relay provides extensive self-diagnostics. The most valuable maintenance activity is regularly downloading and analyzing event logs and disturbance records to identify any developing trends. The ABB PCD231B101​ is designed for high reliability with a long service life. Firmware updates can be applied to add new features or improvements. We provide full lifecycle support for the PCD231B101. from initial configuration and setting guidance, to supplying fully certified and tested units, to assisting with advanced troubleshooting and integration into modern IEC 61850-based substation automation systems.

Protect your critical generation assets with confidence. Contact us for genuine ABB Relion protection relays and expert application support.