Involve to Solve Slide No. 1 Copyright © 2006 TNB Research Development of Automatic Rack-In &...

Involve to SolveSlide No. 1 Copyright © 2006 TNB Research

Development of Automatic Development of Automatic Rack-In & Rack-Out Rack-In & Rack-Out

System for Vacuum Circuit BreakerSystem for Vacuum Circuit Breaker

33.2°C

76.9°C

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Presentation on Project Proposal

TNBR-UNITEN Power Engineering Centre


Project Overview

Customer RequirementsCustomer Requirements A motorized remotely controlled racking system

to eliminate personnel presence in vicinity of VCB during crank in and out operation.

Project backgroundProject background• Part of the TNBR Initiative to collaborate with

external parties

• This project will benefit TNBD ES and possibly local vendors as

• TNBR will have in-house engineering and design capabilities

• VCBs are well protected with interlocking switches for its switching device operation with busbar

• Switching devices in VCBs have to be disabled or enable for raking In-Out operation for maintenance purpose.

• Malfunctioning of interlocking mechanism is very unlikely but if it happens the results are life threatening.

• There has been such failure in past and loss of life in some incidents

Aims & ObjectivesAims & Objectives

DeliverablesDeliverables

A prototype remotely-controlled Rack-in & Rack-out system for existing hand-crank operated VCB

•Aim: To safe guard personnel injuries/fatalities during rank in & out of vacuum circuit breaker

•Objective:To develop automatic motorized remote control System for rack in & out of VCB as per TNBD technicalspecification. The operation should perform the same task as done manually for rack in & out of VCB


Events which Triggers the Project


VCB Failure Analysis - TNBR


Value Creation in TNB

•Supplier prices cost per unit at approx. RM100,000

•TNB needs 60 units ~ total of cost RM 6 Million

•This research will design and deliver a prototype of a VCB Rack with only a fraction of the Supplier cost

•Estimated cost per unit product less than RM15,000 ~ total cost RM 1.13 Million


Project Background …..contdDamaged VCB at TNBR – causing a

fatality


Customer Information Form

Meeting of 5th Jan. 2007Ir. Halim bin OsmanKetua Jurutera(Penilaian & Modenisasi

Teknologi)Unit Perkhidmatan

KejuruteraanBahagian Pembahagian


• TESTING AND COMISSIONING REQUIREMENTS

TYPE TEST • * The system must be able to perform racking-in and racking-out of the vacuum circuit breaker by • motorized operation.• • * The motorization devices must be able to perform rack out – rack in operations for a minimum • of 5 times continuously using the battery supply (without ac source) at ambient temperature.• • *The motorization devices must be able to withstand and be certified for a minimum of 100 cycles • of racking in and racking out endurance test.• • *All type tests required shall be performed by an independent accredited testing laboratory • approved by TNB. These tests are to be witnessed by TNB personnel

Hardanjit Singh Gosal Principal Engineer - Substation Engineering Services Department Tenaga Nasional Berhad - Distribution Division


Chronological Presentations of the Project

• 1st presentation at TNB-Distribution to Ir Halim Osman – Chief Engineer Services and TIO SHIN Yeow - Engineering service unit on Friday, 5 January 2007

Recommended for TNBR – TRC screening

• 2nd presentation to TRC-TNBR on Thursday , 11th January – Dr. Cheong , Dr. Badrul and En. Azmi

Recommendations/comments: TNBR role & Testing and Commissioning details required

• 3rd presentation/meeting with TNBR Dr. Salim – MD, on 1st March 2007

Recommendation/comments: TNBR contribution, VCB failure analysis inclusion, Test and commissioning details, liase with PEC (UNITEN)

Present to TRC


METHODOLOGY

i. To identify both the hardware and software aspects of the VCB automatic operation/control system.ii. To study and evaluate the existing front panel configuration and operation of VCB. iii. To design a flexible and suitable mounting brackets to hold drive system to operate the crankshaft.iv. To measure and calculate the suitable torque force to rotate the crankshaftv. To identify of a suitable motor drive unit vi. Identification of a suitable control system and operational flow chart on operation of the unit.vii. To program PLC logic for operation and interlocksviii. To determine whether the system/scheme is functioning as envisaged.ix. To determine that the designed scheme is as reliable as is that employed by the Tenaga Nasional Berhad.


Scope of Work …..Design Criteria

• Should be able to operate on all configuration of VCB in TNB Substations

• Light Weight, Independent and Portable

• No altercation to VCBs function and operation

• Motorized unit with battery and charging backup

• Complies with IEC/ANSI/IEEE standards

• Raking In-Out time 10sec – 15sec

• Ease of accessing crank nut avoiding control devices on VCB front panel


Mechanical fixtures and fittings Mechanical fixtures and fittings (schematic 1 & 2)(schematic 1 & 2)

i) Triangular mounting frame – Aluminum alloy

ii) Magnetic legs – Steel rod with magnet with pull force 750 N or more.

iii) Sliding and rotating arm – For alignment with crank nut port

iv) Geared 24 VDC motor with encoder – 20 to 30 rpm and torque of ~250Ncm. Encoder provides distance travel by VCB.

v) Adjustable adapter shaft with crank socket - To access the crank nut


Schematic 1: Mechanical fixture and fittings

VCB front Panel

Triangular Frame

Sliding Arm

Magnetic legs

Encoder

DC Motor Gear Box

Crank socket

Crank nut

Anchor bolt


Schematic 2: One possibility of triangular mounting frame


• Control of mechanical unit is achieved by wall mounted control unit

• Programming Logic Controller (PLC) housed in control unit controls the operation of motor

• PLC reads the motor encoder and computes the distance moved by the VCB and controls motor operation

• Interlocking functions of the systems will be provided from the PLC ladder logic programming

• Battery backup and charger will be housed in control unit

• The cables runs ~40m between mechanical and control units

Electrical - Control System and fixturesElectrical - Control System and fixtures (Schematic 3 )(Schematic 3 )


Schematic 3: Electrical Control Unit


System Specification, Testing and validationSystem Specification, Testing and validation• Details provided by TNB Distribution

Power Failure and SafetyPower Failure and Safety• Control unit should be operational for four (4) hours from

battery• Thirty (30) rank In-Out operation from battery• Mount or un-mount status of mechanical unit on VCB front

panel

Materials RequiredMaterials Required• Mechanical Assy: Triangular Frame + sliding/swinging arm +

magnetic stand + adjustable socket adapter shaft • Actuator Assy: Motor + encoder + gearbox• Control & Power Sys: Reversible Controller + PLC + battery +

power supply + charger• Miscellaneous : Cabling + connectors + socket + adapters +

accessories

Development timeDevelopment time• Four (4) months after receiving the approval


TNBR Contribution


Gantt chart and milestones

Month 1 2 3 4

1 Contract signing

Contract preparation & submission

Proposal approval

Kick-off meeting

Prepare contract

Sign & stamp contact

2 Details works and reports

Site visit to sub-station in Lembah Klang Area and ILSAS

To design and fabricate suitable mechanical

mounting brackets on the front panel of the VCB.

To design and fabricate a motor drive

unit to rotate the crankshaft of VCB.

To design and fabricate a control system to

operate the motor drive unit according to the specification stated.

To test the operation and performance

system according to the specification stated


Project Cost (Breakdown)


NameMan – Month

Task

Dr. Farrukh Nagi Hafiz 1.5 Project Technical leaderSystem development and deployment

Abdul Talip Zulkarnain 1 Design, fabrication and testing of Mechanical Parts

Uwe Dippel 1 Design, integration, programming and testing of

Control system Yaakob Raja Omar 1 Design, fabrication and

testing of motor drive and electrical parts

Proposed Team Members


Summary Of Racking Data


VCB Enclosure


33KV VCB at ILSAS


VCB at TNRD


Thank You

Contacts:-

TNB Research Sdn. Bhd.No. 1, Lorong Ayer Itam,Kawasan Institusi Penyelidikan,43000 Kajang, Selangor, MALAYSIA

Tel: +603-89268818 Fax: +603-89268828 / 29

Involve to Solve Slide No. 1 Copyright © 2006 TNB Research Development of Automatic Rack-In &...

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