SWITCHGEAR

The apparatus used for controlling, regulating and switching on or off the
electrical circuit in the electrical power system is known as switchgear. The
switches, fuses, circuit breaker, isolator, relays, current and potential
transformer, indicating instrument, lightning arresters and control panels are
examples of the switchgear devices.

The switchgear system is directly linked to the supply system. It is placed in both
the high and low voltage side of the power transformer. It is used for de-
energizing the equipment for testing and maintenance and for clearing the fault.

Overview
When the fault occurs in the power system, heavy current flow through equipment
due to which the equipment get damaged, and the service also get interrupted.
So to protect the lines, generators, transformers and other electrical equipment
from damage automatic protective devices or switchgear devices are required.

The automatic protective switchgear mainly consists of the relay and circuit
breaker. When the fault occurs in any section of the system, the relay of that
section comes into operation and close the trip circuit of the breaker which
disconnects the faulty section. The healthy section continues supplying loads as
usual, and thus there is no damage to equipment and no complete interruption of
supply.

The earliest central power stations used simple open knife switches, mounted on
insulating panels of marble or asbestos. Power levels and voltages rapidly
escalated, making opening manually operated switches too dangerous for
anything other than isolation of a de-energized circuit. Oil-filled switchgear
equipment allow arc energy to be contained and safely controlled. By the early
20th century, a switchgear line-up would be a metal-enclosed structure with
electrically operated switching elements, using oil circuit breakers. Today, oil-filled
equipment has largely been replaced by air-blast, vacuum, or SF6 equipment,
allowing large currents and power levels to be safely controlled by automatic
equipment.

High-voltage switchgear was invented at the end of the 19th century for
operating motors and other electric machines. The technology has been improved
over time and can now be used with voltages up to 1,100 kV.

Functions
One of the basic functions of switchgear is protection, which is interruption of
short-circuit and overload fault currents while maintaining service to unaffected
circuits. Switchgear also provides isolation of circuits from power supplies.
Switchgear is also used to enhance system availability by allowing more than one
source to feed a load.

Componenets
A switchgear assembly has two types of components:

 Power conducting components, such as switches, circuit breakers, fuses,

and lightning arrestors, that conduct or interrupt the flow of electrical power.
 Control systems such as control panels, current transformers, potential
transformers, protective relays, and associated circuitry, that monitor, control,
and protect the power conducting components.

Circuit Breaker types

A switchgear may be a simple open-air isolator switch or it may be
insulated by some other substance. An effective although more costly
form of switchgear is the gas-insulated switchgear (GIS), where the
conductors and contacts are insulated by pressurized sulfur
hexafluoride gas (SF6). Other common types are oil or vacuum
insulated switchgear.
The combination of equipment within the switchgear enclosure allows
them to interrupt fault currents of thousands of amps. A circuit
breaker (within a switchgear enclosure) is the primary component that
interrupts fault currents. The quenching of the arc when the circuit
breaker pulls apart the contacts (disconnects the circuit) requires
careful design. Circuit breakers fall into these six types:
 AN INTRODUCTION TO ON LOAD TAP CHANGER

A tap changer is a connection point selection mechanism along a power

transformer winding that allows a variable number of turns to be selected
in discrete steps. A transformer with a variable turn ratio is produced,
enabling stepped voltage regulation of the output. The tap selection
may be made via an automatic or manual tap changer mechanism.

VOLTAGE CONSIDERATION
If only one tap changer is required, manually operated tap points are
usually made on the high voltage (primary) or lower current winding of
the transformer to minimize the current handling requirements of the
contacts. However, a transformer may include a tap changer on each
winding if there are advantages to do so. For example, in power
distribution networks, a large step-down transformer may have an off-
load tap changer on the primary winding and an on- load automatic tap
changer on the secondary winding or windings. The high voltage tap is
set to match long term system profile on the high voltage network
(typically supply voltage averages) and is rarely changed. The low
voltage tap may be requested to change positions multiple times each
day, without interrupting the power delivery, to follow loading
conditio ns on the low-voltage (secondary winding) network.
To minimize the number of winding taps and thus reduce the physical size
of a tap changing transformer, a 'reversing' tap changer winding may be
used, which is a portion of the main winding able to be connected in its
opposite direction (buck) and thus oppose the voltage.

CLASSIFICATION OF TAP CHANGING

OFF-CIRCUIT DESIGNS (NLTC OR DETC):

Also called No-Load Tap Changer (NLTC), off-circuit tap changer, or

De-Energized Tap Changer (DETC).
In low power, low voltage transformers, the tap point can take the form
of a connection terminal, requiring a power lead to be disconnected by
hand and connected to the new termina l. Alternatively, the process may
be assisted by means of a rotary or slider switch.
Since the different tap points are at different voltages, the two connections
cannot be made simultaneously, as this would short circuit a number of
turns in the winding and produce excessive circulating current.
Consequently, the power to the device must be interrupted during the
switchover event. Off-circuit or de-energized tap changing (DETC) is
sometimes employed in high voltage transformer designs, although for
regular use, it is only applicable to installations in which the loss of
supply can be tolerated. In power distribution networks, transformers
commonly include an off-circuit tap changer on the primary winding to
accommodate system variations within a narrow band around the
nominal rating. The tap changer will often be set just once, at the time
-of installation, although it may be changed later during a scheduled
outage to accommodate a long-term change in the system voltage profile.
ON-LOAD DESIGNS (OLTC):
Also called on circuit tap changer or On Load Tap Changer (OLTC).
For many power transformer applications, a supply interruption during a
tap change is unacceptable, and the transformer is often fitted with a more
expensive and complex on-load tap-changing (OLTC, sometimes LTC)
mechanism. On-load tap changers may be generally classified as either
mechanical, electronically assisted, or fully electronic.

Fig. On Load Tap Changer

ON-LOAD TAP-CHANGERS FOR POWER TRANSFORMERS
Power transformers equipped with on-load tap- changers (OLTCs) have
been the main components of electrical networks and industrial
applications for nearly 90 years. OLTCs
enable voltage regulation and/or phase shifting by varying the
transformer ratio under load
without interruption.

From the start of tap-changer development, two switching principles

have been used for load transfer operation – the high-speed resistor-
type OLTCs and the reactor-type OLTCs.
Over the decades both principles have been developed into reliable
transformer components which are available in a broad range of current
and voltage applications. These components cover the needs of today’s
network and industrial process transformers and ensure optimal system
and process control.
The majority of resistor-type OLTCs are installed in- side the
transformer tank (in-tank OLTCs) whereas the reactor-type OLTCs are
in a separate compartment which is normally welded to the transformer
tank.
This paper mainly refers to OLTCs immersed in trans- former mineral oil.
The use of other insulating fluids or gas insulation requires the approval
of the OLTC manufacturer and may lead to a different OLTC de- sign,
as shown in chapter.
SWITCHING PRINCIPLE

The OLTC changes the ratio of a transformer by adding or subtracting to

and turns from either the primary or the secondary winding. The
transformer is therefore equipped with a regulat ing or tap winding
which is connected to the OLTC.
The principle winding arrangement of a 3-phase regulating transformer,
with the OLTC located at the wye-delta-connection in the high volt- age
winding. Simple changing of taps during an energized status is
unacceptable due to momentary loss of system load during the switching
operation. The “make (2) before break (1) contact concept”, shown in
Figure 4, is therefore the basic design for all OLTCs. The transition
impedance in the form of a resistor or reactor consists of one or more
units that bridge adjacent taps for the purpose of transferring load from
one tap to the other without interruption or appreciable change in the load
current. At the same time they limit the circulating current (IC) for the
period when both taps are used. Normally, reactor-type OLTCs use the
bridging position as a service position and the re- actor is therefore
designed for continuous loading. The voltage between the taps mentioned
above is the step voltage, which normally lies between 0.8 % and 2.5 %
of the rated voltage of the transformer
Fig switching sequence of OLTC
With a reversing change-over selector the tap winding is added to or
subtracted from the main winding so that the regulating range can be
doubled or the number of taps reduced. During this operation, the tap
winding is disconnected from the main winding. The greatest copper
losses occur, however, in the position with the minimum number of

effective turns. This reversing operation is realized using a change-over

selector which is part of the tap selector or of the selector switch (arcing
tap switch). The rated position is normally the mid position or neutral
position.
Fig. Switching sequence of tap selector – diverter switch (arcing
switch)
The double reversing change-over selector avoids the disconnection of
tap winding during the change-over operation. In phase-shifting
transformers this apparatus called the advance-retard switch.

Which of these basic winding arrangements is used in each individual

case depends on the system and operating requirements. These
arrangements are applicable to two winding transformers as well as to
autotransformers and to phase-shifting transformers where the tap winding
and therefore the OLTC is inserted in the windings (high-voltage or low-
voltage side) depends on the transformer design and customer
specifications. For regulated autotransformers, fig. 8 shows various
circuits. The most appropriate scheme is chosen with regard to
regulating range, system conditions and/or requirements, as well as weight
and size restrictions during transportation. Autotransformers are always
wye-connected.

a)Three pole line-end arrangement

b) One and two pole line-end arrangement

c)Three pole mid-winding arrangement

I neutral end regulation (fig. 8 a) may be applied with a ratio above 1 : 2

and a moderate regulating range up to 15 %. This operates with
variable flux. a scheme shown in fig. 8 c is used for regulating high
voltage for low voltage U2 regulation, the circuits fig. 8 b, 8 d, 8 e and
8 f are applicable. The arrangements fig. 8 e and 8 f are two core
solutions. Circuit fig. 8 f operates with variable flux in the series
transformer, but it has the advantage that a neutral end OLTC can be
used. In the case of arrangement according to fig. 8 e, the main and regulat
ing transformers are often placed in separate tanks to reduce transport
weight. At the same time, this solution allows some degree of phase
shifting by changing the excitation connections within the intermediate
circuit. Over the last few years, the importance of phase- shift ing
transformers used to control the power flow on transmission lines in
meshed networks has been steadily increasing .The fact that IEEE
provides a “guide for the Application, specification and Testing of Phase-
shifting Transformers“ proves the demand for These transformers
often require regulating ranges which exceed those normally used. To
achieve such regulat ing ranges, special circuit arrangements are
necessary. Two examples are given shows a circuit with direct line-end
regulation, fig. 10 an intermediate circuit arrangement illustrates very
clearly how the phase-angle between the voltages of the source and load
systems can be varied by the OLTC position. Various other circuit
arrangements have been implemented.
 (1) DESIGN CONCEPT OF ON LAOD TAP CHANGER

Apart from tap selection, the most important task of an OLTC is the break
function or current (load) transferring action. After transferring the
current, the contact which “breaks” must be capable of withstanding the
recovery voltage. The required switching capacity (the product of switched
current and recovery voltage) for a specific contact in an OLTC is based
on the relevant step voltage and cur- rent but is also determined by the
design and circuit of the OLTC. The switching capacity itself is primarily
a function of the contact design, contact speed and arc-quenching agent.

Historically, most power transformers use mineral oil as a cooling and

insulation medium. The development of OLTCs toward the present “state
of the art” de- signs also focused on transformer oil. Apart from the
insulation properties of the transformer oil, the arc- quenching behavior of
the switching contacts deter- mined the design and size of “oil-type”
OLTCs.

In an oil-type OLTC, the OLTC is immersed in trans- former oil and

switching contacts make and break current under oil. This conventional
OLTC technology has reached a very high level and is capable of
meeting most of the transformer manufacturers’ requirements. This
applies for all the voltage and power fields today, which will probably
remain unchanged in the foreseeable future.

Along with the increase in demand for electrical energy in metropolitan

areas, the necessity for installing transformers in buildings creates a need
for regulating transformers with reduced fire hazards. In addition to this
and with respect to the prevention of water pollution, regulat ing
transformers that do not require conventional mineral oil as an insulating
or switching medium are preferable.

Apart from gas-immersed transformers, which are mainly used in Japan,

dry-type transformers and trans- formers with alternative insulating fluids
meet these requirements, which are increasingly being requested.
Conventional tap-changers are not really suitable for this kind of
regulating transformers, because the use of mineral oil as a switching
medium is – for the rea- sons mentioned above – not desirable and
would also require technically complex and expensive overall solutions.

In addition, worldwide deregulation in the electric industry is still a

concern. As part of this market, mechanisms have been encouraged to
price transmission services and encourage both generation and trans-
mission investment.
OIL-TYPE OLTCS – OILTAP

The OLTC design that is normally used for higher ratings and higher
voltages comprises a diverter switch (arcing switch) and a tap selector.
For lower ratings, OLTC designs in which the functions of the diverter
switch (arcing switch) and the tap selector are combined in a selector
switch (arcing tap switch) are used.
With an OLTC comprising a diverter switch (arcing switch) and a tap
selector, the tap-change operation takes place in two steps. The next tap is
first preselected by the tap selector at no load. The diverter switch then
transfers the load current from the tap in operation to the preselected
tap. The OLTC is operated by means of a drive mechanism. The tap
selector is operated by a gearing directly from the drive mechanism. At the
same time, a spring energy accumulator is tensioned, which operates the
diverter switch – after release at a very short time interval – independently
of the motion of the drive mechanism. The gearing ensures that this
diverter switch operation always takes place after the tap preselection
operation has finis hed. The switching time of a diverter switch is
between 40 and 60 Ms with today’s designs. During diverter switch
operation, transition resistors are inserted which are loaded for 20–30
Ms, i.e. the resistors can be designed for short-term loading. The
amount of resistor material required is therefore relatively small. The
total operation time of an OLTC is between 3 and 10 seconds, depending
on the respective design.
A selector switch (arcing tap switch) as shown in carries out the tap-
change in one step from the tap in service to the adjacent tap. The spring
energy accumulator, wound up by the drive mechanism actuates the
selector switch sharply after releasing.
Fig. oil type OLTC
 (2) DESCRIPTION OF EQUIPMENTS
TAP CHANGER TYPE M

The OILTAP® M on-load tap-changer is used to vary the ratio of oil-

immersed transformers under load. In general it is designed for
network transformer as well as industrial transformer applications.
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.

Fig. OLTC type M

VERSATILITY:

– three-pole design for neutral application at 350 A, 500 A

and 600 A ratings for three-phase wye-connected windings
– single-pole designs at 350 A, 500 A, 600 A, 800 A,
1200 A and 1500 A 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,
potential contact)
COMPACTNESS:

– high speed transition resistor type diverter switch with

arc extinction 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 stand
ability
– radial dimensions of the tap selector are reduced by special
shaping of all parts on high potential, distances between tap
selector bars determined by actual voltage stress –
optimised integration of the change-over selector into the fine
selector contact circle
ROBUSTNESS– LONG LIFE:

– rapid tap change operation, low thermal stress on the transition

resistors
– diverter switch arcing contacts made of tungsten-copper
alloy at 500 A and above
– –simple tap selector design, effective contact cooling, high
short-circuit with stand ability
– 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
MOTOR DRIVE UNIT

An on-load tap-changer is normally used in power transformers in an

electric grid, where its function primarily is to keep a constant voltage out
from the transformer. Some on-load tap- chargers are used in transformers
where their function is to control the power of the transformer by
regulating the voltage. The on-load tap-changer can be described as a
mechanical switching device that will change the turn ratio in the
transformer without interrupting the load current. This makes it possible
to keep a constant voltage out from the transformer and to compensate
for variations in the load.

A common on-load tap-changer generally consists of a motor drive unit,

an axis system, a diverter switch with a housing, and a selector mounted
under the diverter switch. Such an on- load tap-changer is named a
diverter switch type. Another on-load tap-changer, wherein the selector
and the diverter switch are merged into the same unit is named a selector
switch type.

The main objective of an electric motor drive unit is to drive the

connected on-load tap-changer to a higher or a lower tap of a
transformer. Electric motor drive units for tap changers are rather complex
and the cost for their production and assembly- is considerable. Further,
electric motor drive units are to a large extent order designed, with a
customer requirement as basis, which further increases cost for their
production and assembly.
Fig. Motor assembly for OLTC
BENEFITS OF MOTOR DRIVE UNIT:

An object of the present invention is to provide an electric motor

drive unit for tap-changers which is adaptable to different customer
requirements.

The invention is based on the realization that by providing an on-

load tap-changer with an electric motor drive unit at a minimum the
following advantages are achieved:

• Reduced lead time in production

• Flexibility for late order changes

• Service friendly design

• Reduced tap-changer motor drive cost

PROTECTIVE RELAYS:

A relay is automatic device which senses an abnormal condition of

electrical circuit and closes its contacts. These contacts in turns close
and complete the circuit breaker trip coil circuit hence make the circuit
breaker tripped for disconnecting the faulty portion of the electrical
circuit from rest of the healthy circuit. The protective relay is
designed to protect the on-load tap-changer and the transformer during
a malfunction within the on-load tap- changer or the selector switch
oil compartment. It trips when the specified oil flow speed between the
on-load tap-changer head and the oil conservator is exceeded. The
protective relay must be connected so that the transformer is
immediately isolated from the power when the protective relay trips.
Fig Protective Relay
MOUNTING OF DRIVE SHAFT AND BEBEL GEAR UNIT

Due to the special arrangement of the tap-changer phases in three

columns, the horizontal drive shaft must be mounted between the three
tap-changer heads above the tank cover. Since a swivelling of the upper
gear unit will initiate a switching action, make sure that the adjustment
position of the diverter switch is re- gained after the alignment of the gear
units.

Fig Drive Shaft and Bebel Gear FOR THIS

PURPOSE PROCEED AS FOLLOWS:

 Check that the operating positions of all columns are identical (tap-changer
head,
inspection window). Each one of the one-phase OLTCs must be in
the adjustment position.
 Turn the upper gear unit of the tap-changer heads into the desired
installation position
and fix them there (tighten thrust collars and tab-lock the screws).
 Take note of the arrow on the drive shaft flange below the punched
serial number. The direction of the arrow indicates the rotation
 sense when crank- ing the motor drive clockwise and must be
identical on all gear units.
 Operate the tap-changer poles separately by one step by rotating the
trunnions counter-
clockwise until the diverter switch operates once. Check coincidence of
operating positions of all tap-changer heads.
 Mount the horizontal drive shaft between the tap- changer heads.
 Return the OLTC set that is all tap-changer poles together, into the
adjustment position. The adjustment position is reached by turning
the drive shaft in clockwise direction.
Check simultaneous operation of all diverter switches. Check
coincidence of position of all tap- changer heads and the motor
drive unit.
 Mount the vertical drive shaft.

Make sure that bevel gear serial number and on-load tap-changer
serial number are identica l. The horizontal drive shaft must be in
proper alignment with the trunnion in the tap-changer head.
After loosening the thrust collar (6 bolts M8, was. 13) the upper
gear unit can be swivelled (fig. 39). After adjusting the upper gear
unit, the thrust collar must be re-tightened (max. torque 15 Nm).
Tab-lock the screws. In case of bevel gears in special design and
intermediate bearings of the vertical or horizontal drive shaft above
instructions apply analogously.

Square shafts, coupling brackets, coupling bolts, screws, nuts and

lock tabs are made of corrosion-proof steel. We recommend,
however, to apply the same outside coating here as to the
transformer tank. The square shafts and the guard plate for the
footstep protection for the horizontal drive shaft at the trans- former
cover are supplied in oversize (various standard lengths). These
parts must be cut to the required size before mounting. Finally
equalize the rotation lag between on-load tap- changer and motor
drive unit will be completed.