Name: Neeraj Purohit Branch: ECE Batch: C-3 Training Place: ABB Limited, Vadodara

HISTORY (WEEK 1) [27th June to 1st July 2011]

The Company was incorporated on 24.12.1949 as The Hindustan Electric Company Limited. On 24.09.1965, the Companys name was changed to Hindustan Brown Boveri Limited (HBB). Pursuant to the Scheme of Amalgamation of ASEA (Allmanna Syenska Elektriska Aktiebolaget) Limited with HBB with effect from 1st January 1989, the name was further changed to Asea Brown Boveri Limited, with effect from 13.10.1989.

Its Head-Quarter is in Zurich (Switzerland). ABB is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The current MD of ABB India is Mr. Bazmee Hussain. Asea Brown Boveri, Swiss-Swedish Company HQ: Zurich (Switzerland) Power & Automation Technology Merger of ASEA (Swedan) and Brown, Boveri & Cie (Swiss) Hindustan Electric Company to -HBB Corperate Offices: Nashik, Vadodara, Mumbai, Benagluru, Delhi, Haridwar, Kolkata, Faridabad, Nagpur & Chennai MD Bazmi Hussain

Products and Utility:

Power Products Power Products are the key components to transmit and distribute electricity. The division incorporates ABB's manufacturing network for transformers, switchgear, circuit breakers, cables and associated equipment. It also offers all the services needed to ensure products' performance and extend their lifespan. The division is subdivided into three business units.

Work at ABB:
The ABB power plant in Vadodara performs the assembly and packaging of GIS components. All the components are imported from Germany. These components are specially designed by German Engineers for various customers of ABB India as per their requirement, such as TATA, RELIANCE and other big firms. The Indian Engineers perform the task of Operation and Monitoring of components. Even a small fault is corrected by German Engineers. The ABB plant works on 5-S Organisation which is depicted as:

Standarize

Sort

Sustain

Sweep

Strengthen

The working procedure at ABB for a contract job undergoes through following steps: PAGE 1 A Circuit drawing is made on sheet of the required product. The Technical data and Process control specification are specified. The size of components and other ratings are standardized as per customers requirement. It is ensured that all the components are cost efficient and compact in installation. The packaging of the components is done in Alu-Zinc material, which is cut by rivet gun. It is used because it is rust free and malleable. The output and interfacing devices such as LCD Feeder Panel, Alarms and MCB are connected through bus bars. The completed project undergoes through various tests such as Type Test before handing it over to the customer. PAGE 4 PAGE 9 & 8

Switchgear
The term switchgear, used in association with the electric power system, or grid, refers to the combination of electrical disconnects, fuses and/or circuit breakers used to isolate electrical equipment. Switchgear is used both to de-energize equipment to allow work to be done and to clear faults downstream. This type of equipment is important because it is directly linked to the reliability of the electricity supply.

The very earliest central power stations used simple open knife switches, mounted on insulating panels of marble or asbestos. Power levels and voltages rapidly escalated, making open manually-operated switches too dangerous to use for anything other than isolation of a deenergized circuit. Oil-filled equipment allowed arc energy to be contained and safely controlled. By the early 20th century, a switchgear line-up would be a metal-enclosed structure with electrically-operated switching elements, using oil circuit breakers. Today, oil-filled equipment has largely been replaced by air-blast, vacuum, or SF6 equipment, allowing large currents and power levels to be safely controlled by automatic equipment incorporating digital controls, protection, metering and communications.

(WEEK 2) [4th July- 8th July2011]

Substations:
Typically, switchgear in substations is located on both the high voltage and the low voltage side of large power transformers. The switchgear located on the low voltage side of the transformers in distribution type substations, now are typically located in what is called a Power Distribution Center (PDC). Inside this building are typically smaller, medium-voltage (~15kV) circuit breakers feeding the distribution system. The use of SF6 gas as an insulating medium in switchgear reduces the clearance distance between active and non-active parts of a switchgear facilitating the following advantages of gas insulated applications compared to air insulated applications:

Less space requirements - especially in congested city areas Less sensitivity to pollution, as well as salt, sand or even large amounts of snow Less operation & maintenance costs

Types:
By current rating By voltage (low, medium or high) By insulating medium (Air, Gas, Oil or Vacuum) By construction, application, IEC degree, etc.

A piece of switchgear may be a simple open-air isolator switch or it may be insulated by some other substance. An effective although more costly form of switchgear is gas insulated switchgear (GIS), where the conductors and contacts are insulated by pressurized sulfur hexafluoride gas (SF6). Other common types are oil or vacuum insulated switchgear. Circuit Breakers: Oil, Air, Gas, Vacuum

GIS - Gas Insulated Switchgear

Features of GIS, like extremely low space requirements and high reliability, offer smart and economic solutions for complex switchgear applications, e.g. in densely populated areas, for aesthetic town planning or under severe environmental impact.

Characteristics:
SF6 gas as medium at 1.3 bar, insulated with hermetically sealed pressure system. Single and double bus bar design Stainless steel encapsulation Integrated leakage testing of the panels Indoor installation Voltage rating up to 36 KV Current rating up to 40KA

Panel Variants:
Incoming and outgoing feeder panels

Cable Termination panels Termination panels for fully insulated bars Sectionaliser Motoring panels

Circuit Breaker, Disconnector and three position disconnector:

Vacuum Circuit Breaker along with Disconnector with functions for: i) ii) Bus Bar Connection Disconnection

Three Position Disconnector (with earthing switches) with functions for: i) ii) iii) Bus Bar Connection Disconnection Earthing

Connections: Using Cable Plug System Current and Voltage measuring: Instrument transformers and sensors Protection and Control:
i) Combined Protection and Control Devices ii) Discrete Protection and Control Methods

Protection against Mal-operation:

1) Electrical Switch interlocks 2) Mechanical Interlocks (optional)

Pressure Relief:
Via Pressure Relief ducts into switch room or outside

Installation:
Panel joined together by plug-in connections PAGE 6

Applications:
One of the basic application of switchgear is protection, which is interruption of short-circuit and overload fault currents while maintaining service to unaffected circuits. Switchgear also provides isolation of circuits from power supplies. Switchgear is also used to enhance system availability by allowing more than one source to feed a load.

Safety
To help ensure safe operation sequences of switchgear, trapped key interlocking provides predefined scenarios of operation. For example, if only one of two sources of supply are permitted to be connected at a given time, the interlock scheme may require that the first switch must be opened to release a key that will allow closing the second switch. Complex schemes are possible.

Trapped key interlocking

Trapped key interlocking utilizes locks and keys for sequential control of equipment and machinery to ensure safe operation. A simple system might consist of two locks and a single key. Normally inserting the key into a lock would enable a power supply, thus in this simple system

only one power supply could be enabled at any one time. Trapped key interlocks are widely used to ensure safe access to potentially live or dangerous plant or equipment in an industrial setting. Page 3.

Knife switch
A knife switch is a type of switch used to control the flow of electricity in a circuit. It is composed of a hinge which allows a metal lever, or knife, to be lifted from or inserted into a slot or jaw.

Construction of Switchgear (WEEK 3) [11th July-15th July2011]:

Modular Structure: Each feeder panel consists of circuit breaker compartment(A), one
or two bus-bar compartments(B), cable termination compartment(C), the pressure relief duct for cable termination compartment(D), one or two pressure relief ducts for bus bar compartment(E) and low voltage compartment(F). The ciruit breaker compartment and the bus bar compartment are filled with gas. There are no gas connections between two or three compartments or to gas compartments in adjacent panels.

Circuit Breaker:

Functions:
Switching operation current ON and OFF

 Short circuit breaking operations Earthing function in conjunction with three position disconnector

The cable termination compartment constitutes a support frame for the panel manufactured from bended zinc-plated sheet metal. In the unlikely event of an arc fault in the cable termination or circuit breaker compartments, pressure is relieved through rear pressure relief duct (4.0). The upper pressure relief system serves to discharge the pressure in the unlikely event of an internal arc fault in the bus bar compartment. Protection devices and further secondary devices and their wiring are located in the Low Voltage Compartment

WORKING: The LCD Panel of GIS consists of Circuit Breaker connection, Isolator and
switch connection. The Circuit Breaker can be turned ON or OFF by I/O buttons in LCD or by mechanically starting it via chain. It is the most important component of GIS.

i) Grounding the GIS: The circuit breaker has to be turned ON or OFF before performing the Ground operation Isolating Operation: The GIS is grounded, then the Insulator pad is selected before turning ON the Circuit Breaker. For reverse operation, steps are followed in reverse order. Page 3.

Building planning

Site requirementsThe switchgear can be installed: -on a concrete floor: or It requires a foundation frame set into the floor topping. The evenness and straightness tolerances for the base of the switchgear system are ensured by the foundation frame. -on a raised false floor: Below the switchgear, the supporting sections of the raised false floor serve as a base for the panels. A foundation frame is not as a rule necessary.

TECHNICAL SPECIFICATION OF FEEDER PANEL

PARAMETER
Maximum Operating Voltage Rated Frequency Rated Normal Current Rated Peak Withstand Current

IEC Rating
36 V 50 Hz 2500 A 100 kA

Special Rating
40.5 V 50 Hz 2500 A 100 kA

TECHNICAL SPECIFICATION OF CIRCUIT BREAKER

PARAMETER
Maximum Operating Voltage Rated Frequency Rated Normal Current Rated Short Circuit Making Current Rated Short Circuit Breaking Current Power Consumption by Coil

IEC Rating
36 V 50 Hz 2500 A 100 kA 40 kA 250-310 W

Special Rating
40.5 V 50 Hz 2500 A 100 kA 40 kA 250-310 W

TECHNICAL SPECIFICATION OF THREE POSITION DISCONNECTOR

PARAMETER
Maximum Operating Voltage Rated Frequency Rated Normal Current Rated duration of Short Circuit Power Consumption by Coil

IEC Rating
36 V 50 Hz 2500 A 3s 180 W

Special Rating
40.5 V 50 Hz 2500 A 3s 180 W

ZX-Family (WEEK 4) [18th July-26th July2011]

(Gas-insulated medium voltage switchgear) Features of ZX family are: -System in metal enclosed design. -Hermetically sealed pressure systems-gas-tight for life! -SF6 insulated gas for guaranteed dielectric strength. -Metal partitioning between functions where necessary. -Plug-in technology for cables , busbars and voltage transformers. -Enclosures in stainless steel. -Vacuum circuit breakers. -Factory tested quality.

BENEFITS:-

Minimum overall costs- The compact design of the panels reduces the space required and therefore the size of the station. Freedom from maintenance is achieved by constant conditions in the high voltage compartments in conjunction with the selection of the suitable materials. The panels are designed for an expected service life of over 40 years. Because of the plug in technology installation time required is minimum. Maximum operator safety- All live components are enclosed to prevent accidental contact. As the high voltage compartments are independent of external influences ( degree of protection IP65). A further enhancement can be achieved by providing pressure relief to outside the switchgear room. Maximum availability- Easy, simple and fast: the plug-in bus bar technology without screwing couplings permits simple and therefore safe assembly. Replacement of the components in the gas compartments and therefore a rapid return to service after repairs is possible.

ZX2

ABB Protection & Control Unit v) Inductive Proximity Switches vi) Inductive Proximity Switches + Mechanical interlocks vii) Inductive Proximity + Auxiliary Switches viii) Inductive Sensors CTs/VTs Proximity Switches +

ABB Protection & Control Unit + Additional Function i) Inductive Proximity Switches ii) Inductive Proximity Switches + Mechanical interlocks iii) Inductive Proximity + Auxiliary Switches iv) Inductive Proximity Sensors CTs/VTs Switches +

Third Party protection devices + conventional control Mechanical units Interlocks + Auxialiary Switches

Sensors

ZX TYPES :ZX0 has a compact system for distribution application and that too in two basic versions: block and individual panel design. They can be operated by both manual and remote control procedure. Along with vacuum circuit breakers there are switch disconnectors (with and without fuses ). ZX1.2 has metal partitioned single bus bar system for transformer and distribution substations with raised cable terminations for ultra-simple cable installation from the rear. All switching devices can be remote controlled and optionally mechanically interlocked. ZX2 has metal partitioned single or double bus bar system for all applications even with highest parameters, Cable accessible from the rear. All switching devices can be remote controlled and optionally mechanically interlocked. Both combined protection and control devices and pure protection devices are used.