HWC - O&M Manual
HWC - O&M Manual
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A panel at the front of the truck are within the housing, provided with lifting points
housing above the truck and brought externally as a which must be used.
compartment accommodates single connection of the rear of Care must be taken to ensure
the terminal blocks, fuses and the housing. To this connections that no undue stresses are
links for the secondary circuits are connected the main inter- placed on any part of the
and the multicore termination. unit earth bars. equipment.
The panel may also be used to
mount electrical instruments like 2.0 Installation The projecting bases of units
relays, meters etc. should not be distorted in any
2.1 Despatch and packing way. Ensure that any lifting
The primary connection spouts The equipment is designed and slings are of adequate strength
in the truck compartment are despatched so as to involve and in good condition.
equipped with earthed metal minimum erection work. The
safety shutters, which are truck is located and secured in 2.3 Storage
controlled by arms mounted on the housing during transit. If the equipment is not required
the sides of the truck
for immediate use, if should be
compartment and operated 2.2 Unloading and inspection stored in a clean, dry and well
automatically by movement of
IMPORTANT : ventilated place and covered.
the truck. With the truck
THE EQUIPMENT SHOULD BE Should storage be prolonged,
withdrawn from the housing,
C A R E F U L LY E X A M I N E D routine inspections should be
each shutter can be
IMMEDIATELY AFTER IT IS carried out as if the equipment
independently padlocked.
RECEIVED. IF THE EQUIPMENT were in service.
Truck is pushed into the housing Temperature and humidity
HAS BEEN DAMAGED, BOTH
in 3 stages. conditions shall be such that
THE TRANSPORT
The secondary plug from the CONTRACTOR AND ALSTOM condensation of moisture does
panel is first plugged into the SWITCHGEAR DIVISION OR not occur. Where fitted, unit
truck secondary socket and the THE LOCAL REPRESENTATIVE heaters should be energised as
interlock rod is pushed inside. SHALL BE INFORMED AS soon as possible.
This will allow the truck to move SOON AS POSSIBLE. The equipment must not be
further into the panel. Then the exposed to direct moisture as it
Where the equipment is
truck is pushed as far as possible is for indoor use only.
supplied in packing cases, these
into the housing and is finally
shall be placed TOP uppermost 2.4 Site
plugged in by means of a
and the top removed first. All The site should, as far as
detachable winding handle
necessary erection details are possible, be free from damp,
which locates on the racking
supplied in plastic bags or excessive vibration and high
drive shaft situated below the
packing cases which are tagged and widely varying
truck mechanism facia. Reversal
and numbered. The fog number, temperatures. Relative humidity
of the above isolates and
together with a description of must be such that condensation
withdraw the truck. When fully
contents are listed on the in or on the equipment will not
plugged in, multi-fingered
packing list supplied. occur. Special precautions must
contacts on the truck primary
terminals make with contacts in Reference to this list will enable be taken where the relative
the housing primary connection easy location of the required humidity exceeds 80%. These
spouts. components. The equipment may include operating the unit
should be transferred to the heaters and also preferably
Access to the busbar
switch-house immediately after equipping the substation with
compartment for making the
unloading; under no dehumidification equipment.
busbar joints is via removal
circumstance shall if be exposed There should be ample room
covers on top of the housing
to direct and excessive moisture. for pointing and maintenance
and at the rear of the busbar
Where heaters are fitted, they work to be carried out.
compartment.
should be energised as soon as Recommended and minimum
Earth bars associated with the possible. The equipment is distances are shown on the
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FIG. 1. Sectional side view of 6.6 kV draw out type vacuum Contactor Panel
3
FIG. 2. Possible combinations of D/O VCP Truck
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switchboard drawing supplied arrangement drawing of the 2.5.2 Foundation Bolts
with each contract. switchboard, check the unit (Expanding type)
serial numbers and remove the Preparing the floor as stated
2.5 Foundations and Unit Erection truck from the housing to be in Section 2.5 then proceed as
It is important that the finished erected first. Position the housing follows :
floor area is flat, and not sloping on the channels.
a) Determine the highest point on
by more than 3 mm over any iii) Locate the foundation bolts and the floor. This point then
2500 mm. The area shall extend associated washers through the becomes the datum for all units.
a minimum of 600 mm to the holes in the base of the housing It is useful to use this point for
rear of the rear foundation into the spring loaded nuts erection of the first unit.
fixings, 1000 mm to the front within the channels. Do not
of the front foundation fixings Tighten. b) With reference to the general
and 200 mm beyond the arrangement drawing of the
iv) Using 2 plumb lines level the switchboard check the unit serial
extreme right-hand and left-
housing front to back and across numbers and remove the truck
hand foundation fixings.
the width. Leveling is carried from the housing to be erected
Correct operation of the out using shim plates. These first. Position the housing on the
equipment is dependent on if shims shall be located adjacent floor.
being level. It is essential to and on the outside of the
therefore, that care is taken at foundation bolts such that they c) Carry out operations iii, iv, v,
all stages of erection, in will also support the adjacent vi, & vii of Section 2.5.1 except
particular the lining up and housing when that is erected. fit the foundation bolts as
leveling of the first unit, which Refer to Figure 3. follows :
will be the datum for all other Using the holes in the base of
Shims must also be placed
units. Failure to erect the first the housing as a template drill
under the base sheet in the
unit correctly will result in mal- the floor for accepting M12x75
apron area to make up any gap
alignment throughout the mm long expanding bolts.
between the floor. Once the
switchboard & this will cause
housing has been leveled, the
rack in/rack out problem of 2.6.1 General
foundation may be ‘nipped-up’
breakers within the housing. The cross-section of busbars is
but not fightened.
Foundation channels must be given on the general
checked for curvature. Any v) Position the next housing to be
arrangement drawing of the
found to be distorted must be erected close up to the first, fit
switchboard.
straightened if possible or the foundation bolts and level
replaced. Under no up as before. Remove the Before assembly, all contact
circumstances shall distorted housing top and rear covers surfaces of the busbars and
channels be used. and fit the inter-housing fixing housing connections must be
screws, ‘nip-up’ only at this cleaned to ensure a good
Foundation fixings may be one contact surface. Unplated
stage. Refer to Figure 4.
of two types : Foundation contact surfaces shall be cleaned
Channels or foundation Bolts. vi) Repeat the above for the
using fine grade emery cloth.
remaining housings
Plated contact surfaces shall be
2.5.1 Foundation Channels remembering to check the unity
cleaned using a branded liquid
Prepare the floor and serial numbers with the general
silver polish. After cleaning, all
foundations & then proceed as arrangement drawing of the
surfaces shall be wiped with a
follows : switchboard. Finally, fighten all
clean cloth to remove any metal
foundation bolts and inter
i) Determine the highest point on dust, etc. Joints shall be
housing fixings.
the channels. This point then assembled as soon as possible
becomes the datum for all units. vii) Check the alignment of the after preparation. The same
It is useful to use this point for instrument panels for squares treatment of contact surfaces
erection of the first unit. and equality of spacing between shall be carried out on all other
panels. joints, such as the fee off to
ii) With reference to general
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1.5mm
Max variation
1.5mm from verticle
Floor Level
Foundation bolt
Positions
2 - M8 x 16mm long
Hex. HD screws with
washer 6 - M 10x22mm long
Hex. HD screws wih
nuts & washers
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TORQUE SETTING 60NM
BUSBAR
RATING
AND
SIZES
END INTERMEDIATE END
UNITS UNITS UNITS
800A M12 X 70MM HEX HEAD BOLT, PLAIN WASHER, SPRING WASHER, NUT & 10MM SPACER
1
BUSBAR
10X60 SQ. MM.
= 600 SQ. MM.
1250A M12 X 70MM HEX HEAD BOLT, PLAIN WASHER, SPRING WASHER, NUT & 16MM SPACER
1
BUSBAR
16X60 SQ. MM.
= 960 SQ. MM.
133MM LONG STAINLESS STEEL STUD, PLAIN WASHER, SPRING WASHER, NUT & 16MM SPACER
1600/2000A
2
BUSBAR
16X60 SQ. MM.
= 1920 SQ. MM.
165MM LONG STAINLESS STEEL STUD, PLAIN WASHER, SPRING WASHER, NUT & 16MM SPACER
2500A
3
BUSBAR
16X60 SQ. MM.
= 2880 SQ. MM.
197MM LONG STAINLESS STEEL STUD, PLAIN WASHER, SPRING WASHER, NUT & 16MM SPACER
3000A
4
BUSBAR
16X60 SQ. MM.
= 3840 SQ. MM.
NOTE :
1) BUSBAR CONFIGURATION REMAINS SAME FOR ALL THE PANELS IRRESPECTIVE OF INDIVIDUAL PANEL CURRENT RATING
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terminal board and a voltage 3.4.2 High Voltage Test voltage.
of 2 kV A. C. applied for 1 IEC 56 gives full information The integrity of the vacuum
minute between the loops and regarding high voltage testing interrupters can be checked at
earth. after erection at site. site by applying a test voltage
With the truck closed a power of 20 kV ac rms of 30 kV dc
3.4 Electrical Test-Primary
frequency voltage should be for 2 or 3 seconds across the
Insulation
applied to each phase in turn open contacts of each phase in
Warning : turn with the other side earthed.
between the phase conductor
Before commencing tests 3.4.1 and earth for 1 minute. No evidence of breakdown
and 3.4.2 on the primary indicates that the interrupter is
For 3.3 kV system voltage – in a satisfactory condition.
insulation take the following
apply 10 kV ac mms power
precautions : Should a breakdown occur, the
frequency. For 6.6kV system
• Short circuit and earth current apply 20 kV ac r.m.s. power truck should be kept out of
transformer secondary windings. frequency. Both for one minute. service and the matter reported
Under no circumstances shall without delay to the ALSTOM
After high voltage tests have SWGR DIVISION at AEI/Salt
current transformer secondaries
been completed, a further Lake Works.
be open circuited with the
megger test should be made to
primary on load .
check that the initial resistance 3.7 Final Inspection
• On fixed voltage transformers has not altered significantly.
remove the connection between The equipment should be given
the primary terminal. 3.5 High Voltage Test-Voltage a final inspection before it is put
Transformers into service.
• Isolate isolatable voltage
transformers. Where high voltage tests on Check that all covers are in
voltage transformers have been place and fully secured.
• After testing, all conductors shall
be discharged to earth. agreed, they should be in Check earth bars for continuity.
Temporary connections should accordance with IS : 2071, IS Check that all fuses and links
be removed components should : 3156, to which reference are inserted.
be reconnected. should be made.
Check that padlocks are fitted
3.6 High Voltage Tests-Integrity (where applicable).
3.4.1 Megger Test
of Vacuum Interrupters Check all moving parts of the
The primary insulation includes
Important : safety shutters, the truck racking
the insulation associated with
mechanism, circuit and busbar
the high voltage circuit. While X-ray radiation from vacuum
earthing switch operating
carrying out this test, if should interrupters.
mechanisms isolatable voltage
be noted that, insulation varies Any electrical gap in a hard transformer operating
considerably with atmospheric vacuum when stressed mechanisms and all interlocks.
conditions, dr yness and electrically may generate X-
cleanliness of the equipment, Operate the truck electrically
rays.
low readings may occur as a and manually to ensure it is
result of surface leakage over In the case of HWC equipment, functional.
the insulation. Using a 500 V tests have shown that X-ray
Ensure all insulation surfaces
megger measure the resistance emission of the voltage stated
are clean and dry.
to earth of each phase in turn. is less than the permitted level.
It is pointed out that the Touch up paint work where
If the resistance falls below an
permitted level is for continuous necessary.
absolute minimum of 1000
megrims after careful cleaning exposure, whereas the test
voltage is applied for a short 3.8 Recordings
and drying of all exposed
surfaces, a check of the time on each occasion. The Records are of value in
equipment should be made for vacuum interrupter does not establishing the frequency of
insulation damage. emit X-ray radiation at working maintenance therefore careful
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voltage transformers and main off in accordance with the isolated, proved dead and
cable connections. cabling schedule. earthed,
Precautions shall be taken to
2.6.2 Assembly 2.9 Multicore Cables and Inter-Unit
ensure that the isolated
The busbars shall be assembled Wiring (Bus Wires)
equipment cannot be re-
such as to be parallel to the line The only secondly wiring energised from any high or low
of the switchboard and suitable required of site is to run and voltage sources of supply.
for extension, if necessary. terminate the multicore cables
Red and Blue phases (the two and connect the inter-unit bus- 3.2 Electrical Tests – Secondary
outer phases) shall be wires in accordance with the Insulation
assembled on the front face of wiring diagram supplied. Warning :
the spout connection only, yellow Before commencing the tests
2.9.1 Multicore Cables
phase (the centre phase) shall described in sections 3.3.1 and
be assembled on the upper face The multicore cables enter at
3.3.2 on the secondar y
of the spout connection only. the front of the hosing from the
insulation take the following
Assemble Blue phase first, then base of the housing right-hand
precautions :
Red phase and finally yellow and/or left-hand frame, from
phase Ref. figure 5. where they run vertically via a • Disconnect the wiring to
removable wiring though to the /withdraw any relaying devices.
Where multiple busbars are
multicore cable gland • Short circuit current transformer
used, and units require spacers
compartment situated at the top secondary windings.
(supplied) fitting between the
of the housing frame. In this
busbars at the spout • Disconnect secondary wiring on
compartment the outer insulation
connections. Also, where voltage transformers.
on the cable is cut back to allow
busbars on end units are in the • Isolate any isolatable voltage
the multicores to be taken via
front (Red and Blue phases) and transformers.
the main wiring trough to the
upper (yellow phase) positions
termination in the housing front • After completion of testing all
an additional spacer (supplied)
panel. conductors shall be discharged
will be required between the
spout connection and the busbar to earth, temporary connections
2.9.2 Inter-Unit Wiring (Bus Wires)
in order to keep the busbar run removed and components
For ease of location, each wire reconnected.
straight. When an extension
is fitted with an identification
unit is being erected, these
ferrule which corresponds with 3.3.1 Megger Test
spacers must be removed to
that on the wiring diagram. The secondar y insulation
accommodate the extension
Where wires pass through to includes the insulation
busbars and refitted in the same
adjacent panels, the holes shall associated with the secondary
positions in the extension unit.
be fitted with a protective wiring. For this test the ends of
2.7 Unit Earthing government. the secondary wirings should
The main earth bars associated 3.0 Commissioning tests and be looped together at some
with the truck and the circuit convenient point such as
inspection
earthing switch are connected terminal board and using a 500
The tests outlined in this section V megger measure the
within the housing & brought
are those to be made after resistance, which should not be
out externally at the rear of the
equipment has been erected, less than 2 megohms between
housing. the only assembly
but before energisation. the loops and earth.
required at site is to connect the
earth bars of adjacent units 3.1 Precautions 3.3.2 High Voltage Test
together using the main external
earth bars supplied. The policy to be adopted in For this test the ends of the
making the equipment available secondary wirings should be
2.8 Man Cables for commissioning or looped together at some
maintenance shall be that, it is convenient point such as a
The main cables shall be mode
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note should be taken of relevant mechanism from the FREE to the BEING CARRIED OUT.
items each time maintenance is LOCKED position. The truck may Before inserting or removing
carried out. now be operated. test bushing it is essential that
In order that a complete history fixed conductor within the spout
4.3 Insertion of the Truck into the
is available, records should be is proved dead.
Service Position
started immediately after ISOLATE ALL TRANSFORMERS
commissioning and should i) With the truck isolating
DURING TEST
include. mechanism in the FREE position
[Section 4.1 (ii)] push the truck While disconnection /
i) Date of completion reconnection is being carried
as far as possible into the
ii) Interrupter contact wear reading housing. out, it is recommended that
iii) Number of shor t circuit earths are applied.
ii) Locate the racking handle as
operations described in Section 4.1 (b) and 4.5.2 Procedure for Preparing the
iv) Details of any work carried out rotate the handle clockwise until Circuit for Testing
the truck stops moving. (If may
4.0 Operation be necessary to push on the Earth the circuit with the help
truck in order to start the racking of circuit earthing truck/earth
4.1 Withdrawal of the Truck from in operation). Remove the switch
the Service position handle.
iii) Operate the truck isolating 4.5.3 Procedure for Preparing the
a) Read the instructions given in
mechanism to the LOCKED Busbars for Testing
the truck front level.
b) Insert the racking handle into position. The truck can now be Withdraw the truck from its
the racking orifice below the switched ON as described in housing as described and
mechanism facia, locating the Section 4.2 to put the truck into earth the section of busbar,
slot in the handle on the drive service. to be tested with the help of
pin in the racking shaft. Push busbar earthing truck/earth
4.4 F o r V C U a n d l a t c h - i n -
the handle fully on to the shaft switch.
mechanism operation follow
and rotate the handle
the VCU operation &
anticlockwise until the truck
maintenance manual
5.0 Maintenance
stops withdrawing from the The maintenance policy for
housing. Remove the handle. 4.5 Electrical Testing of Busbars HWC switchgear is based on
c) Using the handle on the truck and Circuits IS 10118 (1982) reference to
pull the truck from the housing. which should be made for a
This operation also 4.5.1 General general background to this
automatically closes the safety Electrical testing of the busbars subject.
shutters over the busbar and and circuit may be carried out In particular the maintenance
circuit primary connection on every unit by means of policy is based on the concept
spouts. portable test bushings which of inspection, examination/
are inserted into the primary service and overhaul as defined
4.2 Operation of the Truck in the spout connections. in the standard.
Test Position
Warning : Because of the widely varying
a) Withdraw the truck from the
ON THE UNITS UNDER TEST condition of operation of
housing as described in Section
I T I S E S S E N T I A L T H AT individual installation it is not
4.1 till the TEST position.
PRECAUTIONS, TO ENSURE possible to lay down precise
b) The secondary socket/plug T H AT T H E E Q U I P M E N T recommendations for the
flexible cable between the truck CANNOT RE REENERGISED, intervals between maintenance
and the housing front panel will ARE TAKEN BOTH IN THE required under all
remain connected. PREPARING THE UNITS) AND circumstances.
c) Operate the isolating DURING THE TIME TESTS ARE These intervals may vary greatly
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depending on the duty the equipment c) Without engaging the 4) In case of blowing of any one
is called upon to perform and the secondary plug the truck can’t of the fuses a striker pin shall
environment in which it is situated. be inserted in the cubicle & once come out of the blown fuse(s)
The time intervals are therefore best the truck is inside the cubicle, & shall lift the flop of “fuse trip
determined by user experience based the plug can’t be withdrawn arrangement” thereby tripping
on the behaviour of the equipment except in the defined isolated the contactor. Free movement
on the particular installation. position. of this “Fuse trip” device should
Vacuum contactor unit is low d) Truck can’t be removed from be ensured all the time.
maintenance equipment, the vacuum service position if the contactor 5) The engagement of main power
interrupter being a sealed unit which is in closed position. contacts largely depends upon
does not require maintenance during the settings of the stop bolts
2) In “Test” or in “Service” when
its lifetime. fitted on rear bottom tie, as
the knob of the contactor is put
However the maintenance & to locked position the limit shown in the GA drawing of
operation details of VCU is given in switches get operated by the the truck. The settings of these
the operation & maintenance manual sliding bars housed in the truck bolts must not be altered. If
of VCU. & also the truck gets secured in required, expert advice must be
the particular position. sought.
Special 6) For earthing of circuit side, an
3) Truck can be padlocked by
insturctions/features for putting a lock in the slot of the earthing switch is provided on
truck type “HWC” red push button provided on rear side of the outgoing panels.
the truck front cover. This Operating instructions for the
1) The truck is having following same are provided on rear
interlocks for safety of the padlocking restricts the positions
of the truck. For e.g. if the truck cover of the panel. The
operating personnel : interlocking arrangement
is padlocked outside the panel
a) The truck can’t inserted in the then it can’t be inserted in the ensures that the switch shall
panel if the contactor is in closed cubicle. Similarly if the truck is always be operating when the
condition. padlocked inside the cubicle in breaker is NOT in service
b) Truck can only be operated in either “Test” or “Ser vice” position & the metallic safety
either “Test” or “Ser vice” position then if can’t be moved shutters are closed.
position. from that position.
K.K. GUPTA
MANAGER SWITCHGEAR
TECHNICAL DEVELOPMENT CELL
1, TARATALLA ROAD
KOLKATA – 700 024
PHONE : +91 33 469 9372
FAX : +91 33 469 3511
Email : Kanchan.gupto@alstom.sprintrpg.ems.vsnl.net.in
11
FIG. 6. View of panel from rear with earth switch in open condition
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ALSTOM Limited
Headquarters
1, Taratala Road
Calcutta - 700 024
India
Tel : +91-33-2469 1230/5370/3488
Fax : +91-33-2469 3511/9506/5370
Works
1, Taratala Road
Calcutta - 700 024
India
Tel : +91-33-2469 1230/5370
Fax : +91-33-2469 3511/9506/5370
P. O. Naini
Allahabad - 211 008 (U.P.)
India
Tel : +91-532-697422
Fax : +91-532-69 7604/7606
Regional Offices
North
14th Floor
Pragati’s Devika Tower
6, Nehru Place
New Delhi - 110 019
Tel : +91-11-2644 9902/903/907/851
Fax : +91-11-2644 9447
East
D-2, Gillander House
Netaji Subhas Road
Calcutta-700 001
Tel : +91-33-2203 991/92/93/94
Fax : +91-33-2203 995
Note : West
Narottam Morarji Marg
1. Information/drawings contained in this leaflet are of general Ballard Estate
nature only. Contractual commitment will be strictly governed Mumbai - 400 038
Tel : +91-22-261 8141/42/43/44/45
by information/drawings furnished with order Fax : +91-22-262 1170
acknowledgement.
South
2. The Company’s policy is one of continuous development and 314/315, Anna Salai,
improvement of its products and, therefore, the right is reserved Teynampet,
Chennai - 600 018
to supply products which may differ slightly from those described
Tel : +91-44-436 4575
and illustrated in the publication. Fax : +91-44-432 3462
RMG–LTM–ME–TC 0015/2003
ALSTOM Limited, T&D - Medium Voltage Switchgear, 1, Taratala Road, Calcutta-700 024, India
Phone : 91-33-2469 1230/5370, Fax : 91-33-2469 3511/9506 Website : www.alstom.co.in