Training Program 25.01.2014

Electrical Systems & Equipment
E&A IC
TRAINING PROGRAM ON
MEDIUM VOLTAGE SWITCHGEAR
Project : Ruwais Refinery Expansion Project

EPC
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Training Program Medium Voltage Switchgear
Main Objective:
Familiarize the participants with the Medium Voltage
switchgear supplied by L&T.
Operation, Installation & Maintenance Instructions
Dos & Donts
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Content- Day 1
Training Program on Medium Voltage Switchgear
Sr.
no.
Topic
Description
Introduction to L&T
L&T Corporate Film & Brief Overview to L&T EAIC
Basic Description
Terminologies and equipment used in Switchgear
Evolution of MV
Switchgear
Brief overview of Arc quenching techniques

Evolution of Vacuum as an Arc quenching medium.
Working principle of Vacuum Interrupter
Details on product specifications
Product classification as per IEC standards
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
Operating Instructions &

Interlocks
10
Type Tests information
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
Selection of CT, VT, Surge Arrester, Voltage detecting Indication etc

Importance of Above electrical Components
14
Understanding of Electrical
Scheme
16
Dos & Don'ts
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
Open Forum for Discussion /Queries.
Training
Schedule
DAY 3
Session-5
DAY 3
Session-6
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TRAINING PROGRAM ON
INTRODUCTION TO L&T
L&T Corporate Video
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E&A IC : Business Units

Market leaders in LV
systems in India
MV SWITCHGEAR
Comprehensive
product range
Manufacturing
facility in 6 countries
Electrical Systems & Equipment (ESE)
Leading System
Integration & Automation
Solution Provider
Solutions based on
Open Architecture
SCADA, Drives, Robotics
& Process automation
systems
Control & Automation Systems (C&A)
Market leader in
Switchgear in India
Comprehensive product
range compatible to
International standards
ASTA certified products
Electrical Standard Products (ESP)
Leading manufacturer
of static energy meters.
Market leader in high
end Trivector meters.
In-house products for
pre-paid metering and
AMR
Metering & Protection Systems (MPS)
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E&A IC : Manufacturing Locations

Malaysia
Jebel Ali, UAE
MV Switchboards
Integrated Automation Systems
Indonesia
MV Switchgear
Switchgear Systems
Australia
MV switchboards
Swgr Systems
Saudi Arabia
LV Switchgear & MCCs
Integrated Automation
Systems
Mumbai
Integrated Automation Systems
Ahmednagar
Coimbatore
Mysore
MV & LV Switchgear
Metering & Protection

Systems
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Plant Location - Ahmednagar
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Plant Location - Ahmednagar
Manufacturing Facilities
In House Test Facilities
Certifications
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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
CNC PRESS BRAKE

Model : HDS 8025 NT
Make : AMADA, Japan
Capacity : 80 T
Bending length up to 2.5 M
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AUTOMATIC TOOL GRINDER
Model: TOGU III

Make: AMADA
Used for Sharpening the Tools
CNC TURRET PUNCH PRESS

Model : EUROMAC 1250
Make : EUROMAC
Capacity : 35 T
Used for Cu / AL bus bar
and link punching up to
10 mm Thick CU
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BUS BAR POLISHING MACHINE
MIG WELDING MACHINE
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SPOT WELDING MACHINE
GRINDING AND BUFFING

STATION
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PAINTING SET UP
9 tank process - Pretreatment facility

Fully Automated Powder coating line
Robotic painting applicator
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Testing Facilities
80KV POWER
FREQUENCY TESTER
IMPULSE TEST LAB
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Testing Facilities
SECONDARY INJECTION
TROLLEY
VCB TESTING TROLLEY
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Testing Facilities
PANEL TESTING TROLLEY
CONDUCTIVITY METER
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Testing Facilities
Painting Thickness Meter
Lug Pull Tester
Surface Plate & Measuring

Instrument
Push Pull Meter
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Testing Facilities
TEMPERATURE RECORDER
PARTIAL DISCHARGE
Various In-House Type Tests
Partial Discharge
Lightning Impulse
Corrosion resistance
Temperature Rise
Primary Injection
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Certifications
Quality Systems
ISO 9001 - 2008 - BV
ISO 14001 - BV
OHSAS 18001 - BV
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TRAINING PROGRAM ON
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
There is no special opening condition

for short circuit or other fault.
A fuse is used for over current and short

circuit protection.
A fuse is a part of the circuit which
consists of conductor which melts easily
and breaks the connection when electric
current exceeds the predetermined value.
Fuse has to be replaced after every

Fault.
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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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Insulators - To insulate equipment from ground and
other phases.
Busbar - To allow multiple connections from one

feeder to another feeder.
Surge Arrester Surge Arrester are the primary

protection to make the circuit device immune to
different types of over voltages and spikes either
atmospheric or switching. Surge arrester are generally
connected in parallel with the equipment to be
protected to divert the surge currents. A properly
chosen and installed arrester is to be regarded as
practically maintenance free during its life time.
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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
CBCT - The core-balance CT (or CBCT) is normally of the ring

type, through the centre of which cable is passed that forms the
primary winding. An earth fault relay, connected to the
secondary winding, is energized only when there is residual
current in the primary system
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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.
Voltage Detecting Unit To detect voltage presence on

bus or cable side
Capacitive Voltage Detector To sense the voltage on

Busbar
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Protection System Analogy

Brain = Relay
Eyes, Ears, Nose &

Skin =
CTs, VTs
Hands & Legs

=
Circuit Breakers
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Protection System Analogy

FAULT
Sensed by
Instrument
Transformers &
communicated to
Relay
Relay Issues Trip

Command To
Breaker
Breaker Trips
& Clears Fault
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TRAINING PROGRAM ON
Introduction to MV SWITCHGEAR
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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
Used in three-phase, high-power industrial, commercial and utility

applications
Covers a variety of actual uses, including motor control, distribution panels

and outdoor switchyards
The term "switchgear" is plural, even when referring to a single switchgear

assembly (never say, "switchgears")
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TRAINING PROGRAM ON
Evolution of MV SWITCHGEAR
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ARC Extinction Theory
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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OIL CIRCUIT BREAKER

BULK OIL CB
Oil is used as arc quenching media as well as insulating media between current
carrying contacts and earthed parts of the breaker.
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.
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AIR BLAST CB
Advantages
Disadvantages
There is no chance of fire hazard caused

by oil.
In order to have frequent operations, it is

necessary to have sufficiently high
capacity air compressor.
Arc quenching is much faster

during operation of air blast circuit breaker.
Frequent maintenance of compressor,

associated air pipes and automatic control
equipment is also
As the duration of arc is smaller , so lesser

amount of heat realized from arc to current Due to high speed current interruption
carrying contacts hence the service life of
there is always a chance of high rate of
the contacts becomes longer.
rise of re-striking voltage and current
chopping.
Requires much less maintenance
compared to OIL Circuit Breaker
There also a chance of air pressure

leakage from air pipes junctions.
Air can be considered outdated as arc-quenching medium, due to the

relatively bulky volumes needed, sound aspects when operating and
sensitivity for moisture.
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SF6 Circuit Breaker

Advantages
Disadvantages
SF6 is a gas with good insulating properties,

Have High dielectric strength
colorless, odorless, non-toxic and nonflammable
SF6 is a potent greenhouse gas and should not

be released to the atmosphere.
SF6 molecule is electronegative, it provides

excellent insulation after extinction.
Density approximately five times that of air.
SF6 gives an excellent dissipation of heat

which is cooling the arc and which is important
around the zero crossing
Although pure SF6 is non-toxic, the byproducts after arcing are extremely toxic for
maintenance workers (in case of leakage).
Low force needed for contacts pressure
SF6 arc byproducts (S -2 F-10) are hazardous

waste requiring special care for disposal.
Requires much less maintenance compared

to OIL & AIR Circuit Breaker
Special attention shall be given when the

switchgear has to be cleared at the end of its
life.
The use of SF6 as an interrupting is not ecofriendly and advanced

technology solutions like vacuum is available for upto 52KV. However
for extra high voltages beyond this value it still remains the most
practical solution.
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Vacuum Circuit Breaker

Vacuum as an Arc quenching media have a number of attractive features like being
maintenance-free, compact and environmentally friendly.
Other important features are:
Large operation reliability: Because of its simple construction, the number of
components is small (approximately 50 percent less than a comparable SF6 or
oil circuit breaker).
Small amount of operating energy. Due to the small stroke (8-12 mm) of the
contacts and the light weight of the accelerating mass, the required operating
force is low. Consequently, the operating mechanism is of a very simple design.
Low arcing voltage. Because of the low arcing voltage (30 V) the energy in
the arc is limited.
Environmentally friendly: no danger of explosion and/or fi re, only little noise

when operated.
Excellent interrupting characteristics: arc duration below 10 ms
Better Performance: Switching Life more than 3 times of that of a SF6 CB.
Vacuum Interrupter
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TRAINING PROGRAM ON
MV Switchgear
Standard, Classification & Specification
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Compliance to IEC Standards

IEC 62271-100:
High-voltage switchgear and controlgear
Alternating-current circuit-breakers
IEC 62271-200:
AC metal-enclosed switchgear and controlgear for rated voltages above
1 kV and up to and including 52 kV
IEC 62271-102:
Alternating Current Disconnectors and Earthing Switches
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Product Classification
PM
Partition Metallic Class

(Metal Partitioned Compartment)
M2
Mechanical Endurance Class

(10,000 Mechanical Operations)
E2
C2
IP4X
LSC-2B
Electrical Endurance Class

(Highest Breaking Capacity class for MV Switchgear)
Capacitive Switching Class
(Least chance of restriking during Capacitive Switching)
Degree of Protection
(Ingress Protection against External agents)
Loss of Service Continuity Test
(Continuity access from one compartment to another)
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Air insulated Switchgear
Vacuum Circuit Breaker

Panel
Vacuum Contactor
Unit Panel
- VH1H
2- Tier Design
3.6kV, 400A, 50kA
7.2kV, 400A, 40kA
12kV, 630A, 25kA

12kV, 1250A, 25kA
12kV, 2000A, 25kA
12kV, 2000A, 40kA
12kV, 3150A, 40kA
12kV, 3150A, 50kA
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AIS - 12 kV VCB Panel up to 25kA

Type Designation
VHIH
Voltage
Upto 12 kV
Impulse withstand voltage
75 kVp
One minute power frequency

withstand voltage
28 kV rms
Frequency
50 Hz
Normal current
Upto 1250 A
Short circuit breaking current

25kA
Short circuit making current
63kA
Duration of short circuit withstand
1 sec
IP 41
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AIS - 12 kV VCB Panel 31.5, 40 & 50kA

Type Designation
VHIH
Voltage
Upto 12 kV
75 kVp
One minute power

frequency withstand
voltage
28 kV rms
Frequency
50 Hz
Normal current
Upto 3150 A
Short circuit breaking

current
31.5kA
40kA
50kA
Short circuit making

current
80kA
100kA
125kA
Duration of short circuit

withstand
1 sec
IP 41
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AIS 7.2 kV 2-Tier VCU Panel

Type Designation
VHIH
Voltage
3.6 kV
60 kVp
One minute power frequency

withstand voltage
20 kV rms
Frequency
50 Hz
Normal current
400A
7.2 kV
Short circuit breaking current

40kA
Duration of short circuit

withstand
1 sec
IP 41
50kA
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Panel Specification
Parameters
Rating / Description
System earthing
Low Resistance Earthing
Insulation Level
As per the System Voltage
Design Ambient
40 deg C
Auxiliary Supply-1
110 V DC
Auxiliary Supply-1
240 V AC
VCB Spring Charging Motor Supply
110V DC
Closing Coil Supply
110V DC
Trip Coil Supply
110V DC
Panel Space Heater Supply
240V AC, 50Hz
Plug & Socket Supply
240V AC, 50Hz
Panel Illumination Supply
240V AC, 50Hz
Power Cable Entry
Rear Bottom
Auxiliary Control Supply Cable
Front ( for 25kA Panels)

Rear (for 31.5kA, 40kA & 50 kA Panels)
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Scope of Supply
Board Details
VCU
400A
630A 1250A 2000A 2000A 3150A 4000A

(25kA) (25kA) (25kA) (40kA) (40kA) (50kA)
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
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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Circuit breaker Compartment

The circuit breaker compartment contains a withdrawable
vacuum circuit breaker which moves on two in-built rails.
It can be transferred between the Connected and Test
positions of circuit breaker compartment using a Racking
Handle with the door closed.
In the Connected /service position, the moving upper and
the lower contact arms of the VCB engages with the fixed
contacts connected to the busbars and the outgoing
circuit respectively.
Shutters operated by the VCB movement in the Test
/Disconnected positions, separates the contact arms and
their fixed contacts.
These shutters prevent access to the fixed contacts,
while in isolated position.
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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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Low Voltage Compartment

The low voltage compartment contains the
equipment viz.
Fuses / MCBs
Control terminals
Protective relays
Indicating lamps
Meters
Push buttons
Control switches
Illumination Lamp
These equipment operating on Auxiliary Supply

voltage are mounted on LV compartment door and
inside LV Compartment
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Arc Deflector / Gas Duct

Pressure relief flaps are provided at the top portion of the panel to ensure
safety to the operator in the event of an internal arc fault
The Arc Deflectors / Gas Duct at the top will ensure that the ionized gases are
safely evacuated
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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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Shutter Mechanism- Busbar

Shutter Operation - Busbar
Figure-1 shows the stud which actuates
the movement of the Shutter Assembly
(figure-2) in the VCB Compartment on
LHS.
Figure-3
opened.
shows
the
Busbar
shutter
Figure-1
Figure-2
Figure-3
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Shutter Mechanism- Cable

Shutter Operation - Cable
Figure-4 shows the stud which actuates
the movement of the Shutter Assembly
(Figure-5) in the VCB Compartment on
RHS.
Figure-6
opened.
shows
the
Cable
shutter
Figure-4
Figure-5
Figure-6
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Control Circuit Plug Arrangement

A removable plug at the panel connects these control
wires to the fixed wiring at the metering compartment.
Ensure that the plug makes full connection before
fastening the clasp as shown below figure
Control Plug
Arrangement
on VCB
The breaker can only be racked into

the CONNECTED position when the
secondary control plug is inserted.
Control Plug
Control circuit plug can be inserted

by moving the Red lever
Downwards.
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TRAINING PROGRAM ON
VACUUM CIRCUIT BREAKER
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Vacuum Circuit Breaker- Design

Horizontal Isolation
The mating of the contacts of the VCB is in
horizontal direction
Horizontal Draw-out out Type
The VCB Truck can be drawn out of the panel
horizontally.
Truck Mounted Design
The VCB mechanism is mounted on the truck
(trolley).
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VACUUM CIRCUIT BREAKER- Front
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VACUUM CIRCUIT BREAKER- Rear
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VACUUM CIRCUIT BREAKER- Mechanism

Closing Spring
Charging Motor
Closing
Spring
Closing
Coil
Auxiliary
Switch
Tripping
Spring
Trip Coil
Operation
Counter
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VCB Manual Operation

Note - Confirm that the circuit breaker is in the OPEN state indicated as by
the OFF position at the ON / OFF indicator.
a) Charging Operation
Manual charging can be performed in the event that the motor malfunctions.
The CHARGED/DISCHARGED indicator will change its color from white
(DISCHARGED) to yellow(CHARGED), indicating that the closing spring is
fully charged.
Push the CLOSE button to initiate the close operation. The indicators on the
breaker will now read CLOSED and DISCHARGED.
Push the TRIP button to initiate the opening operation. The indicator will now
read OPEN.
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VCB Electrical Operation

A) Charging Operation Spring
When the power supply is connected to the
operation circuit, energy from the motor is
stored in the closing spring.
When the spring charging is complete, the
limit switches opens and the motor stops.
The indicator shows CHARGED condition,
confirming that the spring charging is
complete.
As the closing spring may be released by a
closing signal, the limit switch closes when
the closing operation terminates, causing
the motor to run.
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VCB Electrical Operation

B) Closing Operation
When the closing coil is excited by a closing
signal, the closing catch is released and the
closing cam is rotated by the closing spring,
which in turn rotates the main shaft.
The main shaft drives the vacuum interrupters
through the wipe spring, and the circuit breaker
closes.
CAUTION: DO NOT repeat the closing
operation once the breaker is closed.
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)
Compact & Light
VCB Safety Interlocks
VCB cannot be engaged or withdrawn unless it is in open

condition
VCB can only be closed or opened if it is in engaged or

isolated position (and in between)
Interlocking with earth switch
Interlocking with cubicle door
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VCU Design and Application
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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Difference between VCB & VCU
Vacuum
Contactor Unit
Vacuum Circuit
Breaker
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CHARACTERISTIC
CIRCUIT BREAKER
Continous Currents High (1200A, 2000A. 3000A, 4000A)

Switching current from very low
(magnetising) values to full system
Switching Capability short-circuit current
CONTACTOR with FUSES

Moderate (400A enclosed- NEMA size H3, or 720A
enclosed size H6)
# Switching current from very low (magnetising)
values to interrupting capability of vacuum contactor
without fuses ( at least 10 x continous rating)
# Fuses operate for currents higher than the
interrupting capability capability of vacuum
contactor alone, up to the interrupting capcity of the
fuse
EnduranceMechanical
EnduranceElectrical
Application
limitations
Operations
High (typically 10,000 operations) ( refer

Very high, 10,00,000 to 25,00,000 operations
to ANSI/IEEE C37.06) & IEC 62271
High
Very high.
# for Vacuum, typically 10,000

operations at rated continous current
#Switching continuous current, 400,000 operations

for 400A & 200,000 operations for 720A
# for Vacuum, typically 30 to 100

operations at full short-circuit rating
Switching short-circuit current, endurence data not

established in NEMA or UL standards; short-circuit
current interruption requires replacement of currentlimiting fuses
Not appropriate for very high endurence

Well suited for very frequent switching operatioons
applications
Electrically operated (manual operation
Electrically operated only
for maintance or emergency)
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CHARACTERISTIC
Control Scheme
Overcurrent/ shortcircuit protection

short-circuit letthrough energy
Remote operation
Control power
CIRCUIT BREAKER
Mechanically latched- circuit breaker remains

closed on loss of system voltage
CONTACTOR with FUSES

# Usually magnetically held-vacuum contactor
opens on loss of system voltage; vacuum
contactor will close automatically on system
voltage return with two-wire control, manual
restart required on system voltage return with
three-wire control
# Latched contactors are also available

Requires protective relays for overload
Requires protective relays
protection and current limiting fuses for shortcircuit protection
Low (current-limiting fuses interrupt in 1/4 cycle
High (three to five cycles or more of short-circuit
for highest short-circuit currents, and peak
current)
magnitute is limited)
Well suited
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
# Drawout, if metal-clad (ANSI/IEEE c37.20.2) #

Drawout or Stationary
Stationary, if metal-enclosed (ANSI/IEEE C37.20.3)
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
Typical loads include transformers, capacitors, larger motors,

generators or distribution feeders,
Ratings required exceed those of vacuum contactors 400A at up
to7.2kV
Continuous load current is high ( larger transformer and larger
motors)
Switching is not very frequent (e.g. weekly or monthly) high endurance
(1000s of operations) is satisfactory
Process continuity critical (e.g.no time for fuse replacement)
Vacuum Contactor Unit are favored when

Typical loads include motors or small transformers
Continuous load current is low or moderate ( e.g. smaller motor or
transformer )
Switching is very frequent (e.g. daily or several times per day
weekly or monthly) very high endurance (100000s of operations) is
needed
Process continuity is compatible with fuse replacement time
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TRAINING PROGRAM ON
Earthing Switch
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Earthing Switch
Window for
Earthing
Switch
Operation
Rotate Earth switch Handle as per

Instruction given . Do Not Rotate
in Reverse Direction. It May
Damage the interlocks.
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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Earthing Switch & Interlocks

These are equipped with a snap action spring device which ensures an
independent closing speed. They can make and withstand short-circuit
currents
Basic Interlocks which are commonly provided in a MV switchboard.
VCB can not be racked in or connected to service position from test
position when;
a. VCB in closed position
b. Without control Plug.
c. Earth switch in closed position.
d. Door is opened.
While VCB in service position;
a. Earth switch can not be closed
b. Control plug can not be removed.
c. Closed VCB can not be racked out.
d. VCB door can not be opened.
While VCB in intermediate position;
a. VCB can not be closed
b. Control plug can not be removed.
While VCB in Test position;
a. VCB door can be opened
b. ESW can be operated.
c. Control plug can be removed and inserted.
VCB only can be opened and closed while in test and service position.
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TRAINING PROGRAM ON
Operating Sequence
/ Instructions
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VCB Rack-In Operation Closed Door
1. ENSURE THE FOLLOWING BEFORE
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.
5. ROTATE THE RACKING

HANDLE CLOCKWISE UNTIL;
a VCB POSITION INDICATOR
SHOWS ;SERVICE AND
b MECHANICAL RESISTANCE IS
FELT TO ROTATE HANDLE
2. CLOSE THE DOOR AND

TIGHTEN THE CAPTIVE
SCREW.
3. LIFT THE LEVER A, OPEN

THE FLAP OF SOCKET FOR
VCB RACKING HANDLE, AND
INSERT THE VCB RACKING
HANDLE,
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VCB Rack- Out Operation Closed Door
1. ENSURE THE FOLLOWING BEFORE RACKOUT;

a VCB IS IN OPEN CONDITION.
b VCB POSITION INDICATOR SHOWS
SERVICE POSITION.
4. REMOVE THE
RACKING HANDLE.
2. LIFT THE LEVER A. OPEN THE

FLAP OF SOCKET FOR VCB
RACKING HANDLE AND INSERT THE
VCB RACKING HANDLE
3. ROTATE THE RACKING HANDLE ANTICLOCKWISE

UNTIL
(a) THE HANDLE STARTS ROTATING FREELY AND
(b) VCB POSITION INDICATOR SHOWS TEST
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VCU Rack-In Operation Closed Door
1. ENSURE THE FOLLOWING BEFORE
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.
4. PULL THE VCU HANDLE UP TO

DRIVE THE VCU TO CONNECTED
AND EARTH OFF POSITION
5. CHECK THE VCU POSITION
INDICATOR FOR CON POSITION
2. CLOSE THE DOOR AND

TIGHTEN THE CAPTIVE
SCREW.
3. OPEN THE VCU OPERATING

WINDOWAND INSERT THE
VCU RACKING HANDLE
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VCU Rack- Out Operation Closed Door
1. ENSURE THE FOLLOWING BEFORE RACKOUT;

a VCU POSITION INDICATION SHOWS CON
b VCU IS IN OPEN CONDITION
4. REMOVE THE
RACKING HANDLE AND
CLOSE THE VCU
OPERATING WINDOW.
2. OPEN THE VCU OPERATING

WINDOW AND INSERT THE VCU
RACKING HANDLE
3. PUSH THE HANDLE DOWN TO BRING THE VCU TO

DISCONNECTED POSITION AND EARTH SWITH ON
POSITION.
4. CHECK THE VCU POSITION INDICATOR
FOR
DCON INDICATION
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Earth Switch Operation

1. ENSURE THAT VCB IS AT
DISCONNECTED & TEST POSITION.
5. REMOVE THE
RACKING HANDLE.
4. PULL THE
HANDLE UPWARD
TO SWITCH ON.
2. MOVE THE LEVER B TO LEFT TO

OPEN THE COVER OF EARTH SWITCH
OPERATING MECHANISM.
3. INSERT THE EARTH

SWITCH OPERATING
HANDLE.
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TRAINING PROGRAM ON
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.
SDS Interlock (Control Plug)

VCB cannot be Racked in unless the Control plug is fitted.
Ensure that SDS is Plugged in during VCB / VCU during Rack In.
Earth Switch Interlock
VCB cannot be engaged when Earthing Switch is CLOSED
Earthing switch cannot be closed when VCB is engaged
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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
PAD LOCKING FACILITY

1. VCB Door Handle
2. Safety Shutter
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TRAINING PROGRAM ON
Type Test Details
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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
HV Power Frequency Dry Withstand Voltage (PFWV)

1. Short Duration (1 minute) test voltage 2 to 4 times the rated maximum Voltage
Eg For rated max. voltage 12 kV = 28kV rms (as per IEC standard)
Lightning Impulse Withstand Voltage (LIWV or BIL)
1. A fast rising voltage impulse 4 to 12 times rated Maximum voltage
2. Rise time = 1.2 microseconds and decay to 50% in 50 microseconds
Eg for rated max voltage 12kV = 75kV peak (as per IEC standard)
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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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Type tests Internal Arc Test - Classification

Classification:
IAC ( Internal Arc Classified )
Accessibility:
A (F, L, R)*
B (F, L, R)*
C
Test values:
F = Front; L = Lateral; R = Rear

A= Autorised operators; B = General
Public; C= Pole mounted /unreachable
Current [ kA ] and duration [ s ]
Example 1:
IAC
FLR
40 kA
1s
Example 2:
IAC
FL
31.5 kA
0.5 s
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Why IEC Evolved wrt Internal Arc
The technical committees responsible for the testing standards, incorporate

the learning from field experience & from the test lab experience.
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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Internal Arc Fault

Overcoming Weaknesses of old IEC
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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Type tests Internal Arc Test

Internal Arc Test in following compartments:
CB Compartment
Busbar Compartment
Cable Compartment
Test Passing Criteria
Criteria 1 Doors & Covers must not open
Criteria 2 Parts of the Switchgear must not fly-off
Criteria 3 Holes must not develop on the external parts of

the enclosure
Criteria 4 Indicators must not ignite
Criteria 5 Earth connections must remain effective
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TRAINING PROGRAM ON
Installation of Spares
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Installation of Spares
Mounting Trip Coil

Removal of Trip coil
Mounting Spring Charging Motor
Removal of Spring Charging Motor
Removal of Closing coil
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TRAINING PROGRAM ON
Maintenance Schedule
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MAINTENANCE AND INSPECTION SCHEDULE

Why Maintenance ?
Preventive maintenance today, Can avoid costly failures tomorrow
The failures that can lead to.

Major breakdowns
A loss of production
A loss of property
Even a loss of lives
Ultimately a loss to the Business
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When maintenance is required ?
The frequency of the maintenance depends essentially on
service conditions viz..
Frequency of operation
Tripping on fault
Relative humidity
Presence of dust & reactive gases
It is Recommended
to carry out
Preventive
Maintenance
After every 3000 mechanical

operations OR
After six months if switchboard is
exposed to dust OR
After an idle period longer than six
months OR
every year
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Upkeep of switchboard room

Switchboard room should be clean, well
ventilated & dust free.
Ensure switchboard room to be free from
insects, rats & lizards
Closed loop air supply & exhaust system to be
ensured in dusty surrounding
Cable trenches, bus duct entries are to be
sealed to restrict the entry of lizards, rats &
snakes
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Pressurized air circulation system to be used in a contaminated
environment where chemical gases, fumes, steam fumes
etc,which can cause harmful effects to the switchboard
equipment
Appropriate measures to be taken to avoid leakage & seepage

of water through ceiling & walls inside the switchboard room as
it can lead to flashovers
A thermometer should be installed in the vicinity of the

switchboard for monitoring ambient temperature
Entry to the switchboard room should be restricted to

authorized personnel only, preferably to have locking provision.
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Name and telephone numbers of the nearest dispensary and
doctor should be displayed
Fire fighting equipment and Fire alarms as prescribed by the

safety department should be available in working condition.
Relevant drawings of switchboard e.g. General arrangement

drawing, Wiring diagram, should be kept inside the cupboard
for reference whenever required
A hydraulic or manual operated trolley should be kept

available for loading & unloading of the Vacuum Circuit
Breakers.
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Before starting the maintenance
Switch off incoming power supply before starting maintenance. Lock out
incoming power supply. For safe operations, rack out incomer VCBs to
isolated position & lock them
Measure voltage on busbars to ensure that busbars are de-energized.
Switch off the control supply.
Isolate remote control voltage sources.
Ensure that only qualified personnel are instructed
and permitted to use the defeat mechanism
to gain access to an energized panel
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Do not attempt to withdraw the unit or disconnect any terminations when
the defeat mechanism has been used to open a compartment door.
Current transformer primaries must not be energized when secondary's
are open circuited.
Only manufacturer recommended lubricants should be used.
For safety of personnel working on busbars, provide temporary earthing
using a metallic chain/strip near the workplace. Remove this earthing
only after the job is completed.
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After maintenance, if Panel is going to be de-energised for a longer
period, switch on the panel space heaters to prevent moisture
condensation on the cables/insulators.
vacuum cleaners should be used to remove dust and avoid moisture
condensation in the switchboard
Use recommend tools and equipment for maintenance of switchboards
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Recommended Tools for maintenance
Cleaning
Dry cloth
CRC 2-26 Spray
Vacuum cleaner with small nozzle
WD - 40 ( Rust Preventer )
Zero Grade Emery Paper ( not for contacts )
Tightening
Screw drivers 6, 8, 10
Double ended spanners ( 4mm to 19mm )
Socket spanner set ( upto 19mm )
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Recommended Tools for maintenance
Torque wrench 0.3 to 1.2 kg.m, 1.2 to 7 kg.m, 5.0 to 23.0 kg.m
Heavy duty Star Screw Driver (12 )
Allen key set 0 - 10mm
Plier 8
Tubular spanners
Nose pliers 8
Wire stripper 0 - 6 sq.mm
Small star screw driver
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General Guidelines for switchboard maintenance
All electrical power should be de-energised, tagged and locked out
accordingly with established procedures.
Access covers and enclosures should be removed and all assemblies
should be hand cleaned with a dry lint free cloth and non metallic brushes.
Do not use cotton waste for cleaning.
Special attention should be given to insulating surfaces.
High power vacuums should be used to remove all loose debris.
Compressed air should be avoided to prevent forcing dust and
contaminates into other components.
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General Guidelines for switchboard maintenance
Contacts in circuit breakers, contactors, and other switching equipment like
Earthing switches should be inspected & cleaned of all dirt.
All the components of switchboard should be examined for cracks, defective
plating, frayed wires, burnt insulation, and general overall condition
Ensure tightness of Cable, connections and components, also mechanical parts
of equipments should be free to function
Loose connections and damaged insulations should be repaired or replaced to
avoid Over heating and flashover
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What to Inspect?
Busbar connections and fasteners to be ensured for tightness
Frame grounding cable for tight connections
Insulating materials / creep surfaces, clean, intact / retape taped bars as
needed
Fuses and earthbar links, right size and tight
Switches, knobs, present and all in good condition
Ensure VCB ON-OFF operation at least 4 to 5 times, also free operation of
other mechanical parts
Lubricate appropriate components, do not over lubricate
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What to Inspect?
Cables and bundles secured, no abrasive contacts
Charging handles and rails, in position and secured
Insulation matting, always in place
Equipment labeling is correct
Structural integrity of enclosures, Gas duct and IAF flaps are in place
Latches and locks operating
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What to Inspect?
(a) Cleaning
All dust and dirt found on the top covers should be brushed off and cleaned prior to
commencing any dismantling to minimize ingress of dirt into internal portions of the
switchgear panel. Use lint-free clean cloth to clean the switchgears.
(b)Insulation
All insulation surfaces should be cleaned and closely inspected for signs of tracking,
treeing, blistering, and delamination or mechanical damage. There should be no trace of
grease on any part of the insulation surfaces especially at the spouts in the breaker
compartment. Clean and dry insulators with a suitable cleaning agent.
Caution: Cleaning agent cannot be used on the black & grey surfaces of the
bushing or on the copper bars.
(c) Heater
The operation of all heaters, where fitted, should be verified.
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What to Inspect?
(d) Main and Earth busbars connections
Ensure that all connections are tight and that good contact is maintained.
This examination should include opening the boots for torque checks on the
busbar bolt joints. There is a very slim chance for yearly shutdown of the bus, but
checks should be done at least once in three years.
(e) Secondary wiring and fuses
Ensure that the connections are tight and good contact is maintained. Verify the
continuity of wiring to the fuses, instrument transformers, relays, instruments and
other associated devices.
All contacts including that for the plug and socket contacts should be cleaned and
lubricated sparingly with the correct lubricant. Fuses should be tested for
continuity and inspected for signs of deterioration.
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What to Inspect?
(f) Auxiliary switches, indicating devices and interlocks
Auxiliary switches should be kept in a clean and operational condition because

they are critical to the correct functioning of the equipment, especially the
protection system.
Indicating devices such as semaphores should be tested for good operations
and blown bulbs replaced. Interlocks and locking devices should receive
particular attention, especially those associated with earthing and testing
facilities. A strained or worn out
device may result in a dangerous condition. It should be verified that any maloperation is satisfactorily inhibited. Lubricate when necessary.
(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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What to Inspect?
(h) Isolating contacts
The isolating contacts should be examined for discoloration and
deformation due to overheating or environmental contamination. Replace if
necessary. Replace conductors if cause is overheating. For environmental
contamination, eliminate source of contamination and clean the plating
surface with appropriate cleaning agent.
(i) Earthing switches
Earthing switches should be examined for correct operation and its contacts
for good connections. The correct interlocking between the earthing switch
and the breaker should be verified.
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What to Inspect?
(j) Meters, Transducers and Batteries
For the following items, refer to the relevant manufacturer's instruction
manuals provided for operation checks:
Protection relays
Voltmeters and ammeters
Energy meters (active or reactive)
Transducers (voltage, current, watt, var)
DC tripping/control supply
(k) Protection relays
Wipe off any dust on the relay covers before removing them. Ensure that
the covers are securely replaced to minimize the ingress of dust into the
relays. Injection testing by primary injection is preferred. However, regular
testing by secondary injection is sufficient to prove the integrity of the relays.
Tests should be made on protection relays to verify the operating and
resetting times, the pick-up and drop-off values.
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What to Inspect?
In the case of electro-mechanical relays, great care should be taken to

avoid damage to the relay mechanisms when manipulating the induction
disc of the relay.
In general, avoid subjecting protection relays to high-voltage tests. If such
tests are required, ensure that the correct test voltages are applied to avoid
damage to the relay, especially the solid state type.
If it is necessary to disturb any connections for testing purposes, ensure that
these connections are correctly restored before returning the switchgears
into service.
(l) Current transformers (CT) and voltage transformers (VT)

Steps should be taken to ensure that voltage transformers are isolated and
discharged to earth before commencing examination. Care should be taken
to ensure that the transformers are not made live inadvertently due to
feedback from the secondary windings.
In the case of the CT, attention is drawn to the dangerous voltages that may
result if the secondary's are open-circuited while the primaries are on load.
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What to Inspect?
Any connections removed for checking/testing must be correctly replaced

and securely tightened. Insulation resistance and continuity tests of the
secondary windings should be carried out where possible.
Generally, check CT's and VT's for physical appearance and that all related
connections are tight. The insulation material should be cleaned and closely
examined for any signs of damage such as cracks, tracking marks or
peeling.
In case of withdrawable VT's, the isolating contacts should be checked,
cleaned and lubricated sparingly. The correct operation of safety shutters for
the VT truck should also be verified. Primary and secondary fuses should
be tested for continuity.
(m) Control relays or contactors

Inspect mechanical parts for free movement with the control and main
circuits isolated. Check the operation of the relays/contactors by energising
the control circuit.
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Maintenance of Switchboard
BUSBAR ZONE
Remove rear door plates and check for tightness (at the specified torque values)
of hardware for busbar / fishplate coupling. Poor connections will cause
overheating.
Check whether joint shrouds are in its place
Close rear door covers/plates
POWER CABLE ZONE
Check that power cables do not exert undue pressure on the termination
Ensure proper clamping of cables on the glands and cable clamps to avoid
weight of cables acting directly on the termination
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Check for unused holes, block them
Check for presence of shrouds/boots on outgoing terminals
Check for proper termination of extension links
Always use copper wires / cables for control purposes
Check all power and control circuit connections at terminal blocks, cable
terminals, switch terminals, contactor terminals, for tightness
Refer to the scheme diagrams and terminal chart before reconnecting the
meters and relays
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Check that fuses are fitted in main and auxiliary circuit and that ratings are
appropriate for the circuit
Check the setting of overload relays and other protection relays
Check the setting of Intelligent relays as per setting chart
Ensure that the wires are not hanging loose. Temporary connections made
during testing should be removed
Check that all CT secondary shorting links are present
Inspect all devices to ensure that the equipment is in proper working order
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Inspect all wiring for wear and cuts, wherever they pass on sharp edges
Look for wear of the silver plating on the contacts & on the earthing contacts fixed to VCB
and at the point where they engage with the fixed contacts.
Clean & lubricate the contacts once a year with HP MPL (EXXON) grease
Look for indications of overheating, arcing or insulation breakdown Inspect power and
control contacts. Replace worn out contacts
Inspect all auxiliary and control circuits for desired functioning
Grease racking screw and telescopic rails at least once a year ( HP - LETHON - 2 or
SYNTHOLUBE-20 of HJ Leach & Co.)
Inspect all door gaskets for wear and replace where necessary
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Before energizing the switchboard
Inspect busbar chamber, unit compartments and cable alleys, remove tools, conductor
strands and any other material lying loose
Use vacuum cleaner to remove dust, small particles etc.
Check tightness of electrical joints
Remove CT secondary shorting while connecting the meters or relays
Close all doors before energizing the board, do not operate any equipment with its
compartment door open when the board is energized
Ensure correct settings of protection relays for overload and short circuit coordination
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Check for operation of the feeders as per scheme drawing
Equipment must be operated at rated voltages. Check the supply voltage before the circuit
is energized
Remove all temporary wires
Remake all connections removed for troubleshooting purposes
Check for the quality of the work after its completion
Ensure proper earthing connections
Be alert of undesirable grounds and eliminate them
Measure the insulation resistance with 2000 volts megger between phases and between
phase and ground. It should be more than 500 Mega-ohm
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Switch ON the space heaters before
energizing of Switchboard
Effect of High humidity & Water sipage in

Switchgear
Space Heater
Repeated HV test deteriorates the insulation properties. Avoid repeated HV

test
Ensure that all other VCBs and switches are OFF while making the Incomer
ON
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CHECK
POINT
CHECK ITEM
Tightness of bolts
and nuts
Entire VCB
Dust and foreign

matter
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
The VCB should be

clear of dust and
stains
Clean with a vacuum

cleaner. Wipe with a
clean, dry cloth and Once in
recommended cleaning
3
agent (AS66)
years*
Visual check
No deformation,
excessive wear or
damage
Replace parts, if
necessary
Visual check
No missing parts
Replace missing parts
Check circuits and the

The closing and
closing and tripping
Check at the
tripping operations
devices.
DISCONNECTED can be done smoothly When the motor cannot
position
Motor can spring
spring charge, check if
charge automatically line fuse is blown.
Replace if blown.
Once in
3
years*
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CHECK POINT
CHECK ITEM
CHECK METHOD
Dust and foreign

Visual check
matter
CRITERIA
There should be no
dust and foreign
matter
Smooth operation Manual operation

Operating
Operation should be
Lubricant of
Check by sight
mechanism
smooth
bearing pins
and touch
Shaft of closing
and tripping
Visual check
Must rotate smoothly
portion
Main circuit
Dis-colouration of
disconnects/
Visual check
contacts
contact finger
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.
Clean the contact

There should be a thin
surface of old grease Once in 3
film of contact grease
and apply a thin film
years*
on the contact surface
of new grease
Clean with pressured
air and then wipe
with clean cloth
Once in 3
years*
There should be no
Replace when
tracking marks, cracks
damaged
or damages
There should be no
foreign matter
Visual check
E&A IC

CHECK POINT
Measurement
of insulation
resistance
CHECK ITEM
Main conductorGround / Main

conductors
CHECK METHOD
500M or more
Control circuit Ground 2 M or more
Measurement Measuring location

of contact Across each set
resistance contacts
Timing Test
Across each set of

contacts
CRITERIA
2000V
500V
Resistance
Tester
1250A <75
Micro-Ometer
Trip test & Close test
WHAT TO DO
FREQUENCY
When the insulation

resistance between
the main circuit
terminals is low,
clean the surface of
the vacuum
interrupter with a dry
cloth and then take
the measurements
again
Once in 3
years*
Check wipe and

contact gaps
Once in 3
years*
As per specs
Carried out
when speed
of operation
is critical
E&A IC
Troubleshooting
Part
Trouble
Possible Cause
DOOR
Wrong key (if any)

Handle cannot be
locked
Internal mechanism rusted

Internal mechanism faulty
Remedy
1.
Check key number
2.
Lubricate hole
3.
If in emergency, cut off the

handle
Re-tighten the screws
Fixing screws loose
1.
Internal mechanism worn out
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
Door deformed by external force
Partition plates vibrating due to

electromagnetic Induction/loose screws
on partition plates
Internal noise
Cable touching gland plate.

Partial discharge due to stained or moist
insulating material
Rectify the hinge pin

Repair the deformed portion
For screwed on partition plates,
retighten the screws.
For gland plates, add sealing
compound between cable and
plate
Shutdown power and clean the
surface of the insulating
material. Switch on the heaters
to dry the air inside the cubicle
E&A IC
Troubleshooting
MAIN CONDUCTORS
Part
Trouble
Connections overheated
Possible Cause
1.
Loose bolts
2.
Overload
Insulators cracked
Ground fault or failed
dielectric tests
Insulators stained with foreign matters and

moisture
Intrusion of rodents
Bulb filament broken
Fuse or resistor burnt
Control
Circuit
Extinction of indicating
tights
Poor contact of auxiliary switches at the

breaker
Auxiliary supply switches open circulated
Limit switch contact shifted or faulty
Remedy
Re-tighten bolts to specified torque

or replace busbar if necessary
Limit current to the rated value
1.
Replace insulators
2. Clean and dry insulators with

suitable cleaning agent
3. Plug gaps and openings and
remove rodents
Replace bulb
Replace fuse or resistor
Clean the auxiliary contacts
Check MCCB of fuse and wire
terminals
Check limit switches contact and
operation of limit switch.
Poor contact of breaker auxiliary switches

Simultaneous lighting of Contact resistance increased due to dust
both ON and OFF
contamination or oxidation of contacts
indicating lights
(especially when they are not operated for
prolonged period)
Poor operation of control Loose screws on the terminal blocks
circuits
Control circuit plug not properly connected
Clean contacts of auxiliary switch

Operate the auxiliary switch several
times
1. Re-tighten screws on the
terminal blocks
2.
Re-insert the control circuit plug
E&A IC
Troubleshooting
Part
Trouble
Possible Cause
Circuit breaker not fully inserted
VACUUM CIRCUIT BREAKER
REMOTE/LOCAL selector switch incorrectly

selected
VCB cannot close
Auxiliary supply MCCB open

Control circuit plug not connected
Control circuit voltage drop
Closing coil burnt
VCB cannot open
1.
REMOTE/LOCAL selector switch

incorrectly selected
2.
Auxiliary supply MCB/switch open
3.
Control circuit voltage drop
SHUTTER
Wrong rating of breaker

VCB cannot be inserted into
Lock lever does not lift up due to the
cubicle
CLOSED position of breaker
Shutters cannot close
1.
Shutter damaged
2.
Moving parts poorly adjustment and

lubricating oil deteriorated
Remedy
1.
Breaker to be aligned with

the CONNECTED position
sticker
2.
Switch to correct position
3.
Close the MCCB
4.
Connect the control plug
5.
Restore the voltage
6.
Replace the coil
Switch to correct position

Close the MCB/Switch
Restore the voltage
Insert the breaker of the correct
rating
Trip the breaker
Adjust the shutter mechanism,
lubricate the moving part
Repair damaged shutters
Adjust moving parts and apply
lubricating oil
Clean the moving part
E&A IC
TRAINING PROGRAM ON
Electrical Components
E&A IC
TRAINING PROGRAM ON
Understanding of Electrical Scheme
E&A IC
TRAINING PROGRAM ON
E&A IC
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.
E&A IC
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.
E&A IC
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
E&A IC
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
E&A IC
Q&A
E&A IC
Thank you
E&A IC

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Electrical Systems & Equipment

Project : Ruwais Refinery Expansion Project

Electrical Systems & Equipment

Training Program Medium Voltage Switchgear

L&T Corporate Film & Brief Overview to L&T EAIC

Terminologies and equipment used in Switchgear

Brief overview of Arc quenching techniques

Electrical Systems & Equipment

Operating Instructions &

Type Tests information

Electrical Systems & Equipment

Selection of CT, VT, Surge Arrester, Voltage detecting Indication etc

Dos & Don'ts

Open Forum for Discussion /Queries.

Electrical Systems & Equipment

L&T Corporate Video

Electrical Systems & Equipment

E&A IC : Business Units

Electrical Systems & Equipment (ESE)

Control & Automation Systems (C&A)

Electrical Systems & Equipment

Electrical Standard Products (ESP)

Metering & Protection Systems (MPS)

E&A IC : Manufacturing Locations

Jebel Ali, UAE

Integrated Automation Systems

LV Switchgear & MCCs

Metering & Protection

Electrical Systems & Equipment

Plant Location - Ahmednagar

Electrical Systems & Equipment

Plant Location - Ahmednagar

Electrical Systems & Equipment

CNC PRESS BRAKE

Electrical Systems & Equipment

Model: TOGU III

CNC TURRET PUNCH PRESS

Electrical Systems & Equipment

MIG WELDING MACHINE

Electrical Systems & Equipment

GRINDING AND BUFFING

9 tank process - Pretreatment facility

Electrical Systems & Equipment

Electrical Systems & Equipment

IMPULSE TEST LAB

Electrical Systems & Equipment

VCB TESTING TROLLEY

Electrical Systems & Equipment

Lug Pull Tester

Electrical Systems & Equipment

Surface Plate & Measuring

Push Pull Meter

Various In-House Type Tests

Electrical Systems & Equipment

ISO 9001 - 2008 - BV

Electrical Systems & Equipment

Electrical Systems & Equipment

There is no special opening condition

A fuse is used for over current and short

Electrical Systems & Equipment

Fuse has to be replaced after every

Electrical Systems & Equipment

Busbar - To allow multiple connections from one

Surge Arrester Surge Arrester are the primary