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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
40
50
60
70
Presentation on Project Proposal
TNBR-UNITEN Power Engineering Centre
Involve to SolveSlide No. 2 Copyright © 2006 TNB Research
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
Involve to SolveSlide No. 3 Copyright © 2006 TNB Research
Events which Triggers the Project
Involve to SolveSlide No. 4 Copyright © 2006 TNB Research
VCB Failure Analysis - TNBR
Involve to SolveSlide No. 5 Copyright © 2006 TNB Research
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
Involve to SolveSlide No. 6 Copyright © 2006 TNB Research
Project Background …..contdDamaged VCB at TNBR – causing a
fatality
Involve to SolveSlide No. 7 Copyright © 2006 TNB Research
Customer Information Form
Meeting of 5th Jan. 2007Ir. Halim bin OsmanKetua Jurutera(Penilaian & Modenisasi
Teknologi)Unit Perkhidmatan
KejuruteraanBahagian Pembahagian
Involve to SolveSlide No. 8 Copyright © 2006 TNB Research
• 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
Involve to SolveSlide No. 9 Copyright © 2006 TNB Research
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
Involve to SolveSlide No. 10 Copyright © 2006 TNB Research
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.
Involve to SolveSlide No. 11 Copyright © 2006 TNB Research
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
Involve to SolveSlide No. 12 Copyright © 2006 TNB Research
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
Involve to SolveSlide No. 13 Copyright © 2006 TNB Research
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
Involve to SolveSlide No. 14 Copyright © 2006 TNB Research
Schematic 2: One possibility of triangular mounting frame
Involve to SolveSlide No. 15 Copyright © 2006 TNB Research
• 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 )
Involve to SolveSlide No. 16 Copyright © 2006 TNB Research
Schematic 3: Electrical Control Unit
Involve to SolveSlide No. 17 Copyright © 2006 TNB Research
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
Involve to SolveSlide No. 18 Copyright © 2006 TNB Research
TNBR Contribution
Involve to SolveSlide No. 19 Copyright © 2006 TNB Research
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
Involve to SolveSlide No. 20 Copyright © 2006 TNB Research
Project Cost (Breakdown)
Involve to SolveSlide No. 21 Copyright © 2006 TNB Research
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
Involve to SolveSlide No. 22 Copyright © 2006 TNB Research
Summary Of Racking Data
Involve to SolveSlide No. 23 Copyright © 2006 TNB Research
VCB Enclosure
Involve to SolveSlide No. 24 Copyright © 2006 TNB Research
33KV VCB at ILSAS
Involve to SolveSlide No. 25 Copyright © 2006 TNB Research
VCB at TNRD
Involve to SolveSlide No. 26 Copyright © 2006 TNB Research
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