Professional Documents
Culture Documents
Abb Training Report
Abb Training Report
on
Submitted by
Neeraj Kumar
Electrical Engineering
[1]
PREFACE
Neeraj Kumar
Electrical Engg.
Final Year
[2]
ACKNOWLEDGEMENTS
First and foremost, I would like to thank Dr. Y.Singh (HOD Electronics and
Electrical Dept., G.B.P.E.C.) and Mr. Sandeep Kumar (Training and
Placement Officer, G.B.P.E.C.), who gave me a chance to undergo training at
ABB Ltd. Vadodara Gujrat . My sincere thanks goes to Mr. Mihir Sabnish
(B&S HR) for his prodigious guidance, persuasion, and painstaking attitude,
reformative and prudential suggestion throughout my summer training
schedule.
Last but not the least, my sincere thanks to all the staff members and friends
for instilling in me a sense of self-confidence.
[3]
CONTENTS
Title…………………………………………………………………………….page no.
Chapter 1 Introduction…………………………………………………………….05
Chapter 6 Bibliography…………………………………………………………….44
Chapter 7 Conclusion…………………………………………….………………45
[4]
CHAPTER 1
INTRODUCTION
The history of ABB goes back to the late nineteenth century ,and is a long illustrious
record of innovation and technological leadership. The ABB group of companies
[5]
operates in around 100 countries and employs 110,000 people.ABB operate in india
include 14 manufacturing facilities and over 6500 employees.
The company was incorporated on 24th December 1949 as Hindustan electric limited. In
1965,the company‘s name was changed to Hindustan Brown Boveri Ltd(HBB).pursuant
to scheme of amalgamation of Asea Limited with HBB with effect from 1st january
1989,the name was further changed to Asea Brown Boveri Ltd(ABB) with effect from
13th october 1989. Flakt India Ltd. Was amalgamated with ABB with effect from 5th
October 1995.
[6]
1.3 MAIN PLANTS IN INDIA
NORTH ZONE
• NBCC Tower
4th Floor
No. 15, Bhikaji Cama Place
New Delhi 110 066
EAST ZONE
• 4th Floor
No. 9
Elgin Road
Kolkata 700 020
WEST ZONE
• ABB House
Dr. S B Path
Ballard Estate
Mumbai 400 038
SOUTH ZONE
[7]
Bangalore 560 052
• Century Plaza
No. 3C, 3D, 3F, 3rd Floor
561 / 562, Anna Salai
Teynampet
Chennai 600 018
CENTRAL ZONE
• Vandana House
1st Floor
G E Road, Ramkund
Raipur 492 001
[8]
1.4 Breakers & Systems : Landmarks
[9]
[10]
CHAPTER 2
Circuit breaker
The circuit breaker is the most important and complicated of all types of power
circuit interruption equipment.
This is due to its highly important capability of interrupting the powerful short
circuit current, over and above its normal role of conducting, isolating and
interrupting nominal load currents.
• Power circuit
It is where the main current flows or is interrupted; and it includes:
• Arcing chamber
The arcing chamber is a closed volume containing a fixed contact, a moving
contact and the interrupting medium. The current is established when the moving
contact touches the fixed contact and interrupted when they part.
An arc is created when the contacts part. The interrupting medium is responsible
for quenching the arc and establishing the nominal level of isolation between the
open contacts.
• Insertion resistor
The sudden modification of circuit characteristics, when circuit breakers operate,
produces peak voltage impulses where the level is determined by the circuit
[11]
characteristics. These impulses may reach very high levels and must be
reduced.
• Operating mechanism
It is where the needed energy to part the contacts and to extinguish the arc is
developed.
➢ Springs
➢ Nitrogen-charged cylinders
➢ Spring operated
➢ Hydraulically operated
➢ Pneumatically operated
Control
The order to operate the breaker is launched in the control part of the circuit
breaker, as an electric impulse of a fraction of a second duration. The order is
then amplified in the operating mechanism to a complete circuit breaker
operation capable of interrupting short circuit currents.
[12]
2.1Circuit breaker types
The main problem of circuit breakers stems from the nature of their existence.
One of the major factors influencing the capacity of circuit breakers is the
interrupting medium. It affects circuit breakers' concept and design.
By this principle, circuit breakers are classified in families according to the type of
interrupting medium used.
Three of them are widely preferred by circuit breaker designers around the world. This
is due to their excellent breaking and insulating properties that lead to high performance
and economic designs. They are:
➢ Mineral oil
➢ Compressed air
➢ Sulfur hexafluoride, or SF6
2.1.1Mineral oil
It has excellent breaking and insulating quality especially when it is very pure, as
is the case when it is used in certain devices such as capacitors or transformers,
which are airtight devices.
However, circuit breakers have breathing holes and the oil is in contact with the
arc. Thus, one finds in the breaker's oil a certain amount of impurities, in the form
of moisture and miscellaneous dust, including carbon particles. This decreases
its isolation properties significantly.
[13]
It is imperative to monitor the state of the oil inside breakers in service, and to
replace it periodically in function of the number of breaks performed by the
device.
The criteria for oil replacement depend on the structure of the breakers and are
indicated by the manufacturer.
Compressed air was mainly used for interruption in the earlier pneumatic circuit
breaker designs. Later on it was used for insulation between the contacts after they
opened, the latter being placed inside an insulating chamber designed to resist the
air pressure. This reduced significantly the distance between the open contacts.
It should be noted that the excellent quality of air is greatly affected by the humidity.
Indeed, it is important that any condensation in the insulators and air conduits be
[14]
avoided, or internal tripping may occur. Installing the costly drying compression
stations greatly raises the cost of operating air blast circuit breakers.
It is five times heavier than air, odorless, colorless, nonflammable and non-toxic
when new. Its dielectric strength is 3 times the air's dielectric.
[15]
Oil circuit breaker
The first high voltage breakers were the bulk oil circuit breakers, followed by the
minimum oil circuit breakers.
In an oil circuit breaker, the arc decomposes part of the oil into gases composed of
70% Hydrogen and 20% Acetylene, and also produces carbon particles.
It consists of a steel tank partly filled with oil, through the cover of which are mounted
porcelain or composite insulating bushings.
Contacts at the bottom of the bushings are bridged by a conducting cross head
carried by a wooden or composite lift rod, which in common designs drops by gravity
following contact separation by spring action, thus opening the breaker.
An air cushion above the oil level serves as an expansion volume to prevent
pressure from building up inside the chamber after the interruption of the short circuit
current.
[16]
Minimum oil circuit breaker
These breakers were developed for 170 and 245 kV systems, the highest voltages
at the time, where the inherent problems of bulk oil breakers were the most severe,
also to eliminate oil as insulating medium and thus reduce the quantity of oil in
switchgear installations to an amount that would not cause any hazard. The
excellent arc-quenching properties of oil, however, were used later in specially
developed oil- and pressure-tight arc-interrupting chambers.
Minimum oil circuit breakers for high voltage are single-interrupter up to 170 kV and
multiple-interrupter breakers for 230 kV and higher.
They use an arc-control device in the arcing chamber which physically shortens the
arc and the arcing time, thereby reducing the arc energy.
When the breaker interrupts small currents, the arc is extinguished by a forced axial
flow of oil. In short-circuit range the arc is quenched as a function of current. The arc
is blown by a jet of oil at right angles to its axis, and extinguished.
[17]
Until recently, the air blast circuit breakers have dominated the high and very high
voltage applications. From 170 kV to 800 kV and breaking capacity from 20 kA to
100 kA.
Over 100 kV the breaker has multiple chambers connected in series. Each element
is optimized to around 80 kV. At first, 800 kV breakers had 12 chambers in series
per phase, now they have only 8 chambers per phase.
Although increasing the air pressure increases the speed of dielectric regeneration,
it is still relatively slow. Insertion resistors are often used to reduce voltage surges.
For example, adding insertion resistors, single or double step, to reduce closing
voltage surges, is easily done. Also, it is capable of achieving very fast breaking
times, 2 cycles and even less, improving the network's stability.
In general, air blast circuit breakers are high tech and robust equipment, with great
electrical and mechanical endurance. Contact wear is low due to the short arc
duration and low arc voltages.
SF6 breakers are available for all voltages ranging from 14.4 kV to 800 kV,
continuous current up to 4000 A and symmetric interrupting ratings up to 63 kA.
SF6 circuit breakers are either the dead tank design, or the live tank design and the
GIS design.
[18]
During recent years SF6 circuit breakers have reached high phenomena.
Their completely closed gas system eliminates any exhaust during switching
operations and thus adapts to environmental requirements. They may be installed
horizontally or vertically, according to the structural requirements of the substation.
The quick dielectric regeneration of the arc plasma in SF6 makes insertion resistors
unnecessary, simplifying the apparatus.
Their compact design considerably reduces space requirements and building and
installation costs. In addition, SF6 circuit breakers require very little maintenance.
[19]
Figure 1. SF6 gas power circuit
breaker Figure 2. SF6 gas power circuit
breaker
In SF6 circuit breakers, the same principle is employed, with SF6 as the medium
instead of air. In the "puffer" SF6 breaker, the motion of the contacts compresses the
gas and forces it to flow through an orifice into the neighborhood of the arc. Both types
of SF6 breakers have been developed for EHV (extra high voltage) transmission
systems
The breaker's heart is the switching element. It is where the arc quenching takes
place. It mainly contains the make/break contacts and the interrupting medium. The
make/break contacts functions can be reduced to:
[20]
Generally, the make/break contacts have a stationary part and a moving part. By
bringing the moving part to touch the stationary one, electric current flows and the
breaker is closed.
By driving the moving contact away from the stationary contact the electric arc
develops and by quenching it the current stops flowing and the breaker is open.
Contact design and choice of materials are greatly affected by the arc's energy, duration
and the chemical reactions that may occur with the ambient medium under the arc's
effect.
[21]
Fig-4 Electric Arc Chamber
2.4 HIGH-PRESSUREARC
Found in blast type circuit breakers (air-blast, SF6 and oil circuit breakers). Great
heat generation and relative long durations characterize them. They also
generate deposition of solid by-products that may affect the conductivity of the
contacts.
[22]
CHAPTER 3
[23]
• Options:
• Composite insulators
• Grey insulators
• Bursting discs
• Technical data :-
• Options:
[24]
• Composite insulators
• Grey insulators
• Bursting discs
• Technical data
CHAPTER 4
LTB E is an outdoor SF6 circuit breaker designed for System voltages in the range of
245 to 550 kV and rated short-circuit currents up to 50 kA. The design incorporates an
advanced Auto-Puffer interrupter based on the latest developments in arc technology
and dielectrics. The energy required for interrupting short circuit Currents is partly drawn
from the arc itself, thereby
reducing the energy required for the operating mechanism by more than 50 percent as
compared with a conventional SF6 puffer type circuit breaker.The low energy
requirements result in a design optimized for low operating forces which in turn results
in higher reliability .All single pole operated circuit breakers are equipped with one
operating mechanism per pole .Circuit breakers with one breaking unit per pole can be
[25]
operated with one operating mechanism per breaker .The LTB E circuit breaker
complies with the international standards IEC and ANSI.
restrike-free interruption of capacitive currents due to optimized ‘contact’ design and
movement Optimum quenching at zero current ensures low over-voltages during
switching of inductive currents Protection from gas leakage by double X-rings in
dynamic seals and double O-rings in static seals, tested in varying climatic conditions
over 30 years of field operations. (SF6 gas loss lower than 1 percent / year.)
[26]
4.1 Design.
Circuit-breaker type-LTB 72.5-170D1/B.
[27]
current path and a puffer. The puffer, which is designed with integrated lower
operating current contacts, runs outside of the lower current path. The upper
operating current contacts are integrated in the upper current path.
➢ The poles are mounted on a separate hot-dipped galvanized column frame.
➢ The frame consists of two welded formed plate halves, which are interconnected
with bolted cross stays.
The circuit-breaker poles are as standard design, permanently filled with gas to
the following pressure at +20°C:
[28]
• 0.7MPaabs,SF6 gas mixed with N2 gas or CF4 gas for circuit-breakers
operating down to -50°C ambient temperature.
[29]
➢ The circuit-breaker is closed by means of the operating mechanism, which
houses the closing springs. On closing, the opening spring is tensioned, which is
permanently fixed to the pole’s link gear. The tripp latch in the operating
mechanism keeps the circuit-breaker in the closed position. Opening of the
circuit breaker only requires the release off the trip latch.
➢ The normal operating cycle is: O-0.3 s-CO-3 min-CO (according to IEC) or CO-
15 s-CO (according to ANSI)
4.5 Standards
[30]
ensure the highest quality standards.
➢ The manufacturing facility is also EHS certified
for Environment and Occupational Health and
Safety Management Systems (OHSMS).
The LTB E circuit breaker poles are transported as complete units filled with SF6
gas to a slight overpressure. Circuit breaker poles with two breaking units per
phase are supplied as two separate units: breaker-head
and support insulator.
[31]
4.7 Lubricants
Safety instructions
Protective gloves, long-sleeved overalls and eye protection must be worn when
handling greases and oils.
All spillage shall be covered with an absorption agent and taken care of as
chemical waste according to applicable local directives.
4.8.1 Oil
➢ Oil “A”
Thin, fully synthetic lubricating oil for precision components in the operating
mechanism and circuit-breaker Also used for post lubrication of bearings that
cannot be lubricated with grease “G” without dismantling, e.g. links and link
gears.
Viscosity at 40°C: 62-65 cSt
Lowest pour temperature: -52°C
[32]
➢ Oil “D”
Breaker oil with a low viscosity ~ 6.0 cSt at 20°C. Also used as oil in dashpots.
Dashpots with the letter “s” punched on the cover shall be filled with oil “S”.
➢ Oil “S”
Silicone oil intended for dashpots in heavy-duty operating mechanisms, type
BLG.
Only dashpots with the letter “s” punched on the cover shall be filled with this oil.
4.8.2 Grease
➢ Grease “G”
Low-temperature grease for all types of bearings, gearing and worm gears and
valves in air-blast circuit-breakers.
Also used for greasing sealing rings and crevice corrosion protection on
breakers type HPL and for moving contacts (opening contacts) for
disconnectors.
➢ Grease “K”
Molykote grease for lubricating pins in link gears and in earthquake dampers
➢ Grease “N”
For lubricating moving contacts and puffer cylinders in SF6 circuit-breakers The
grease shall be applied in a very thin layer on the contact’s sliding surfaces.
➢ Grease “L”
Low-temperature grease especially suitable for lubricating precision
components, for example, latch mechanisms in operating mechanisms that shall
work in severe cold.
➢ Grease “M”
Low-temperature grease for long-term and permanent lubrication of worm gears,
and spur gears and other machine elements. Counteracts wear and corrosion.
Also for lubricating moving contacts (opening contacts) for earthing switches.
➢ Grease “P”
[33]
Vaseline for coating contact surfaces on fixed joints on the inside of the breaking
unit.
➢ Grease “S”
Fluoro-silicone grease for lubricating the EPDM-O-rings and as crevice corrosion
protection on circuit-breakers type ED as well as for lubricating rotating shaft
seals on circuit-breakers types LTB and HPL.
4.7 Assembly
Before starting the assembly, make certain that all requisite tools and documents
are on hand.
➢ Standard tools with torque wrenches (10 - 430 Nm).
➢ Lifting device and lifting slings.
➢ Lubricants, see Lubricants 1HSB445409-1 for suppliers and brand names.
Grease “G”: ABB Art. No. 1171 4014-407
Grease “SV”: ABB Art. No. 1171 4016-610.
➢ Check pin, ABB Art. No. 1HSB539782-1
➢ Crank extension, ABB Art. No. 1HSB532188-F.
➢ Crank, ABB Art. No. 2188 754-G.
➢ Applicable dimension drawing and diagrams for the order.
[34]
4.7.2 Foundation
The circuit-breaker’ foundation must be flat and level deviations in mm for the
position of the foundation bolts and phase clearance.
See the dimension drawing for the dimensions of foundation bolts and nuts.
Adjust any deviations using spacer washers, see .The nominal dimensions are
stated on the dimension drawing
for the order in question.
The frame is supplied in welded halves with six cross stays and nuts, bolts and
washers. Bolt together the halves as shown in Fit the cross stays according to
the numbering 1-4, using the supplied nuts, bolts and washers. N.B Make sure
the stays are fitted as set out in Tighten the bolted joints to a torque of 190 Nm.
The three frames are the same. Locate the frames on the foundation as in Check
that the frames are upright and adjust them to the same level using the nuts (2).
For dimensions of foundation bolts, spacer washers and nuts refer to the
dimension drawing.
Fill the gap between the lower nut and the foundation, which should be as small
as possible, with spacer washers. Final tightening of the frame is done with the
[35]
upper nut, which is tightened to a tightening torque of 300-350 Nm.Foundation
bolts, nuts and spacer washers are not supplied.
[36]
CHAPTER 5
Circuit breaker Applications
[37]
Fi
g5-Switching phenomena of Circuit Breaker
[38]
5.1 Terms Related to Circuit Breaker
[39]
5.1.2 TRV (Transient Recovery Voltage)
Fig-7 TRV
[40]
➢ Unity power factor current: at current zero, voltage across CB contacts
also zero hence no stress on contact insulation
➢ Zero power factor current at current zero, voltage is at peak hence stress
on contact insulation due to transient & high rate of rise of TRV
➢ Conclusion : interrupting low power factor current is difficult
BIBLIOGRAPHY
[41]
The following sources have contributed to an extent for some of the contents of this
project. These sources are:-
➢ Reference sources:-
Product Manual
Electricity Today
Advanced Power system
Sunil S.Rao “Switchgear Protection and Power System”
Wadhwa C.L. “Electrical Power System”
Ashfaq Husain & Harun Ashfaq “Basic of Electrical Power System”
Rajput A.K. “Power System Element”
IEEE Journal
Design Section Department of ABB
➢ Internet links:-
www.abb.co.in
www.wikipedia.com
Google search engine
www.electricitytoday.com
www.electricaltools.com
CONCLUSION
[42]
obiviously made a tremendous impact on my quest for further knowledge
in the field of Electrical Engineering. It has given me a better
understanding and exposure to some of the operational and practical problems
that engineers have to grapple in the designing of Circuit Breaker. The pleasant
working atmosphere and helpful nature of people made staying there and
working a memorable experience.
[43]