Sluggish VCB to TNBR Ver 10 (3)

UNIVERSITI TENAGA NASIONAL COLLEGE OF ENGINEERING Project Proposal Project Title: Sluggish VCB Mitigation Solution 1

Background TNBR is conducting a research to investigate and identify root causes of sluggish switchgear switchgear operation. The sluggishness has caused the fault isolating function of  the breaker is being taken over by the back-up protection, thus cause a major  system breakdown. A sluggish gear will aggravate the supposed to be a single feeder outage to half or full bus interruption which involves 7 to 15 feeders. Such size of blackout tends to erode TNB’s reputation and will always become news headlines. The prime objective of the research is to identify the root causes and to propose remedial actions from the aspect of specification review, material handling, quality inspection, diagnostic and maintenance procedures. The main objective of this assignment is to investigate and mitigate the sluggish operation of switchgears caused by mechanical and electro-mechanical issues. The study will be carried out on the 11 kV switchgears from TAMCO, EPE and TOPRANK and 33 kV breakers from EPE. The scope of the assignment is to identify the appropriate close and trip coil capacity (VA) that capable of operating the breaker under common stage of  sluggish condition, to explain the phenomena (failure modes), identify the root causes and their locations as well as to develop or enhance the maintenance procedure.

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Objectives 1.

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To investi investigate gate the the capacit capacity y (VA) of of the closin closing g coil and and the trip trip coil coil that that are capable of overcoming the retarding force from the gears experiencing sluggishness.

Custom tomer Requir uiremen ment 1.

To study study the operat operatin ing g mechan mechanism ism for openi opening ng and closing closing of the vacuu vacuum m interrupters for the following gears:a. 11kV Ta Tamco b. 33kV 33kV EPE EPE and and 11kV 11kV EPE EPE

R & D Project  Proposal

 ________________________________________________________________________  c. 11kV Toprank

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UNITEN shall not do destructive tests on the new breakers as these breakers will be used to replace the old breakers supplied by TNBD to TNBR.

3.

UNITEN shall submit Gantt Chart with detail activities under each scope. The deliverables shall be planned to complete in stages and the status will be reported in the monthly progress meeting.

4.

UNITEN shall state his/ her requirements from TNBR such as testing equipment etc. TNBR may assist to find the required manpower but their  service charge will be paid by UNITEN.

Project Impact to TNB • •

•

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2.

Improved switchgear performance and hence improved network reliability. The findings of this project will be later used as input to the development of the switchgear condition-based maintenance (CBM) The competency of TNB workers in switchgear maintenance will be enhanced

Methodology

1. To check the threshold force value for the initiation of the operating mechanism to trip or close the (new) breaker. The relationship (either Mathematical or  graphical) between VA (capacity) and the force will be presented and the safety factor of the coils will be determined. 2. Based on the knowledge or investigation on the dominant sluggish root causes in the switchgear operating mechanism we are to determine the most probable retarding force generated by sluggishness. The value will be proven either by calculation, simulation or other credible method/ sources. The threshold force value required to initiate the operation of the close and trip mechanism will be determined. This information will be used to calculate the appropriate coil capacity for that scenario based on industry design practice. UNITEN will declare the assumptions used in the calculations. In TNB, breakers are maintained once in 18 month and a breaker is considered sluggish if the closing or tripping time takes longer than 100ms. UNITEN shall advise on the practicality of the using the calculated coil capacity, the methods of implementing the findings as well as to propose alternative solutions.

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Scope of Work Tests will be conducted on each of the following breakers: TAMCO 11 kV  Toprank 11 kV

 ________________________________________________________________________  Universiti Tenaga Nasional

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 ________________________________________________________________________   33kV EPE and 11kV EPE Task 1 : To calculate the safety factor of the trip and close coil. The force exerted by the plunger to the hook and the minimum force required to initiate the movement of the hook will be measured. The electrical parameters will be recorded. The relationship between force and current will be verified either by using mathematical calculation, graphical table or other reliable tools. (Repeat few times each, for statistical analysis) Task 2: To identify the required coil VA to release the latch successfully under sluggish scenario. We will create a scenario where the roller bearing housing at the linkage is  jammed so that the tip of the hook has to experience friction in order to unlatch. The force required for unlatching the linkages is measured. The test is repeated few times to comply with intended level of confidence in statistical analysis) The degree of hardening of the lubricant is not critical for the force to unlatch because it will only create one scenario i.e. failure of roller bearing housing to rotate. The relationship between force and coil capacity (VA) will be estimated. Based on the industrial design safety factor, the equivalent coil capacity is determined. If  such coil capacity is available in the market and exchangeable with the existing one in the breaker, we will purchase and proceed with testing the new coil. Force generated by the new coil will be measured and tested to release the latch under  the sluggish scenario above. If such coil capacity is not a practical replacement, alternative solutions would be sought. For example, our focus will be on maintaining the grease to avoid hardening to such stage whereby the roller bearing housing gets stuck.

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Deliverables

(a) Report on the compliance of the brand new trip coil and close coil to specifications and their safety factors as derived from the laboratory experiments.

(b) To report on the required trip and close coil capacity (VA) to overcome the retarding force from sluggishness, the practicality to replace the existing coils with the new ones. (c) To report on other alternative solutions, especially if (b) is found not practical to be implemented.

 ________________________________________________________________________  Universiti Tenaga Nasional

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 ________________________________________________________________________  8 Project Implementation Plan 8.1 Please refer to Appendix I for a detailed Gantt chart and milestones. 8.2 Critical Path Work The critical tasks are: 1.

Acquisition of Circuit breaker 

2.

Acquisition of test and measurement instruments

3.

Arranging the contract workers to assemble and dissemble

the circuit breaker  4.

Development of procedures to test the solenoid force,

effect of grease hardening. 5.

Design and develop jigs and fixtures for force testing

6.

Experimentation and Data collection

7.

Compilation and Analysis of data

and dissemination of 

results 8.3 Milestones Milestone 1: Receiving VCBs Milestone 2: Understanding Basic Linkages/ Plunger operational Milestone 3: Hiring contract workers Milestone 4: Development of jig and fixture for testing Milestone 5: Conclusion of experimental testing Milestone 6: Compilation and Analysis of project Report

 ________________________________________________________________________  Universiti Tenaga Nasional

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 ________________________________________________________________________  9 Resource Plan 9.1 Human Resource Project members have been identified from UNITEN as follows:

NAME  Abdul Talip Zulkarnain Dr. Farrukh Nagi Hafiz  Dr. Jawaid 

POSITION

MAN – MONTH 

Senior   Lecture  Asst. Prof.  Asst. Prof 

Mohd Hafiz  Dr. Faris John Stevens

Syed Khaleel Uwe Dippel

Lecturer   Asst. Prof  Senior   Lecturer 

TASK  Project coodinator 

1

Design, fabrication and  testing of  Mechanical Parts

1/0.3

0.45

Mechanical  linkages Design, fabrication and  testing of  Electrical Parts Controls

0.3

Electrical work  

0.3/member 

0.3

Senior   Lecturer  Senior   Lecturer 

Details Costing

days/m th

mth Rate/day

20

leader 400

memb er 300

Specialised Services & Consultancy 

Abdul Talip Zulkarnain Dr. Farrukh Nagi Hafiz Dr. Jawaid Mohd Hafiz Dr. Faris John Steven Syed Khaleel

1 1 0.3 0.3 0.3 0.3 0.45

20 8000 20 6000 6 1800 6 1800 6 1800 6 1800 9 2700 23900

Instruments/Materials

Load Cell 2000 Eye bolts 50 Stainless wire grips 150 Rigging screw 350 Shackles 250 Steel wire 100  ________________________________________________________________________  Universiti Tenaga Nasional

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 ________________________________________________________________________  Data Acq. Board 3000 Signal Conditionor 1100 Miscellane ous 100 7100

 Travels

1000

 Jig & Fixtures (&Workmanship) To fabricate the load measuring device and attachment for different VCB make. External Contractor (Assemble/Dissemble VCB ) Charges per visit RM1500 4 (Type VCB)x 4 (dismantle each unit)=16

8000

25000

Grand  Total

6500 0

9.2 Facilities • •

Manufacturing process workshop Electrical equipment and accessories

10 Costing

The total Project Contract Cost is RM 65,000

 ________________________________________________________________________  Universiti Tenaga Nasional

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 ________________________________________________________________________  11 Project Organisation Pro ect Coordinator

Abdul Talip Zulkarnain

Electrical Section

Mechanical Section

Dr. Farrukh Nagi John Steven Uwe Dipple

Control Section

Syed Khaleel

Dr. Jawaid Dr. Faris Mohd Hafiz

VCB fitters/assemblers

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 ________________________________________________________________________  12 Appendix 1 Gantt chart and milestones Month 1

2 i ii iii iv v

Contract signing Contract preparation & submission Proposal approval Kick-off meeting Prepare contract Sign & stamp contact Details works and reports Profile measurement of new switchgear  Electrical parameter testing and measurement Mechanical parameter testing and measurement Compilation and Analysis Report

1

2

a

3

4

5

b

c

Note: a. Report on the compliance of the brand new trip coil and close coil to specifications and their safety factors as derived from the laboratory experiments. b. To report on the required trip and close coil capacity (VA) to overcome the retarding force from sluggishness, the practicality to replace the existing coils with the new ones. c. To report on other alternative solutions, especially if (b) is found not practical to be implemented.

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 ________________________________________________________________________  13 Appendix II Duration Six (6) months from the date of receiving the of DC power supply unit , profile analyzer, and new switchgears.

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The following cost estimates are provided for review and approval. Scope of Work Item Estimated Estimated Comments Man-Days Costs Task 1 :To calculate the safety 30,000.00 factor of the trip and close coil. Task 2: To identify the required

35,000.00

coil VA to release the latch successfully

under  

sluggish scenario. Sub Total Man-hours 3

65,000.00

EXPENSES Flight Fare Local Travelling Hotel Meal(s) Sub Total Disbursements

0

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 ________________________________________________________________________  COST (RM) Month 1-2 Month 3-4 Month 5 TOTAL A)Direct Cost

Man Power Cost * 

15,000

5,000

Material/ jig and fixture for testing  12,000 Specialised Services & Consultancy 

10,000

Seminar / Training  Travelling & Miscellaneous Expenses

2,000 10, 000

-

-

500

250

-

-

5,000

25,000.00

1,1 00 3,9 00

15, 100.00 23, 900.00

250

1, 000.00

B)Capital Expenditure Equipment  New VCB with breaker truck 

- -

GRAND TOTAL Notes Triggering for 1st invoice cost incurred (Submission of sec. 7(a) report)

40%

Triggering for 2nd invoice cost incurred (Submission of sec. 7(b) report)

20%

Triggering for 3rd invoice cost incurred (Project completion and final report submission)

40%

* Price subjected to changed according contractor worker rates and requirements

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Appendix III

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65,000 .00

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 ________________________________________________________________________  PROFILE OF PROJECT TEAM MEMBERS Farrukh Nagi Dr. is working as associate professor in Universiti Tenaga Nasional, department of mechanical engineering. Graduated from NED engineering university, Karachi (1982). Worked in Pakistan International Airline for seven years as a project engineer on the development of guidance and control systems and was responsible for  integration and testing of flight by wire system. Completed his MS from university of  Miami USA (1989) and PhD from university of Nottingham UK (1993). During this  period he has gained hand-on experience of working with PLCs, data acquisition and   programming techniques. From 1994-1997 worked in Saudia Arabia – Yanbu AlSinayah in industrial training institute; where engineers and technicians were taught to use instrumention for control system in petrochemical industries. From 1997-2000 worked in Pakistan Navy engineering college –NUST and had undertaken research  projets pertaining to submarine accoustic detection. Since 2001, is working in UNITEN and had consulted with company ‘Cognis’ for Automatic waste material disposal system and is undertaking IRPA and E-science projects from MOSTI. Recently, successfully developed VCB racking In-Out prototype system for TNBD, which is installed at PPU Bangi Resort for trails. Tel: 03-89287226 Email: [email protected]

 Abdul Talip b. Zulkarnain is currently a lecturer with the Department of Mechanical Engineering, College of Engineering (COE), University of Tenaga Nasional Berhad. He holds a Diploma in Mechanical Engineering from Niihama College of Technology, Japan(1988) and a Bachelor of Mechaninal Engineering from Osaka Institute of  Technology , Japan). He obtained her Master degree from Universiti Tenaga Nasional, Malaysia, in the area of vibration damper in 2005. Prior to joining Uniten in 1999, he was a TNB traineer for 5 years, in Institute Latihan Sultan Ahmad Shah, in Electrical and Instrumentation and working experience with Project Hydro Department, LLN. Recently, successfully developed VCB racking In-Out prototype system for TNBD, which is installed at PPU Bangi Resort for trails.

Tel: 03-89212238 Email: [email protected]

  Jawaid I. Inayat-Hussain obtained his B.Eng. (Mech.) and M.Eng. (Mech.) from Universiti Teknologi Malaysia, and Ph.D. (Rotor Dynamics) from Kobe University, Japan. He spent his entire career in research and development, both in the academia and in the industry, working mainly in the field of vibration and noise control. He has also undertaken consulting work in the areas of vibration and noise control, and machinery condition monitoring for various industries. In recent years his research work has been

 ________________________________________________________________________  Universiti Tenaga Nasional

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 ________________________________________________________________________  focused on nonlinear response of rotor dynamical system. He is presently an associate  professor at the Department of Mechanical Engineering, Universiti Tenaga Nasional. Tel : 03 89282263 Email : [email protected]

 Mr John Steven Navamany is currently a senior lecturer in the Department of Electrical Power Engineering at the College of Engineering, University Tenaga Nasional (UNITEN). He received his Diploma (Electrical Power Engineering) from Polytechnic Ungku Omar in 1980, BSc in Electrical Engineering from Purdue University, USA in 1998, and M.Eng in Electrical Power Engineering University Tenaga Nasional in 2002. He has more than 10 years experience as a lecturer. Served as a senior  instructor( electrical ) at the utility company’s technical training centre for a period of 15 years. Instructs the technical staff of the utility company and the electrical maintenance   personnel from the electrical industry on the fields of, operation and maintenance of  switchgears and transformers, generator maintenance, power station electrical practice, motors (AC/DC) and motor controls. Responsibilities include developing and documenting short term courses. Has undergone industrial training on Power Generation Equipment for a period of 8 months at Hitachi Power Generation Company of Japan. Performed overhaul and inspection on switchgears, transformers, generator and exciter  systems and electrical auxiliaries at Port Klang Power Station in 1988 for a period of  about a year. Performed commissioning tests on all electrical equipment in Putrajaya Power Station, including Gas Insulated Switchgear in switchyard. Tel: 03-89212235 Email: [email protected]  Syed Khaleel Ahmed is currently a Senior Lecturer in the Department of Electronics and Communication Engineering of the College of Engineering, Universiti Tenaga Nasional. He received his B.E. from Anna University, Chennai, India in 1988, and M.S.E.C.E. from the University of Massachusetts at Amherst, USA in 1994. His interests are in Robust and Fuzzy Control, Signal Processing, Numerical Techniques, and Neural Networks. He is a member of IEEE, Inc, USA and ISTE, India.

Tel: 03-89212276 Email: [email protected]  Mohd. Hafiz Hasan is a faculty member of the department of mechanical engineering in UNITEN. He graduated summa cum laude from the University of Michigan, Ann Arbor, USA with a Bachelor of Science degree in mechanical engineering in 2003. He served as a tutor in the department of mechanical engineering in UNITEN from 2004 to 2006, after  which he went to Nanyang Technological University, Singapore. He graduated in 2008 with a Master of Science degree in smart product design, and also won the Professional Engineer’s Board gold medal for graduating with the highest CGPA from his school. He

 ________________________________________________________________________  Universiti Tenaga Nasional

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 ________________________________________________________________________  currently serves as a lecturer in the department of mechanical engineering in UNITEN, where he carries out research on optical motion tracking devices and network flow optimization algorithms. He also teaches an undergraduate course on modeling, designing and analyzing mechanisms. Tel: 03-8921 2020 ext. 6048 Email: [email protected] Uwe Dippel  is currently employed as Senior Lecturer in the Department of Computer  Science of the College of Information Technology, Universiti Tenaga Nasional. He holds a Masters Degree in Electrical Engineering from Technische Universität Berlin, Germany, and has over the last twenty-five years acquired professional experiences in various areas of the field; ranging from the German Ministry for Research and Technology to Broadcasting.

Tel. (03)8921-2374 E-mail: [email protected]

 Ir. Dr. Faris Tarlochan is currently an Assoc. Prof. in the Department of Mechanical Engineering of the College of Engineering, Universiti Tenaga Nasional. He received his BSc and MSc from Purdue University, USA in 1998 and 2001 respectively. He completed his PhD at UPM, Malaysia in 2007. His interests are in applied mechanics, finite element analysis, failure analysis and composite materials. He is a Chartered and Professional Engineering registered with the UK Engineering Council and IEM respectively. He is also a member of IMeche (UK), ASME, IMM, mSET.

Tel: 03-89212224 Email: [email protected]

 ________________________________________________________________________  Universiti Tenaga Nasional

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