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E&A IC
TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
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Main Objective:
Familiarize the participants with the Medium Voltage
switchgear supplied by L&T.
Operation, Installation & Maintenance Instructions
Dos & Donts
Electrical Systems & Equipment
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Content- Day 1
Training Program on Medium Voltage Switchgear
Sr.
no.
Topic
Description
Introduction to L&T
Basic Description
Evolution of MV
Switchgear
MV Switchgear Standard,
classification and
specification
Training
Schedule
Day 1
Session-1
LUNCH- BREAK
5
MV Switchgear
Basic Switchgear Structure
Panel Construction & Operating Sequence / Instruction
operation
Importance of Interlocks from Safety / Operation point of view.
All in built Interlocks of VCB and earth switch
Vacuum Circuit
Vacuum Circuit Breaker detail overview
Breaker
- VCB Design
- Operating Mechanism
- Familiarity with the electrical devices
- Shutter Mechanism
- SDS
Day 1
Session-2
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Content- Day 2
Training Program- Medium Voltage Switchgear
Sr.
no.
7
Topic
Vacuum Contactor Unit
Earthing Switch
10
11
Installation of spares
12
Maintenance Schedule
Description
VCU design
Application of VCU
Operating Mechanism (Opening & Closing)
Familiarity with the electrical components
Shutter Mechanism
Comparison between VCB and VCU
Importance of Earthing.
Operating principle of Earthing switch
Interlocks with earthing switch
Operating Sequence of VCB / VCU
Operating Sequence of Earth Switch
General Interlocks
LUNCH- BREAK
Significance of the Type tests as per the IEC standards
IEC 62271-100, IEC 62271-200, IEC 62271-102
Mounting & Removal of Closing, Tripping Coils & Spring Charging
motor
Importance of Maintenance as a Preventive measure / Elongation of
product life.
What to do?
When to do?
How to do?
Training
Schedule
Day 2
Session-3
Day 2
Session-4
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Content- Day 3
Training Program- Medium Voltage Switchgear
Sr.
no.
Topic
Description
13
Electrical Components
14
Understanding of Electrical
Scheme
16
Emphasis on understanding
Wiring Scheme
Control Circuit
Power Circuit
Wiring scheme Interlocks
LUNCH- BREAK
Good operation and maintenance practices.
Preventive & Corrective Measures to be followed in a Substation.
Special DOs & Donts for MV Switchgear
17
Q&A
Training
Schedule
DAY 3
Session-5
DAY 3
Session-6
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TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
INTRODUCTION TO L&T
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Leading System
Integration & Automation
Solution Provider
Solutions based on
Open Architecture
SCADA, Drives, Robotics
& Process automation
systems
Market leader in
Switchgear in India
Comprehensive product
range compatible to
International standards
ASTA certified products
Leading manufacturer
of static energy meters.
Market leader in high
end Trivector meters.
In-house products for
pre-paid metering and
AMR
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MV Switchboards
Indonesia
MV Switchgear
Switchgear Systems
Australia
MV switchboards
Swgr Systems
Saudi Arabia
LV Switchgear & MCCs
Integrated Automation
Systems
Mumbai
LV Switchgear & MCCs
Integrated Automation Systems
Ahmednagar
Coimbatore
Mysore
MV & LV Switchgear
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Manufacturing Facilities
In House Test Facilities
Certifications
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Manufacturing Facilities
CNC TURRET PUNCH PRESS
Model : AE255 NT
Make : AMADA , Japan
Capacity : 20 T
45 Tool Station
Punching up to 4 mm MS
Auto sheet loader facility
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Manufacturing Facilities
AUTOMATIC TOOL GRINDER
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Manufacturing Facilities
BUS BAR POLISHING MACHINE
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Manufacturing Facilities
SPOT WELDING MACHINE
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Manufacturing Facilities
PAINTING SET UP
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Testing Facilities
80KV POWER
FREQUENCY TESTER
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Testing Facilities
SECONDARY INJECTION
TROLLEY
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Testing Facilities
PANEL TESTING TROLLEY
CONDUCTIVITY METER
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Testing Facilities
Painting Thickness Meter
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Testing Facilities
TEMPERATURE RECORDER
PARTIAL DISCHARGE
Partial Discharge
Lightning Impulse
Corrosion resistance
Temperature Rise
Primary Injection
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Certifications
Quality Systems
ISO 14001 - BV
OHSAS 18001 - BV
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TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
DESCRIPTION OF MV Equipment
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Introduction to Switchgear
SWITCH
A switch is simply a means of opening or
closing the current path in an electric
circuit.
FUSE
Introduction to Switchgear
CIRCUIT BREAKER
The circuit breaker is a device which
Makes or breaks a circuit either manually or
by remote control under normal conditions
Breaks a circuit automatically under fault
conditions
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Introduction to Switchgear
Insulators - To insulate equipment from ground and
other phases.
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Introduction to Switchgear
CT Current Transformer are instrument transformer that are
used to supply a reduced value of current to meters, protective
relays and other instrument. CTs provide isolation from the high
voltage primary , permit grounding of the secondary for safety
and step down the magnitude of the measured current to a
value that can be safely handled by instruments
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Introduction to Switchgear
Voltage Transformers - Transformers which convert high
voltages into measurable and standardized voltages.
These are then proportional and in-phased to the primary
signal. They are intended to supply electrical measuring
instruments, meters, relays or other electrical devices.
Furthermore the connected measuring and protective
devices are electrically insulated against live parts.
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Sensed by
Instrument
Transformers &
communicated to
Relay
Breaker Trips
& Clears Fault
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TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
Introduction to MV SWITCHGEAR
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Introduction to Switchgear
SWITCHGEAR
It is the generic term including the entire range of switching devices and their
combination with associated control, measuring, protecting, and regulating
equipment.
Carrying the normal load current
Making or breaking the normal load current
Clearing the fault current (for which sensing devices like CT, PT
and various relays are employed) Assemblies containing electrical switching,
protection, metering and management devices
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TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
Evolution of MV SWITCHGEAR
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When two current contacts just open, an arc bridges the contact gap
through which the current gets a low resistive path to flow so there will not
be any sudden interruption of current.
The intensity of arc column depend up on the presence of ionized media
between separated electrical contacts, hence, special attention should be
given in reducing ionization or increasing deionization of media between
contacts.
That is why the main designing feature of circuit breaker is to provide
different pressure control methods, cooling methods for different arc media
in between circuit breaker contacts.
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MINIMUM OIL CB
A Minimum Oil circuit breaker places the interrupting unit in insulating
chamber at live potential. The insulating oil is available only in interrupting
chamber.
The features of designing MOCB is to reduce requirement of oil, and
hence these breaker are called minimum oil circuit breaker.
Oil is outdated in MV switchgear as insulating material because of fire
risk and its susceptibility to contamination (moisture and by-products
after switching). The maintenance requirements with its related costs
also plays a negative role in the application of oil.
Electrical Systems & Equipment
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AIR BLAST CB
Advantages
Disadvantages
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Disadvantages
Although pure SF6 is non-toxic, the byproducts after arcing are extremely toxic for
maintenance workers (in case of leakage).
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Better Performance: Switching Life more than 3 times of that of a SF6 CB.
Vacuum Interrupter
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TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
MV Switchgear
Standard, Classification & Specification
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IEC 62271-200:
High-voltage switchgear and controlgear
AC metal-enclosed switchgear and controlgear for rated voltages above
1 kV and up to and including 52 kV
IEC 62271-102:
High-voltage switchgear and controlgear
Alternating Current Disconnectors and Earthing Switches
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Product Classification
PM
M2
E2
C2
IP4X
LSC-2B
Electrical Systems & Equipment
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Vacuum Contactor
Unit Panel
- VH1H
2- Tier Design
3.6kV, 400A, 50kA
7.2kV, 400A, 40kA
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VHIH
Voltage
Upto 12 kV
75 kVp
28 kV rms
Frequency
50 Hz
Normal current
Upto 1250 A
63kA
1 sec
Degree of Protection
IP 41
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VHIH
Voltage
Upto 12 kV
75 kVp
28 kV rms
Frequency
50 Hz
Normal current
Upto 3150 A
31.5kA
40kA
50kA
80kA
100kA
125kA
1 sec
Degree of Protection
IP 41
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VHIH
Voltage
3.6 kV
60 kVp
20 kV rms
Frequency
50 Hz
Normal current
400A
7.2 kV
1 sec
Degree of Protection
IP 41
50kA
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Panel Specification
Parameters
Rating / Description
System earthing
Insulation Level
Design Ambient
40 deg C
Auxiliary Supply-1
110 V DC
Auxiliary Supply-1
240 V AC
110V DC
110V DC
110V DC
Rear Bottom
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Scope of Supply
Board Details
VCU
400A
SR
NO
BOARD
NO
NO. OF
PANELS
1
2
MYB0230
MYB0231
31
12
MYB0232
33
MYB0233
37
49
MYB0234
45
MYB0235
MYB0236
22
MYB0237
17
MYB0238
16
11
10
MYB0239
19
13
TOTAL
236
QTY
20
7
3
25
3
3
34
2
15
14
70
84
37
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TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
MV Switchgear Panel Construction
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Panel Construction
Type VHIH switchgear is completely metal-clad (LSC2B) and compartmentalized.
The switchgear is fully assembled, wired-up and tested in the factory before
delivery.
The VHIH panel is fabricated from high grade pickled and oiled steel sheets,
which is chemically treated before painting to provide adequate protection
against corrosion and weathering.
The cubicle parts are Powder coated process which provides optimum protection
against corrosion and weathering.
The paintwork is tested to withstand 1000 hours in a 5% salt spray.
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Panel Construction
The Panel consists of four
compartments
Circuit breaker compartment
Busbar compartment
Cable & CT compartment
Low voltage compartment
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Cable Compartment
No live parts are located less than 300 mm
above floor level.
The cable termination height is well above floor
level, and generous space is provided for
terminating power cables.
This ensures a higher bending radius as well
as reduces tension on the terminals.
The cable chamber also houses the CT and the earthing Switch and main earth
busbar.
The Gland Plate is fitted at rear bottom of cable compartment. The cable is
accessible from rear of the cubicle by opening the cable compartment covers.
All CT, CBCT, fixed type VT, Surge Arrestors , Earth Switch are mounted here.
Anti-condensation Space Heater along with the thermostat to keep moisture away.
Pressure relief flaps are provided at top.
Earthbar running throughout the switchboard
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Busbar Compartment
Busbar Bushing / Fixed contacts is
connected to breaker.
The busbar extends from one Compartment
to the adjacent.
All the busbar joints are covered with PVC
Boots.
Main busbar extensible at both ends
Main Busbars
Boot
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Fuses / MCBs
Control terminals
Protective relays
Indicating lamps
Meters
Push buttons
Control switches
Illumination Lamp
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Shutter Mechanism
Shutter Operation
Metallic Shutters covers the Fixed contacts
in the VCB compartment.
Opening / Closing of Shutters is actuated
with the movement of the VCB.
Shutters for Fixed contacts on Busbar and
Cable side can be padlocked individually
during maintenance.
Metallic Shutters are earthed.
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shows
the
Busbar
shutter
Figure-1
Figure-2
Electrical Systems & Equipment
Figure-3
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shows
the
Cable
shutter
Figure-4
Figure-5
Electrical Systems & Equipment
Figure-6
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Control Plug
Arrangement
on VCB
Control Plug
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TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
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Closing
Spring
Closing
Coil
Auxiliary
Switch
Tripping
Spring
Trip Coil
Electrical Systems & Equipment
Operation
Counter
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C) Tripping Operation
When the tripping coil is excited by a tripping signal, the tripping
catch is released, and the breaker is opened by the opening
spring.
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VCB Features
A) Excellent Breaking Performance
B) High Reliability
C) Safety for personnel and operating safety
D) Minimized Maintenance
E)
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Vacuum
Contactor Unit
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VCU Construction
HT Fuse
Jaw
Contacts
Vacuum
Interrupter
Shutter
Cradle
Vacuum
Contactor Unit
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Application of VCU
Main application in motor switching duty like Pumping stations
Cranes, Forward Reverse operations in mines, Lift Hoists
Transformer Switching
Neutral grounding of Generators, Operations of soft starters
Switching of Reactor Capacitor switching for reactive power
compensation
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VCU Features
A) Excellent Breaking Performance
B) No Surge Protection Required
C) Safety for personnel and operating safety
D) Minimized Maintenance
E) Compact & Light
F) Low Power consumption
G) Conformity to Insdustrial Standard
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Vacuum
Contactor Unit
Electrical Systems & Equipment
Vacuum Circuit
Breaker
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CIRCUIT BREAKER
EnduranceMechanical
EnduranceElectrical
Application
limitations
Operations
Very high.
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Control Scheme
CIRCUIT BREAKER
Well suited
Control power usually provided by control
Control power needed for protective relays, circuit
power transformer (CPT) incorporated in the
breaker operation and space heaters ( if present)
controller
Construction
Space requirement
# Large enclosure
# NEC required workspace equal
Purchase cost
Maintenance
Relativally high
Medium (long maintenance intervals, need to
clean insulation)
# Smaller enclosure
# NEC required workspace equal
# Rear access not required
Moderate
Low (simple mechanism, need to clean
insulation, replace fuses)
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Conclusion
Circuit breakers are favored when
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TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
Earthing Switch
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Earthing Switch
Window for
Earthing
Switch
Operation
Window for
VCB racking
Handle
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Earthing Switch
Earth Switch
Operation
OFF Position
Insert ESW
Handle till Red
Mark
Earth Switch
Handle
Earth Switch
Operation
ON Position
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TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
Operating Sequence
/ Instructions
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RACK-IN;
a VCB IS IN TEST POSITION
b CONTROL PLUG IS PROPERLY
CONNECTED TO VCB.
c VCB IS IN OPEN CONDITION.
d. EARTH SWITCH IS OFF
6. REMOVE
THE RACKING
HANDLE.
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4. REMOVE THE
RACKING HANDLE.
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RACK-IN;
a VCU POSITION INDICATIONS SHOWS
DCON
b CONTROL PLUG IS PROPERLY
CONNECTED TO VCU.
c VCU IS IN OPEN CONDITION.
d. EARTH SWITCH IS OFF
6. REMOVE
THE RACKING
HANDLE AND
CLOSE THE
VCU
OPERATING
WINDOW.
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4. REMOVE THE
RACKING HANDLE AND
CLOSE THE VCU
OPERATING WINDOW.
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5. REMOVE THE
RACKING HANDLE.
4. PULL THE
HANDLE UPWARD
TO SWITCH ON.
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TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
General
Interlocks
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General Interlocks
Closed Door Operations
All operations are behind closed door.
In any case VCB/VCU should not be operated in open door
condition
VCB Positive Interlock
VCB cannot be engaged or withdrawn unless it is in OPEN position
VCB Negative Interlock
VCB cannot be operated unless it is in Service or Test position. Ie
VCB cannot be closed when in intermediate position.
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General Interlocks
OTHER INTERLOCKS
1. Racking in & racking out of VCB & VCU is not possible unless it is OFF
2. VCB/VCU can be closed only when it is in service or test position
3. VCB/VCU cannot be operated while it is in intermediate position
4. VCB/VCU cannot be racked in or operated unless control plug is inserted
5. VCB/VCU can be withdrawn only when control plug is removed
6. It shall not be possible to remove control plug while the VCB/VCU is in
Intermediate or service position
7. Control Plug can be removed only when VCB/VCU is in Test Disconnected
Position
8. VCB/VCU can be operated / moved from Disconnected position/ test position only
when Earth Switch is in OPEN condition
9. Earth Switch can be operated only when VCB/VCU is in test/disconnected position
10. Earth Switch cannot be operated if VCB/VCU is in service / intermediate position.
Access to Earth switch Operating Handle is Blocked.
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General Interlocks
OTHER INTERLOCKS
11. VCU trips automatically if VCU fuse is blown
12. Rating error preventer is provided to prevent rack in with different rating of
VCB/VCU
13. Door can be opened only when VCB/VCU is in test position
14. Door cannot be opened if VCB/VCU is in service position
15. Safety shutter opens when the VCB contactor is racked into service position
16. Safety shutter closes automatically once VCB/VCU is withdrawn from Service
position
17. VCB/VCU of same rating can be interchanged
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TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
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Type tests
Short Time Current Withstand & Peak Withstand
HV Power Frequency Dry Withstand Test
Lightning Impulse Voltage Withstand
Temperature Rise Test & Measurement of Resistance
Mechanical Operation & Integrity of Interlocks Test
Basic Test Duty
Degree of Protection Test
Internal Arc Fault Withstand Test
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Type tests
Short Time Current Withstand & Peak Withstand
1. STC = Fault current duration in kA for 1 Sec / 3 Sec (rms)
2. Peak Current = 2.5 times (rms) for 50 Hz Application
3. Peak Current = 2.6times (rms) for 60Hz Application
4. Followed by supplementary test of contact resistance measurement & dry power
HV Withstand capacity test
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Type tests
Mechanical Operation
Switching devices and withdrawable parts shall be operated 50 times,
Removable parts inserted 25 times and removed 25 times to verify satisfactory
operation of the equipment
Ingress Protection - IP
Extent of protection provided by an enclosure, partition or shutter if applicable, against
access to hazardous parts, against ingress of solid foreign objects and/or ingress of
water and verified by standardized test methods
Eg IP 4X for Indoor Sub station Panels
Basic Test Duty
1. Short circuit switching duties verified for different fault currents as under for breaker
operating sequence ( O - 0.3sec - CO 3 min CO )
2. Switching Current (kA) = T10, T30, T60, T100s & T100a
3. Followed by supplementary test of contact resistance measurement & dry power HV
Withstand capacity test
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Accessibility:
A (F, L, R)*
B (F, L, R)*
C
Test values:
Example 1:
IAC
FLR
40 kA
1s
Example 2:
IAC
FL
31.5 kA
0.5 s
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The whole idea is to built in more safety, better reliability, practical condition
simulation......................to be able to protect the operators & general public.
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1: Old IEC allowed middle cubicle of the switch board for internal arc testing.
Consequence - The middle cubicle was supported from the 2 sides & was not tested
for the worst condition.
Remedy - The new IEC makes it mandatory to perform the internal arc test on the
extreme cubicle.
2: Old IEC did not demand simulation of room condition
Consequence - The hot gases, released from the test object, went up in the sky
whereas in real condition these shall hit the roof & get reflected from the roof & may
cause fatality.
Remedy - The new IEC makes it mandatory to simulate side walls & roof like a room &
then only test the switchgear.
3: Old IEC did not demand close door operation
Consequence - The MV switchgear could be operated with the door open thereby
exposing the operator directly to the possible arc products & rendering the IAC test
meaningless.
Remedy - The new IEC makes it mandatory to test the switchgear in real operating
condition. Implying that if the door has to be opened for operation then the switchgear
be tested with door open condition. Indirectly making all operation behind closed door
a mandatory feature.
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CB Compartment
Busbar Compartment
Cable Compartment
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TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
Installation of Spares
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Installation of Spares
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TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
Maintenance Schedule
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It is Recommended
to carry out
Preventive
Maintenance
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Tightening
Screw drivers 6, 8, 10
Double ended spanners ( 4mm to 19mm )
Socket spanner set ( upto 19mm )
Electrical Systems & Equipment
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(g) Shutters
The shutter mechanisms should be verified for correct operation and lubricated
sparingly. This should normally be carried out immediately after the withdrawal of
the breaker from its housing or immediately prior to reenergization.
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Space Heater
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CHECK ITEM
Tightness of bolts
and nuts
Entire VCB
Deformation,
excessive wear
and damage
Lost or missing
parts
Control
circuit
Electrical closing
and tripping
CHECK METHOD
By tightening them
with screw driver
and wrench
CRITERIA
FREQUE
NCY
WHAT TO DO
No loose connections
Re-tighten loose
connections
Visual check
Visual check
No deformation,
excessive wear or
damage
Replace parts, if
necessary
Visual check
No missing parts
Once in
3
years*
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CHECK ITEM
CHECK METHOD
CRITERIA
There should be no
dust and foreign
matter
Contamination
Main barrier and discolouration
WHAT TO DO
FREQUENC
Y
Remove foreign
matter with
pressurized air
Clean off old
Once in 3
lubricant and apply a
years*
small amount of
fresh lubricant, if
necessary.
Visual check
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Measurement
of insulation
resistance
CHECK ITEM
CHECK METHOD
500M or more
Timing Test
CRITERIA
2000V
500V
Resistance
Tester
1250A <75
Micro-Ometer
WHAT TO DO
FREQUENCY
Once in 3
years*
Once in 3
years*
As per specs
Carried out
when speed
of operation
is critical
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Troubleshooting
Part
Trouble
Possible Cause
DOOR
Remedy
1.
2.
Lubricate hole
3.
1.
2. Replace handle
Re-adjust the door and tighten the
screws
Loose handle
Loose screws at the hinges
Door warped and loose Hinge pin bent
STRUCTURE
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Troubleshooting
MAIN CONDUCTORS
Part
Trouble
Connections overheated
Possible Cause
1.
Loose bolts
2.
Overload
Insulators cracked
Ground fault or failed
dielectric tests
Control
Circuit
Extinction of indicating
tights
Remedy
Replace insulators
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Troubleshooting
Part
Trouble
Possible Cause
1.
2.
3.
SHUTTER
1.
Shutter damaged
2.
Remedy
1.
2.
3.
4.
5.
6.
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MEDIUM VOLTAGE SWITCHGEAR
Electrical Components
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MEDIUM VOLTAGE SWITCHGEAR
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MEDIUM VOLTAGE SWITCHGEAR
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DOs
DOs
All operation behind Close Door.
Ensure following before racking VCB from TEST to
SERVICE position
1. VCB is in TEST Position
2. VCB is in OPEN condition
3. Earth Switch is in OFF condition
4. Control Circuit plug is fully engaged. Red lever on control
plug mechanism should come upward direction when
Control Plug is fully engaged
Earth Switch shall be operated when VCB is in
DISCONNECTED position.
Earth switch handle shall be rotated in direction shown only.
Electrical Systems & Equipment
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DOs
DOs
Cross check rating of VCB before insertion inside the panel
Complete switchboard shall be free from Dust & other foreign
particles
All opening including hole provided for earthing connection
are properly closed with seal to avoid vermin/reptile entry
Ensure VCB Compartment door is fully closed and all Allen
bolts on VCB compartment door is fully tightened. Then Door
Padlock shall be done.
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DONTs
DONTs
Do not apply any flammable lubrication on busbar joints
or VCB finger contacts
Do not perform any operation in OPEN door condition
Do not try to rack in VCB when control plug is not
engaged. By operating the VCB forcefully it may damage
the control plug mechanism
Do not try to rack in VCB when VCB is in CLOSED
condition
Do not try to operate Earth Switch when VCB is in
CONNECTED position
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DONTs
DONTs
Do not try to insert wrong rating VCB inside the panel
Do not insert VCB without unlatching the shutter
assemblies
Do not try to by pass VCB compartment door interlock
when the feeder is in live condition
Do Not operate the padlock handles if door bolts are not
tightened fully by Allen key.
All Interlocks are designed as per IEC working with
certain Torque Limits. Do not exert force higher than 750
Newton as per IEC.
Do Not try to rotate ESW in the wrong direction
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Q&A
E&A IC
Thank you
E&A IC