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3.1 Introduction to Switch Gear

A circuit breaker is an automatically operated electrical switch breaker designed to protect an electrical
circuit from damage caused by overload or short circuit. Its basic function is to detect a fault condition and,
by interrupting continuity, to immediately discontinue electrical flow. Unlike a fuse, which operates once
and then must be replaced, a circuit breaker can be reset (either manually or automatically) to resume normal
operation. Circuit breakers are made in varying sizes, from small devices that protect an individual
household appliance up to large switchgear designed to protect high voltage circuits feeding an entire city.

Difference between a switch and circuit breaker

Circuit Breaker: - A circuit breaker is an automatically-operated electrical switch designed to protect an

electrical circuit from damage caused by overload or short circuit. Its basic function is to detect a fault
condition and, by interrupting continuity, to immediately discontinue electrical flow.

Switch:- Switch is an electrical component that can break an electrical circuit, interrupting the current or
diverting it from one conductor to another

1. Switches are not automatic as they need to be manually turned on or off while circuit breakers just
trips off on certain conditions
2. Switches allow users to cut off power supply to a certain area or equipment while circuit breakers
are more preventive in nature.

3. Circuit breakers are essentially automatic off switches designed for a very specific purpose, which is
to prevent unnecessary electrical circuit damage.

Difference between circuit breaker and switchgear

A circuit breaker is an automatically-operated electrical switch designed to protect an electrical circuit from
damage caused by overload or short circuit. Its basic function is to detect a fault condition and, by
interrupting continuity, to immediately discontinue electrical flow.

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.

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Fig: Switchgear Fig: Switch Fig: Circuitbreaker

3.2 Operating principle

Two contracts called electrode remains closed under normal operating conditions. When fault occurs on any
part of the system, the trip coil of the circuit breaker get energized and contacts are separated.

Arc Phenomenon

An arc is struck when contacts are separated. The current is thus able to continue. Thus the main duty of a
circuit breaker is to distinguish the arc within the shortest possible time.

The arc resistance depends upon the following factors :

 Degree of ionization
 Length of the arc
 Cross Section of the arc

3.3 Types of Circuit Breakers

Classification on the basis of Service
1. Indoor
2. Outdoor

Indoor – For in house application such as indoor substation.

Outdoor- Used outside subject to whether

Depending upon the arc quenching circuit breakers are classified as follows:

1. Air Circuit breaker

2. Air blast Circuit breaker
3. Oil Circuit breaker
4. Vacuum Circuit breaker
5. SF6
6. GIS

Air circuit breaker

An air circuit breaker automatically interrupts the current flowing through it when the current
exceeds the trip rating of the breaker. Air is the medium of electrical insulation between
electrically live parts and grounded (earthed) metal parts.

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 Air Blast circuit breaker
These type of breakers employ ‘air blast’ as the quenching medium. The contacts are opened by
air blast produced by the opening of blast valve. The air blast cools the arc and sweeps away the
arcing products to the atmosphere. This rapidly increases the dielectric strength of the medium
between contacts and prevents from re-establishing the arc. Consequently the arc is extinguished
and the flow of current is interrupted.

Advantages:

An air blast circuit breaker has the following advantages over an oil circuit breaker:

1. The risk of fire is eliminated

2. The arcing products are completely removed by the blast whereas the oil deteriorates with successive
operations; the expense of regular oil is replacement is avoided
3. The growth of dielectric strength is so rapid that final contact gap needed for arc extinction is very
small. This reduces the size of device
4. The arcing time is very small due to the rapid build up of dielectric strength between contacts.
Therefore, the arc energy is only a fraction that in oil circuit breakers, thus resulting in less burning
of contacts
5. Due to lesser arc energy, air blast circuit breakers are very suitable for conditions where frequent
operation is required
6. The energy supplied for arc extinction is obtained from high pressure air and is independent of the
current to be interrupted.

Disadvantages:

1. Air has relatively inferior arc extinguishing properties

2. Air blast circuit breakers are very sensitive to the variations in the rate of restriking voltage.
3. Considerable maintenance is required for the compressor plant which supplies the air blast
Air blast circuit breakers are finding wide applications in high voltage installations. Majority of
circuit breakers for voltages beyond 110 kV are of this type.

3.4 Vacuum Circuit Breakers( VCB )

In this breaker, vacuum is being used as the arc quenching medium. Vacuum offers highest insulating
strength, it has far superior arc quenching properties than any other medium.
Used in 11kv panel in control room of grid station.

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When contacts of a breaker are opened in vacuum, the interruption occurs at first current zero with dielectric
strength between the contacts building up at a rate thousands of times that obtained with other circuit
breakers.
Principle: When the contacts of the breaker are opened in vacuum (10 -7 to 10 -5 torr), an arc is produced
between the contacts by the ionization of metal vapours of contacts. The arc is quickly extinguished because
the metallic vapours, electrons, and ions produced during arc condense quickly on the surfaces of the circuit
breaker contacts, resulting in quick recovery of dielectric strength. As soon as the arc is produced in vacuum,
it is quickly extinguished due to the fast rate of recovery of dielectric strength in vacuum.
Construction: Fig shows the parts of a typical vacuum circuit breaker. It consists of fixed contact, moving
contact and arc shield mounted inside a vacuum chamber. The movable member is connected to the control
mechanism by stainless steel bellows .This enables the permanent sealing of the vacuum chamber so as to
eliminate the possibility of leak .A glass vessel or ceramic vessel is used as the outer insulating body. The
arc shield prevents the deterioration of the internal dielectric strength by preventing metallic vapours falling
on the inside surface of the outer insulating cover.

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Relay are used for operation of circuit breaker (relay senses current ,if current increases the certain value
then it tells the circuit breaker about this alarming situation)

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 SF6 Circuit breaker

 Sulphur hexafluoride (SF6) gas is used as an arc quenching medium .

 SF6 is an electro-negative gas.
 It has strong tendency to absorb electrons
 When contacts are open in a high pressure flow of SF6 gas, arc produced.
 Free electrons in the arc are captured by the gas.
 Which build up enough insulation for high power and high voltage services

Advantages
 Simple construction and less cost.
 SF6 gas is inflammable, non toxic and chemical inert gas.
 Same gas is recirculated in the circuit.
 Maintenance free Circuit breaker
 Ability to interrupt low and high fault current
 Excellent Arc extinction

Advantage of SF6 over Oil circuit breakers

 Short arcing time.
 Can interrupt much larger currents
 Gives noiseless operation due to its closed gas circuit .
 No moisture problem.
 No risk of fire.
 No carbon deposits .So no tracking and insulation problems
 Low maintenances cost

3.5 Indoor Switch Gear

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 (VM 12 & VM 36)
Introduction

Vacuum circuit breakers are most commonly used and they score over the conventional oil circuit breakers.

Vacuum interrupters have reduced contact movement which imposes reduced mechanism, energy leading to
minimum component wear. Consistent and comparatively reduced arcing time coupled with absence of
arcing media, impart exceptionally high contact life. These benefits of vacuum circuit breakers impart higher
reliability to the system.

General Construction

The design incorporates fully compartmentalized panels having single busbar system and set of interlocks
for safety operation.

A panel consists of a fixed portion which is modular construction having three high voltage chambers,
namely: breaker chamber, busbar chamber and Cable Termination chamber. The panel also houses a moving
portion which comprises of wheel mounted truck fitted with an operating mechanism, vacuum interrupters
and isolating contacts. Motor operated spring closing mechanism keeps the spring charged after every
closing operation making it ready for next closure. Instrument panel is a separate low voltage chamber.

Main Breaker Chamber

The main breaker chamber is of bolted sheet steel construction which accepts the moving portion at the floor
level. The primary isolating contact comprising of self aligning type spring loaded, silver plated copper
fingers on moving portion engages with silver plated copper flats on the fixed portion of the switchgear
panel. This chamber also includes features like, secondary plug and socket guides for the moving portion,
earthing contact which meets with an earthing strip on the moving portion and the safety shutters.

The moving portion with VCB can be kept either in the ‘SERVICE’ or ‘TEST’ position inside the breaker
chamber.

Instrument and Relay Chamber

The instrument and relay chamber is of folded sheet steel construction with a hinged instrument panel door
suitable for flush mounting of instruments in the front. This chamber also accommodates terminal blocks
inside the instrument panel and other internal mounting electrical item viz. fuses, contactor, transducers etc
as per contractual requirements.

Busbar Chamber

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The busbar chamber is of bolted sheet steel construction and houses the horizontal busbars which consists of
double or single parallel bars per phase of aluminium or copper supported on epoxy support insulators.

The busbar chamber is provided with bolted covers at the top and the back. A pressure release valve
assembly is also provided on top of this chamber. Insulation barriers provide partition between two adjacent
busbar chambers.

C.T. and Cable Termination Chamber

The C.T. and cable termination chamber is also of bolted sheet steel construction with an ample space of
cable termination and current transformers of various types. This chamber also houses connections, lugs and
bottom fixed contacts.

Breaker Trolley

The moving portion consists of a truck frame on 4 wheels. Three vacuum interrupters and the operating
mechanism are mounted on the truck frame. The interrupters are mounted between top pole head and bottom

pole head which are supported through epoxy support insulators and are shielded from each other by means
of insulating barriers. Top and bottom insulating contacts are used for current transformer connected to
interrupter through top and bottom pole head. These isolating contacts have parallel spring loaded fingers.

Operating Mechanism

Vacuum Interrupter

Vacuum Interrupter used in circuit breakers to conduct and to interrupt normal current at system voltage and
for making and breaking fault currents.

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 It has several advantages –

 High and consistent dielectric strength of

vacuum, unaffected by environment and
switching operations.
 Brazed joints ensure retention of vacuum for
lifetime.
 Low and stable contact resistance contact
resistance.
 Very low arcing voltage and minimum contact
erosion.
 Long life expectancy.

Fig. Vacuum interrupter

General Operation of Breaker

The operating mechanism is stored energy type. It has 3 helical springs to store energy for closing,
tripping and maintaining desired contact pressure.

Energy is stored in closing spring either by motor charging or manual charging. The tripping and contact’s
pressure springs are automatically charged during closing operation. Part of energy of closing spring is used
to close the breaker and balance energy is transferred to tripping and contact pressure springs after every
closing operation, closing spring automatically gets charged through motor so that mechanism is ready for
next closing operation.

A closed breaker with charged closing spring can perform auto reclose duty, i.e. open-close-open can be
done without any intermediate manual or motor charging. Breaker ON-OFF is indicated by mechanical ON-
OFF indicator and charging or closing spring by mechanical CHARGED-DISCHARGED indicator.

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 Gearbox

Operating
coil (closing)

Operating coil
(opening)

Spring Charging motor

Closing spring Mechanism shaf

Tripping spring

Fig. Operating mechanism

There are two options of charging the closing spring-

1. By motor
2. By manual operation.

Closing Operation

After the completion of charging operation of the closing spring, the breaker is ready for closing. If the
breaker is to be closed locally, the spring is released by pressing CLOSE button. In case of remote operation,
the closing coil unlatches the closing spring. As the closing spring is under discharge process, the crankshaft
is turned and the cam disc at the other end of the crankshaft actuates the drive lever with the result that the
mechanism shaft is turned by a lever by the coupling rod. At the same time the levers, fixed on the breaker
shaft operate three insulated couplers and move the bottom contact of breaker poles up. Lever charges the
tripping spring during closing and the breaker is latched in the closed position with pawl roller and by
closing latch.

Opening operation

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If the breaker is to be tripped locally, the spring is released by pressing the OPEN button. This unlatches the
tripping spring. The tripping spring turns the mechanism shaft through the tripping latch.
In case of tripping operation through electrical command “tripping solenoid” operates and unlatches the
tripping spring, turning the mechanism shaft through the tripping latch.

SALIENT FEATURES
 Confirms to IEC62271-100.

 Vacuum interrupter and insulating pull rod assembled in an envelope of dry pressurized air to
prevent surface tracking.

 Easy to install.

 Highly reliable.

 Minimum number of components in mechanism and pole unit assembly.

 Maintenance free design.

 Additional structure for mounting CTs/PTs can be provided along with outdoor CTs and PTs.

 Outdoor Relay cabinet housing Relays, meters etc. for control of breaker can be provided.

Relay Cabinet can be provided with outdoor Battery/Power Pack design.

Arrangement available for providing double trip coils.

APPLICATIONS
1. Power station and process industry auxilliaries.
2. Distribution duty (width 550 mm).

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 3.6CONSTRUCTION
1. POLE UNIT ASSEMBLY WITH INTERPHASE

POLE ASSEMBLY

It consists of vacuum Interrupters, current transferring contacts and an insulating rod.

The cover ceramic part is stabilized against lateral forces by centring ring.
1.1.1 Vacuum interrupter
- Used to conduct and to interrupt normal current.
- Leads to low arcing voltage so min. Erosion.
- For low power loss
1.1.2 Inter phase mechanism
1.1.3 Contains interphase shaft supported on bearing brackets at both ends, to which the
insulated pull rods of all 3 poles are connected for gang operator.

2. BASE CABINET WITH OPERATING MECHANISM

2.1 Base cabinet is mechanically linked to all 3 poles. It consists –

o operating mechanism
o auxiliary switch
o fuses, fuse plates and terminal blocks
o mechanical interlock
o breaker control switches
o AC/DC fuses
o Auxiliary wiring
o Terminal block
2.2 Operating mechanism
o Stored energy type
o Closing spring is automatically charged by motor afeter the closing operation.
o Mechanical ON/OFF, spring charge indication and operation counter are provided.
o Trip and close coils, push buttons, terminal blocks and secondary windings etc.

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 RECEIPT, INSPECTION AND COMMISSIONING
After tests and inspection, it is dismantled into 3 parts
- Structure
- Mechanical house
- Pole unit with interphase mechanism

RECEIPT and INSPECTION

- Dispatch advice note.

- PUIM & mech. house are seperately packed.
- Spring charging handle and slow closing handle are kept inside mech. House.
- Other screws, bolts etc. are kept in small box fixed to main packing box.

STORAGE

- If they are not erected immediately, they should be re-packed.

- Breaker if stored outdoor, should be well covered with tarpaulin.
- Air gap between tarpaulin and breaker should be there to prevent condensation.
-

Specifications for PVN 12

No. Of poles -3

Class- outdoor

Rated voltage – 12kV

Rated insulation level –

1. One min. Power frequency voltage – 70kV rms

2. Lightening impulse voltage- 170kVp

Rated frequency – 50 Hz

Rated normal current – 630/800/1250A

Rated braking current capacity – 63/80 kA

Rated short time withstand current and its duration –25/31.5kA n 3s

Auxiliary supply for spring charging motion – 220 V ac

Auxiliary supply for closing/tripping coil – 24 to 250 V dc

ELECTRICAL CHECKS

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  Ensure isolation of breaker from high voltage system and earthing.
 Do charge closing spring by motor. Charging time should not exceed 12s. If timing is more
check voltage. If OK, then check the linkage and gear movement.
 Electrically close/open the circuit breaker through push/control switch
 Check contact resistance between upper and lower terminals with breaker closed under spring
force.
 Check insulation resistance across breaker open terminals and between lower terminals to
earth with 5kV megger.
 Check opening and closing of breaker from remote control and through relays.

OPERATING MECHANISM
 Charging of closing spring is indep of closing or opening of breaker can be operated
manually or by motor
 Closed breaker with charged closing spring can perform auto-reclose duty i.e. -close-open
can be done without any intermediate manual or motor charging. Breaker On-Off indicator
and spring charging/discharging indicator

Components-

1. Gearbox
2. Closing spring
3. Spring charged indicator
4. On-Off indicator
5. Tripping spring
6. Motor cut-off limit switch
7. Mech shaft
8. Dash pot
9. Manual push button (closing)
10. Operating coil (closing)
11. Operating coil (opening)
12. Manual push button
13. Motor
14. Motor
15. Tripping catch
16. Closing catch
17. Crankshaft
18. Comuter coil

Operating mechanism
- Switching operations
- By motor
- Manual operation

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 Motor charging
Motor rotates -> gear set starts rotating -> gear set makes engagement with crankshaft -> starts
pulling the closing spring which is continued till 180degrees of crankshaft, when spring charge
indication appears motor supply gets cut off. Closing spring is then ready to release.

Manual charging
Insert the hand crank and turn it clockwise until the indication shows “spring charged”.
1. Closing operation
2. After closing of spring -> breaker ready to get closed -> spring is released by pressing closed button
-> the crankshaft is turned -> disc at its other end actuates the driver lever -> at the same time, via
drive rod. -> Movement is transferred to interphase shaft -> moves 3 insulated rods -> closing of
breaker

Opening operation
If breaker is to be tripped locally, the spring is released by pressing the open button -> the tripping
solenoid unlatches the tripping spring -> the tripping spring turns the mechanical shaft -> the
sequence is similar but motion is reversed to that of closing.

Slow closing operation

(Only for maintenance purpose condition)
- Circuit breaker : open
- Closing spring : discharged
- Motor supply : disconnected
- Tripping spring : discharged

Hold the handle -> press it downwards until contacts touch -> pressure is higher as it compresses the spring
until the trip panel catches with trip lever roller and the mech is latched in closed position.

Slow opening operation

- Circuit breaker : closed
- Closing spring : discharged
- Motor supply : disconnected
- Tripping and contact pressure spring : compressed

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Spring energy released will be restrained by downward pressure on handle pressed by operation. Slowly
release the pressure by moving handle upwards. Mech. Shaft and interphase shaft will slow open.

MAINTAINENCE
Interval at which maintainence is done depends upon:
1. No. Of short circuit interruptions
2. Switching frequency
3. Actual service time

Before maintainence – both closing and tripping springs are discharged.

Operation: frequency of inspection

Visual inspection: twice a year

Lubrication of operation mechanism: once or after 2000 operations

Overhauling of mechanism: after 30000 operations

Connections and cleaning: once in a year

Cleaning of insulating part: once in a year

Checking the contact erosion

Red line is there on steel stem will gradually diminish with successive switching. Contact wear is
considered within permissible limit as long as this mark is visible when the breaker contacts are
closed.

Changing the vacuum interrupter

1. Open and isolate circuit breaker
2. Unscrew protective cap
3. Insert flat bar to prevent movement of stud. Take out the lock and gasket.
4. Take out top terminal and insulator.
5. Take out stud from the interrupter.
6. Remove contact block from the stem.
7. Refit the eyebolt into new interrupter and set to the original dimension. Tighten the nuts.
8. Check nut and disc are tightened. Fit the new interrupter and connect with the fork.
9. Clean the entire surface of porcelain and apply anti-oxidant coat.
10. Refit the top porcelain insulator and top flange.
11. Refit gasket and cap.

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 12. Check tightness of all hardware.

Lubrication of operating mechanism

1. All the points not marked should be treated with molykote spray.
2. To lubricate – remove the mechanical parts cover. Parts not rigidly fixed should be moved
slightly to and fro to let the coil penetrate.

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Fig. PVN36

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 3.7 Control And Relay Panel

INTRODUCTION
Control and relay panels (CRP’s) include

1. Generator relay panels (GRP’s)

2. Switch yard circuits

CRP’s are used for protection of transformer circuits.

1. GRP
 Used in power plants.
 Depends on the amount of power being produced and amount of protection needed.
 They have relays in them.
 Receives voltage and current signals.
 Using algorithms, identifies the fault and operates accordingly.
 It has 2 relays :
a) Protection relays
- Numerical variety
b) Auxiliary relays
- Electromechanical relays
- Help the main protection relays
- By multiplying the contacts and sending tripping signal.

2. Switch yard circuits and their protection

- Line circuits and transformer circuits

- They have 2 panels

1. Relay panel
- Protects from important faults
- In case of line circuits also tells the distance of the fault (distance protection)
- If transformer ratio is not maintained in transformer circuit, differential fault is observed and
protection relays are used.

2. Control panel

Used for controlling the main forces on breakers.

Contains instruments to measure current, voltage, power etc., signals (both audio and visual),
LEDs, lamps, alarm initiators etc.

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 3.8 SCR DIVISION OF BHEL BHOPAL
Switchgear Control gear & Rectifier (SCR) Division of BHEL Bhopal is in the field of design,
manufacture and supply of Control and Protection Panels for turnkey Substation and Power Plant
Projects ever since its inception in 1960. More than 10000 panels are in service for various
applications. The department caters for the requirement of Control & Protection Panels for all Power
Plant and Transmission Project applications.

PRODUCT RANGE:

1) Generator Protection Panels:

Generator protection is a complex and elaborate task due to the following reasons:

a) Generator is a large machine with associated components like transformers and other
auxiliary equipment.

b) Generator consists of subsystems like excitation system, prime mover, voltage regulator,
governor, cooling system, etc.

c) Generator is a costly and important equipment. As far as possible, it should be in service. The
protection system should provide sufficient advance information so that the corrective action
can be initiated well in advance.

d) Generator should not be tripped for the faults which are external to the generator and which
external equipment can clear

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 Generator relay panel

2) Switchyard Control & Protection Panels:

SCR is in the field of design, manufacture and supply of Control and Protection Panels for 33kV
to 400kV Switchyard. These cover the following main circuits:

a) Transmission Lines.
b) Generator Transformers.
c) Inter Connecting Transformers.
d) Feeder Transformers.
e) Reactors.
f) Tie / Transfer Bus Coupler.
g) Bus Coupler.
h) Bus bars.

Switchyard Control & Protection Panels are designed for all types of Bus Configurations which
include the following:

a) One and a Half Breaker Schemes.

b) Two Main and Transfer Bus System.
c) One Main and second Main / Transfer Bus System.
d) Two Main Bus System.
e) Single Bus System.
f) Other non-standard bus configurations.

switchyard control and relay panels

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 3.9 TECHNIQUE
The demand of the day is for Integrated Protection and Control Systems. These systems employ
numerical communicable protection and control devices at bay level to be integrated to a remote
Substation Automation Systems (SAS) and Digital Distributed Control and Monitoring Information
Systems (DDCMIS) by exchange of information through data. SCR BHEL Bhopal together with
BHEL Electronic Division at Bangalore is equipped to supply the integrated solutions.

Manufacturing set up should be equipped with all modern facilities necessary for
manufacturing of C/R Panels:

 Latest CNC Turret Punch and Bending Machines for fabrication of Panels.
 Full fledged Chemical pre treatment process line and Powder Coating Plant.
 Dust Free enclosure for assembly and wiring of Control Panels.
 Latest CMC256 Automatic Relay Test kits of Omicron make.

CONSTRUCTIONAL DETAILS OF STANDARD PANEL

1) The standard Sheet steel cubicle is 2230 mm (height) & 800 mm (depth) resting on 50 mm high
plinth & 15mm thick anti-vibration pad. The width of the panels is suitable to accommodate all the
fitments. The fitments are comfortably mounted to provide easy accessibility for maintenance. No
relays or fitments are mounted below 300 mm level. Hand reset type tripping relays and main
protection relays requiring programming are mounted at normal reach.

2) Finish: (Powder Coated, Plain Finish)

a) Exterior Shade - Light Grey to Shade 631 of IS-5

b) Interior Shade - White

c) Plinth - Black, Semi Matt

3) Cubicle is suitable for IP:54 degree of protection to IS:13947.

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 4) Base frame, door frames, front sheet of the cubicle is manufactured from 3 Thick C.R.S. sheet
and 2 mm for rest of the cubicle.

5) Terminal blocks are clip-on to channel, screw driver operated stud type. Disconnecting type
(CATDM4 of Elmex or equivalent make) for CT & PT circuits and non-disconnecting type
(CATM3 of Elmex or Equivalent make) for rest of the circuits.

6) Panel wiring: PVC insulated, 1100V grade FRLS & stranded copper conductor wire (ISI
mark) with conductor cross section as under:

o Square mm for CT, PT & earth circuits.

o Square mm for rest of the circuits.

Wire terminations:- Using solder less crimping lugs.

7) Color of wires:-

1 phase AC circuit (Phase & Neutral) : Black

DC circuits ( Positive & Negative) : Grey

Earth : Green

Spare contacts : Grey

3 phase CT & PT circuits:-

A phase: Red

B phase: Yellow

C phase: Blue

Neutral: Black

8) For identification of wires, numbered ferrules with black letter / digit over white surface at
both ends of wire are provided.

9) At least 20% spare terminal blocks are provided on each terminal strip.

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 10) Minimum clearance of 250 mm between the first terminal block and associated cable gland
plate is maintained. Also the minimum clearance of 150 mm between edges of two adjacent
columns of terminal blocks.

11) All internal wiring to be connected to external equipment are terminated on vertically
mounted terminal blocks on each side of the cubicle.

12) Cable gland plate: Cable entry is from bottom. Un drilled cable gland plate with proper
gasket is provided. Cable gland plate is earthed (connected to earth bar) using copper braided
flexible cable. Thickness of gland plate is 3 mm.

13) Lifting Arrangement: Lifting eye bolts are provided at the 4 top corners of cubicle. Suitable
plugs are provided for blanking eye bolts after erection.

14) Panel Lock: Concealed handle with built-in lock & shooting bolts with 3 point latching at
top, middle & bottom.

15) Suitable stiffeners are provided at the back of front panel to avoid buckling & waviness after
cutouts are made and fitments are mounted.

16) Door: Lift off type doors are provided in the panel. Doors are provided with ventilating
louvers having fine suitable washable filter for dust proofing. EPDM rubber gasket & door
pocket is provided. Each door of cubicle is connected to earth bar using flexible copper braided
cable.

17) All ferrous components like internal mounting plates, C channels, fuse panels, brackets etc.
are painted, same as interior finish, to prevent any kind of rusting or corrosion.

18) Earth Bar : 3 mm * 25 mm cross section tin plated copper bar is provided at the bottom of
the panel across the width and one depth of the cubicle.

19) All non ferrous items are tin plated.

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 20) Each cubicle is provided with :-

1 No. Door switch operated CFL 18W rated for 240V, 50Hz.

1 No. 5 pin, 240V, 50Hz AC socket with switch suitable for 5/15A

1 No. thermostatically controlled space heater of suitable wattage and rated for 240V AC,50Hz.

1 No. Heater ON/OFF switch.

Control and relay panel

3.10 On Load Tap Changer (OLTC)

ON LOAD TAP CHANGER TYPE M (OLTC)

The type M on-load tap changers are used to vary the ratio of oil-immersed transformers under load. In
general they are designed for network transformer as well as industrial transformer application. The tap
changers comprise a diverter switch and a tap selector in a single column design and represent the most
recent state of technology. The tap changers offer both transformer manufacturer and user a great number of
essential advantages.

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On-load tap changers type M

Versatility:

 Three-pole design for neutral application at 350A, 500A and 600A ratings for three-phase wye-
connected windings.
 Three-pole fully insulated design, at 350A, 500A and 600A ratings for the three-phase delta or auto
connected windings.
 Single-pole designs at 350A, 500A, 600A, 800A, 1200A, 1500A and 1800A ratings for auto
connected windings or single-phase transformers.
 Available with ±9, ±11, ±13, ±15, ±17 steps.
 Insulation to ground and tap selector size can be selected independently of one another.
 Convenient for bell-type tank installation.
 Additional devices for potential tie-in of tap winding during change-over operation of the change-
over selector (tie-in resistors, tie-in contact).

Compactness:

 High speed transition resistor type diverter switch with arc extension at the first current zero.
 Diverter switch uses snap-action mechanics by energy accumulator mounted directly on the diverter
switch.
 Minimum possible tap selector dimensions because four available sizes ensure matched impulse
voltage with standability.
 Radial dimensions of the tap selector are reduced by special shaping of all parts of parts on high
potential distances between tap selector bars determined by actual voltage stress.

Robustness-long life:

 Rapid tap change operation, low thermal stress on the transition resistors.
 Diverter switch arcing contacts made of tungsten-copper alloy at 500A and above.
 Simple tap selector design, effective contact cooling, high short-circuit withstandability.
 Tap selector gear with steady torque during the tap changer operation.

Easy to install- cost saving:

 Oil immersed installation of the entire tap changer in the transformer main tank.
 Simple to connect.
 Drive shaft and pipe connections easy to orientate.
 Straight forward coupling to motor drive unit

Reduced maintenance:

 Long contact life.

 Quick and easy to disassemble diverter switch insert.
 Simple to adjust and control.
 Oil suction pipe built-in diverter switch contacts easy to replace.
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The Diverter Switch Unit:

This unit comprises of the spring operated energy accumulator, the diverter switch itself and the transition
resistors. For inspection, the unit has to be withdrawn from the oil compartment through the head.

The Tap Selector

The tap selector comprises of the gearing, the column with take-off rings, the insulating bar cage with
connecting terminals, the contact bridges with corresponding drive tubes and segments, and the upper and
lower cage rings. The tap selector may also include a change-over selector.

OLTC Type V vs. Type M:

Type V

Type M

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 Conclusion

BHEL Bhopal is a vast service centre. The headquarters of the services of BHEL is in Bhopal. It was a great
experience for me to interact with the engineers and learn about the working of such a huge organisation of
the stature of BHEL. The Switchgear department is one of the largest of its kind in India today. This is the
only place in India to manufacture Gas Insulated Switch Gear with a clean room facility. BHEL Bhopal
houses Asia’s largest Ultra High Voltage Lab ( UHV Lab ) operating at voltages as high as 3 million
volts !!!!

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