3.

Career Episode 3

3.1 Introduction

Project: Failure analysis of 6.6kV Auxiliary switchgear system,

testing and installation of the new multi-purpose relay
system.
Duration: May 2013 August 2013
Position Title: Assistant Engineer
Location: Raipur.
Name of the organization: CSPGCL.

This career episode will provide a concentrated snapshot of the project Failure analysis of 6.6kV
Auxiliary switchgear system, testing of the new multi-purpose relay system and installation at
Chhattisgarh state Power Generation company limited referred to by the abbreviation CSPGCL, is the
sub company of Chhattisgarh State Power Companies Limited headquartered in Raipur, India. It
provides electricity to 94% of the state load and is the 10th in the country in terms of size. I completed
this project in August 2013 as an Assistant Engineer.

3.2 Back ground:

In this position, I was posted in the head-quarters and oversaw technical and commercial aspects of
the powerplants, including Failure analysis (Electrical) and assess the application of new viable
technology. This aspect of the business was an essential element not only to present the real picture
of the system in generation scheduling but also to avail the benefits of the capital-intensive assistance
available from the state government.

There were multiple failure (tripping) because of electrical switch gear failure in last quarter of
operations at the 500MW Korba West plant. With the rising pressure from the load dispatch centre
and grid control due to unbalance load schedule and losses at the distribution end, a Trip Failure
Analysis Committee (TFAC) was formed (which I was a part of) to investigate the electrical failures and
to implement a commercially viable solution in 3 months. Following are the main roles I used to
perform during this phase of my career:

- Analyze the various technical reports on the tripping to locate the areas that need specific in
depth tests and analysis.
- Planning the safe outage of the switchgear system with the local Electrical maintenance
system such that the load schedule is balanced.
- Testing the compatibility of the various systems connected to the auxiliary supply system.
- Prepared technical and commercial offers for the product required (MV, LV and packages)
available via different suppliers in the market.
- Scheduling the implementation plan of the new system as per the plant operation guidelines.
- Skill development at both operation and maintenance level to ensure reliable operation of the
new relay system to be installed.
Hierarchical Structure of the Project

Below is the hierarchical structure of the above explained project, by role is highlights in green:

3.3 Personal Engineering activity:

3.3.1 Skill enhancements before the project commencement: As described above it is a technical-
commercial position. Since I already had good technical experience, I only had to enhance and
strengthen my commercial as well as managerial capabilities. I was trained for one month on
the different quotation tools, and financial aspects such as Letter of Credit (L/C), bank
guarantees, logistics and incoterms. I also underwent some training courses to improve
communication skills, negotiation skills, time management and problem solving capability.

3.3.2 Our project scope was mainly divided into two major phases:

Phase-1: Physical Inspection of the failure sites and analysis of the post failure reports.
Preparation for detailed tests on specific sites to find a pattern.

Phase-2: Pilot project to test the new relay system, application of the new relay system in
specific 6.6KV auxiliaries and monitoring the outputs preparing the case study for the
installation of the relay system on the major auxiliaries with techno-commercial aspects for
representation to the board and the government for capital assistance.

3.3.3 Initial analysis and problem identification: On the analysis of the 6 failures that occurred in the
last quarter I found that the 6.6KV MOCB of motors placed high load environment such as Mill
motor, Boiler feed pump, Condensate pump etc. showed abnormal current values during
failures. I insisted to investigate further on these breakers as I expected that Induction motor
load unbalancing is causing disturbances in the Bus bar leading to the electrical tripping. The
input and out wave forms with CB contact out timings of all the six incidences were analysed. A
typical wave form analysis is shown as under:
3.3.4 I had to overcome a critical problem in this stage, which was the lack of downstream electrical
bus data and difficulty of achieving selectivity. The purpose of the relay co-ordination study is
to achieve selectivity (discrimination) between different levels of the network, to ensure
continuity of service and reliability. In other words, it is to set the protection relays with fault
values and time values in such a way as to ensure that in case of any electrical fault, the closest
circuit breaker feeding the fault will trip not the main upstream breaker, thus we can isolate the
faulty section without interfering with other loads in the network.

We needed the settings and type of curve of the existing upstream relay so that we can carry
out the coordination study, but the testing department confirmed that these data and
documents are not available and that the upstream relay is an old fashion electro-mechanical
relay supplied more than 20 years ago. I checked the upstream existing switchgear at site to
get the exact type and model of the relay as well as the settings, and later with very much
difficulty I found the curve characteristics on the internet. Then I found the main problem, when
it was found out that according to the information of the downstream relay it was impossible
to achieve co-ordination since the downstream over current and time settings were very low.

3.3.5 Initially we requested testing department to check the possibility of changing the upstream
settings to the required settings. However, after they checked the complete upstream network
they came back to us confirming that it is not possible to make any changes. It was a serious
problem especially since the project start-up date was planned to be within a three months
time.

3.3.6 It was apparent that the current or time selectivity cannot be achieved, so I was looking for an
alternative solution, and after few days of checking the detailed technical manuals and
catalogues of our microprocessor protective multifunction relays Sepam (MG type), and the
schematic drawings, I found that we can achieve logic discrimination between our provided
6.6Kv and .415KV switchgears, since this feature is available in our provided relays. When a
downstream relay senses a fault, it will give a blocking digital input signal to the upstream relay
to delay its tripping for an adjustable time, which is sufficient to let the downstream relay trip
and isolate the fault. This solution was an alternative solution to the normal (commonly used)
time and current discrimination with the use of a multi-functional relay.

3.3.7 With the help of the Electrical maintenance department and testing departments regular
monitoring, I collected data around how unbalanced load effects the efficiency and impedance
 level of the motor. This data set bolstered my case for the initial pilot program Multifunctional
relay in the 6.6kV auxiliary breaker system. The multifunctional relay system not only helps in
voltage and load protection but also helps to detect fault in the motor itself such as hot spots,
uneven temperature rise etc.

3.3.8 To complete the task at hand in time, I established ground breaking concepts strengthened with
my intelligence by creating a project tracking sheet that allowed me to have a reality check on
project time line status. Because of this document I was always able to update my seniors about
project shortfalls/achievements. I also regularly updated my management for various
professional circumstances in project including team interrelationship.

3.3.9 After completion of the first phase, we started preparations in advance for the second phase by
evaluating technical and commercial offers for the product required (MV, LV and packages)
available via different suppliers in the market. We finalised ABB multifunctional relay based on
their price point and post installation warranty.

3.3.10 With the initial single offer tender in place, we discussed the financial aspects and negotiation
over the pilot project implementation for the 6.6KV CB auxiliary. The detailed aspect of the
resources required in the system was also finalised. I also ensured that the cost points for
various level CB required in the system and the supplier side warranty on the relay operation
and synchronisation with both upstream and downstream was also finalised in the contracts.

3.3.11 Pilot Project planning and implementation: The circuit breaker of a standby Condenser vacuum
pump (6.6kV) was chosen, after the written permission by electrical testing, electrical
maintenance and Head of the plant. The shift operators were trained on what parameters to
record the reading every hour. One month test results and forced trips of the breaker revealed
consistent operation and lesser wear and tear of motor as well as CB trip circuit connections.
This helped to build strong case with commercial team for the implementation changes in the
system and get commercial approval with government capital grant.

3.3.12 The commercial approval took 2 months with 5 explanatory rounds (out of which one was
represented by an Executive Engineer and myself). After the approval, order was placed to
replace 8 major relays of 6.6 KV auxiliaries such that material could be received before the
planned outage of the power station. I prepared the list of changes of the relay settings in
coordination with the testing department engineers. The software test flow model was
prepared as under:
 Above flow chart was to be repeated three times for three parameters i.e. Temperature,
Voltage and Current.

3.3.13 Further, process of change over was handed over to the Overhaul team (consisting of the
Electrical maintenance and Testing engineers deputed for this specific task) I made a point to
continuously make list of corrective actions during project and planned preventive actions. I
worked with my team closely and cohesively to get best out of them and ultimately make
project a successful event. I was all earful and respectful to them during project tenure.

3.3.14 One of prime aspects of having good communication proficiency is to listen cautiously and
devotedly to what others say and then reciprocate with most pertinent response which would
upsurge over-all efficiency of subject. I was always keen on doing so and was always open to
healthy advice from either my subordinates or my seniors. This helped me in having a positive
professional relationship in factory.

3.3.15 I also prepared commissioning reports with analysis for possible ways of improvement. It is
also submitted to the Management for their reference, review and comments about
improvement opportunities.

3.3.16 Summary: Since all the improvement method were implemented, I with help of my team
calculated final KPI Index which showed improvements against target. While performing this
project I continuously maintained cordial relationship with thorough professionalism with my
team members which in return also made it possible for me to get over any sort of hurdle a long
way in project. The above-mentioned project gave me an opportunity to work on multiple
threads at the same time efficiently and effectively. It helped me to take up new challenges. It
was an era changes in the system which is difficult time for both employers and employees, but
I managed to optimistic and kept my morale high to bring innovation to the techniques and
processes used in Power station. My department appreciated my efforts and I received
appreciation at various occasions.