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BANGALORE METRO RAIL CORPORATION LIMITED
BANGALORE METRO RAIL CORPORATION LIMITED
TRACTION OPERATION & MAINTENANCE MANUAL
CONTRACT: EP1-CC M/s. LIMITED, BANGALORE
OPERATION & MAINTENANCE MANUAL
BANGALORE METRO RAIL CORPORATIOn limited
OPERATION & MAINTENANCE MANUAL
BANGALORE METRO RAIL CORPORATIOn limited
TABLE OF CONTENTS:
Description of Content
1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 3.0 3.1 GENERAL OVERVIEW Introduction 66 kV Network RSS Configuration 33 kV Distribution Network Auxiliary Substations Traction Substations Third Rail & Stinger System Earthing, Bonding & Stray Current Management SCADA, ETS & Power Supply Protection System ORGANIZATION OVERVIEW Organization Chart Duties & Responsibilities SAFETY Safety Information 31 - 33 23 - 23 24 - 30 12 - 14 15 - 15 15 - 16 17 - 17 18 - 18 18 - 18 19 - 19 20 - 21 21 - 22
OPERATION & MAINTENANCE MANUAL
BANGALORE METRO RAIL CORPORATIOn limited
Description of Content
1.0 1.1 1.2 1.3 1.4 1.5 1.6 2.0 2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 RECEIVING SUBSTATIONS General RSS Scheme RSS Layout RSS Operation Logic 66 kV Feeders & RSS Protections Metering at 66 kV Level RSS EQUIPMENTS 66/33 kV Power Transformer Technical Specification Operation of Transformer Energization Procedure Energization General Supervision & Maintenance Maintenance Schedule 44 - 49 50 – 50 50 - 51 51 - 51 52 - 54 55 - 57 35 - 35 35 -35 36 – 36 37 - 38 39 – 41 42 - 42 43 - 43
OPERATION & MAINTENANCE MANUAL
4.2.5 2.3.74 58 . 188.8.131.52.3 2.4 2.3 2.2 2.3 2. BANGALORE METRO RAIL CORPORATIOn limited Sl.2.2 184.108.40.206 2.2. Description of Content Page No.58 59 – 61 62 – 63 64 – 64 64 – 64 65 .3.73 73 .2.1 2.No.6 2.4 2.2 2.1 2.Nitrogen 75 – 76 77 – 78 79 – 79 67 – 68 69 – 70 70 .1 2.4.5 2.3.2 2.3 66 kV Circuit Breaker General Description Technical Specifications Operating Mechanisms Closing & Opening Operations Auto-Reclosing Maintenance Schedule 66 kV Current Transformer General Description Technical Specifications Operation Parameters Filling Procedure of CT with Gas – SF 6 General Supervision & Maintenance Maintenance Schedule 66 kV Potential Transformer General Description Technical Specifications Filling Procedure of PT with Gas .70 71 – 72 73 .66 OPERATION & MAINTENANCE MANUAL Page 05 .6 2.2.
3 2.90 91 .220.127.116.11 2. BANGALORE METRO RAIL CORPORATIOn limited Sl. Description of Content Page No.4.6.82 83 .5 18.104.22.168 2.6.3 2.5.4 2.2 2.5.88 89 .2 2.5 Oil Filtration General Supervision & Maintenance Maintenance Schedule 66 kV Isolator General Description Technical Specifications Isolator Installation Procedure Earth Switch Installation Procedures Operating Instruction Maintenance Neutral Grounding Resistor General Description Technical Specifications Operation Mechanism General Supervision & Maintenance Maintenance Schedule 79 – 80 80 – 81 81 .4. 2.6 2.6 2.No.93 93 .6.4 2.95 96 – 97 98 – 99 99 – 100 100 – 101 102 .5 2.5 2.91 92 .1 2.5.6 2.103 OPERATION & MAINTENANCE MANUAL Page 06 .92 93 .5.
4 2.2 2.2 2.1 2.0 2. BANGALORE METRO RAIL CORPORATIOn limited Sl.5.5 2.5.3 2.5.112 113 .3 2. Description of Content Page No.5.III 1.110 111 .4 2.1 2.119 120 .5.No.107 108 .109 105 .1 1.105 105 – 106 OPERATION & MAINTENANCE MANUAL Page 07 .5 2.121 122 – 122 123 – 124 107 .109 109 – 109 109 . CHAPTER .2 2.6 AUXILIARY SUBSTATIONS Overview ASS Types TRACTION SUBSTATIONS Overview TSS Types ASS Equipments TSS Equipments 33 kV Switchgear General Description Structure & Design of Panel Compartments Technical Specifications Operating Mechanism General Supervision & Maintenance Maintenance Schedule 110 .5.0 1.
No.12 22.214.171.124.6.6.125 126 .6.138 139 – 139 139 – 139 140 – 140 140 .11 126.96.36.199 2. Transformer Transformer Protection Connections Parallel Operation Ground Connection Tap Connection Cable Connection Bus Connection Pre-Operation Checks Operation of Transformer Maintenance Schedule 125 .6.5 2.133 134 .7 2.15 2.138 138 – 138 138 . Transformer Auxiliary Transformer (2000 kVA) Technical Specifications of 2000 kVA Aux.9 2.6.129 130 – 132 133 .141 141 .141 142 .6.14 2.4 2.6.6 2. 2.6.16 Dry Type Transformer Auxiliary Transformer (200 kVA) Technical Specifications of 200 kVA Aux. BANGALORE METRO RAIL CORPORATIOn limited Sl.13 2.10 2.144 OPERATION & MAINTENANCE MANUAL Page 08 .6.128 129 .6 2.6.1 2.3 2.8 2. Transformer Auxiliary Transformer (500 kVA) Technical Specifications of 500 kVA Aux.136 136 – 137 137 . Description of Content Page No.6.
11 1.12 1.178 179 .2 1.0 2.5 1.160 161 – 164 165 .IV 1.8 1.3 1.No.7 1.2 THIRD RAIL Installation of Brackets Installation of Insulators Installation of Conductor Rails Installation of Splice Assemblies Installation of Expansion Joints Installation of Anchor Blocks Installation of Cover Fasteners (Clips) Installation of Ramps Installation of connector plates.179 180 . CHAPTER .13 2. Power Feeds Installation of Insulted Joint Assemblies Installation of UPVC.10 1.166 167 – 170 171 .155 156 .9 1.186 OPERATION & MAINTENANCE MANUAL Page 09 . Description of Content Page No.6 1.1 1.147 148 .149 150 – 153 154 .and GRP Protective Covers Installation of UPVC.and GRP Insulator Covers Structure Dimensions Control Maintenance Troubleshooting 146 . 1.172 173 – 174 175 – 176 177 – 177 178 .4 1.0. BANGALORE METRO RAIL CORPORATIOn limited Sl.
1.5 1.6 SCADA Basic Operation Control of Objects Limit Supervision Control System Maintenance Schedule of RTU Glossary & Abbreviation 188 .3 1.201 202 .201 201 .1 1. BANGALORE METRO RAIL CORPORATIOn limited Sl.2 1.V 1. CHAPTER .4 1.194 195 – 198 199 – 199 200 .No. Description of Content Page No.203 OPERATION & MAINTENANCE MANUAL Page 010 .
I OPERATION & MAINTENANCE MANUAL Page 011 . BANGALORE METRO RAIL CORPORATIOn limited CHAPTER .
of approximately 18.2 Fig.1: Schematic representation of Phase-I of Bangalore Metro OPERATION & MAINTENANCE MANUAL Page 012 .1 1. BANGALORE METRO RAIL CORPORATIOn limited General Overview Introduction Bangalore Metro Rail -.83 km length with 23 stations. out of which 3 are underground stations.1.West (E-W) Corridor. out of which 5 are underground stations and the North-South (N-S) Corridor of approximately 23. The network map of the Phase-I of Bangalore MRTS is shown in Figure 1.1. purely for operational purposes.Phase 1 comprises of two corridors.1 1.1 1. Two corridors are inter-connected for interchange of train rakes at Majestic underground Station. 1.1 km length with 17 stations . The mode of traction is 750V dc Third Rail.0 1. the East.
BANGALORE METRO RAIL CORPORATIOn limited
The details of station names in respective corridors of BMRCL Phase-I network are shown in Table 1.1 below. Table 1.1: Stations’ details
SN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Station Name Mysore Road Terminal Deepanjali Nagar Attiguppe Vijayanagar Hosahalli Magadi Road City Railway Station Kempegowda
East - West Corridor
Sir M Visveshwaraya Vidhan Soudha Cubbon Park Mahatma Gandhi Road Trinity Circle Halasuru Indiranagar Swami Vivekananda Road Baiyappanahalli
OPERATION & MAINTENANCE MANUAL
BANGALORE METRO RAIL CORPORATIOn limited
SN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Station Name Nagasandra Dasarahalli Jalahalli Peenya Industry Peenya Yeshwantpur Industry Yeshwantpur Sandal Soap Factory Mahalakshmi Rajaji Nagar Kuvempu Road
North - South Corridor
Srirampura Sampige Road Chickpete Krishna Rajendra Market National College Lalbagh South End Circle Jayanagar Rashtreeya Vidyalaya Road Banashankari Jaya Prakash Nagar Puttenahalli
OPERATION & MAINTENANCE MANUAL
BANGALORE METRO RAIL CORPORATIOn limited
66 KV Network KPTCL is the nodal agency for the supply of power for different utilities. Four RSSs are envisaged for receipt of power from KPTCL for further distribution to Traction and Auxiliary networks of Metro corridor. Corridor RSS Locations Feeding Substation Grid No. Of Incoming Feeders (1 x 66 kV Feeder)
Baiyappanahalli RSS EASTWEST CORRIDOR Mysore Road RSS
HAL 220/66kV Substation
Hoody 400/220/66kV (1 x 66 kV Feeder) Substation Vrishbhavathi Valley (1 x 66 kV Feeder) 220/66kV substation REMCO (220/66 kV) substation (1 x 66 kV Feeder)
Peenya (SRS) 400/220/66 (2 x 66 kV Feeder) kV substation Khoday substation 220/66kV (2 x 66 kV Feeder)
RSS Configuration The incoming power supply is at 66 KV level. Each RSS will have feed from two different feeders. Each feeder will consist of one circuit (1 C x 630 Sq. mm Aluminium). The RSS at Baiyappanahalli, Peenya and Puttenhalli are AIS type. Whereas, the 66 KV switchgear at Mysore Road RSS is GIS type. Each RSS will consist of two transformer bays, of which one would be a hot stand-by. The transformer will convert the 66 KV level voltages to 33 KV and feed to the Ring circuits. The power at 33 KV level will be distributed among the Auxiliary and Traction substations for Auxiliary and Traction loads. The electric traction supply system has to be continuous without any kind of interruption. Hence, maximum level of redundancy has been maintained. In this regard, one feeder – 66 kV has been kept as a hot stand-by, in case, one feeder fails, the other feeder can be brought into service to continue power supply.
OPERATION & MAINTENANCE MANUAL
BANGALORE METRO RAIL CORPORATIOn limited
Figure 1.2: Bulk Supply Arrangement
OPERATION & MAINTENANCE MANUAL
4. Power supply at 33kV is also distributed to Depot / Workshop (Baiyappanahalli and Peenya) for Traction and Auxiliary substations through two separate 33kV cable feeders from the respective RSS.2 1.4.4. Complete segregation of traction and auxiliary supplies at 33kV cable distribution network is maintained. These interconnections will make it possible to transfer power from one corridor network to another corridor network in emergency situations for both the traction and auxiliary loads. 1. it is by Open loop system. The 33kV power supply drawn from RSSs of each corridor is distributed along the alignment through 33kV Ring main cable network for feeding to traction and auxiliary loads.4.5 OPERATION & MAINTENANCE MANUAL Page 017 . Baiyappanahalli station (from Baiyappanahalli RSS).1 1. the 33kV distribution network of both corridors are available for interconnection through Circuit Throw Over (CTO) at Kempegowda Station (two level underground station with passenger interchange) through 33kV cables.3 1. by means of a 33kV ring main feeder network having 4 circuits in trefoil formation of size [3 x (1C x 240) Sq. Mysore Road station (from Mysore Road RSS) and Puttenhalli station (from Puttenhalli RSS).4. For provision of more flexibility of power supplies in emergency situations. BANGALORE METRO RAIL CORPORATIOn limited 33 kV Distribution Network The 66kV power supply received from KPTCL is stepped down to 33kV level at the four RSSs of BMRCL.4 1. 33 kV power supply for Traction Power is by closed loop and for Auxiliary power.4 1. mm Cu] – two each for 33kV Power Supply to Traction Substations (TSS) and Auxiliary Substations (ASS). Power supply at 33kV is distributed to various traction substations as well as auxiliary substations located in stations. The 33kV feeds from RSSs are fed to TSSs and ASSs at Peenya station (from Peenya RSS).
2 1. the two transformers of ASS for elevated / at-grade stations and two ASSs of underground station is receiving power supply from different sources. 2 x 2000 kVA dry type transformers is provided. each with 33 kV / 415 V. In normal scenario. which provides power to 33kV busbar.6.3 188.8.131.52.4 1. BANGALORE METRO RAIL CORPORATIOn limited Auxiliary Substations RSS are equipped with 2 x 200 kVA 33 kV/415 V Dry type Auxiliary Transformers for LT Supply.5. Each underground station is provided with two Auxiliary Substations ASS1 and ASS2. 2 x 500 kVA dry type transformers. at Kempegowda for rings from all the RSSs.6.6. Each elevated and at-grade station is provided with one Auxiliary Substation (ASS) having 33 kV / 415V. The depot TSSs (and ASSs) are fed from respective RSSs through 33kV ring main feeders from the two halves of the RSS 33kV busbar. Separate TSSs is provided for Depots and in the normal scenario the complete isolation of mainline and depot supplies can be achieved. In addition.1 Traction Substations 33 kV / 750 V dc Traction Substations (TSSs) is provided at stations along the corridor. Since one transformer is in hot standby and each receiving supply from different source.4 1.5 OPERATION & MAINTENANCE MANUAL Page 018 .6.e. The feeding to TSSs is with close ring systems – i. 1 x 2000 kVA dry type transformers.5 1. This arrangement of TSS feeding ensures that one ring main cable fault will not put any of the TSS out of service.6 1.5 1. from the respective RSS two 33kV feeders (one from each half of 33kV busbar in RSS) to feed alternate TSSs and the ring is closed at appropriate location. 1.g. another auxiliary substation having 2 x 500 kVA dry type transformers is provided for Operation Control Center in Byappanahalli Depot. e. every TSS has 2 switchgear feeders. auxiliary substation having 33 kV / 415 V.1 1. Each traction substation is receiving power at 33kV from the 33kV ring feeder.5. from where the rail cars will finally draw power for propulsion.6. The 750V dc is fed to the third rail system through high-speed circuit breaker (HSCBs) and disconnecting switches are incorporated for sectionalizing the third rail as per the operational requirements.2 1. 1.3 1. Rectifier transformer(s) are fed from this busbar. for loop-in-loop-out of 33kV ring main feeder. In each Depot. Normally. where the 33kV is transformed and rectified to 750V dc for feeding the Third Rail. either of ring cable fault or transformer fault will not impact the station supply.
7.3 The conductor rails are rated at a nominal resistance of max. 17% Chromium. X6Cr17. The conductor rail is symmetrical around the vertical centre line.007 Ω / km at a current of 4500 A. The inspection tracks inside the workshop are provided with individual stinger lines.7. 1.5 1.7. The power supply from the suspended rail to the vehicle is made via a current collecting trolley. The typical configuration of the conductor rail is – Aluminium: EN-AW 6101B & Stainless Steel: 1.7 1.7. 0. whereas the other depot tracks are equipped with regular conductor rail equipment. The power is provided to the vehicles by cables with special contacts simply known as stingers.7.7 OPERATION & MAINTENANCE MANUAL Page 019 . BANGALORE METRO RAIL CORPORATIOn limited Third Rail and Stinger System The Third rail system at 750 V DC is utilized for transferring power to the Rolling Stock. When not in use. Rail lengths are of 15m with pre-drilled holes for splice joints. This trolley. The third rail is made of an aluminium body designed for a nominal current of 4500A and a stainless steel contact path for current transfer to the collector shoes.7.1 1. the stingers down-end shall be attached to cable clamps in an upright position.4 1.6 1. The traction power is transferred via the vehicle collector shoes by contacting the surface of the contact rail from underneath. The web recess of the rail has facing tapered surfaces for the purpose of amplifying the compression load of the clamping bolts of connections on the current carrying surface of the connection. Components The Third Rail system consists basically of the following main components: a) Conductor Rail b) Splice Joint assembly for third rail c) Expansion Joint d) Anchor Assembly e) Insulated Joint assembly f) Power Feed Assembly g) Ramp h) Support Assembly i) Protective Cover system 1.2 1.4016. running on the I-profiled conductor rail is provided with an adequate cable with a special plug. The third rail system as used for traction power supply along the electrified tracks is replaced in train inspection tracks inside the workshop by ceiling conductor rails.7.
Short Circuit Level: . 1. TSSs are designed for 35 kA and the ASS for 17. 1. BANGALORE METRO RAIL CORPORATIOn limited Earthing.As per IEEE 80-2000. the short term rating of most of the equipment is based on 1. 1.3 Earth mat for each receiving substations are installed individually. These IRJs are placed in-between the main line and the depot line to isolate them from each other by a length more than a full train length with six cars. The earth mat is installed as per the site conditions and ensures a low over all resistance (not more than 0.1 1. 1 second has been adopted as the duration of fault in the calculations to determine the size of conductor for the earth mat.8. The running rails of Depots are electrically separated from mainlines through Insulated Rail Joints (IRJ). The Grid Earth resistance has been taken as follows: Sl. No. The following parameters have been taken into account for earth mat. Running rails are insulated from the structure to comply with the requirements of EN 50122-2. Bonding and Stray Current Management The earth mat design and installation conforms to IEEE 80-2000.0 1.0 second duration of fault. For depots.5 1.8 1.8 OPERATION & MAINTENANCE MANUAL Page 020 .4 1.5 ohms) and a current carrying capacity consistent with the fault current magnitude. 3. Duration of Fault Current: . for the safety reasons of workmen.The short circuit current for the Earth mesh design at RSS has been taken as 40 KA.8. the traction return system is earthed.0 1.8.8. 1.8.7 Location Receiving Substations Auxiliary Substations Traction Substations Grid Resistance (Ohms) 0. 184.108.40.206 1.6 To address the stray current corrosion problem associated with the dc traction system. Therefore.8. however. the traction return circuit (running rails) is floating with respect to the earth on the mainlines.5 kA.2 a) Magnitude of fault current b) Duration of fault c) Soil resistivity d) Resistively of surface material e) Earthing mat geometry f) Material of earth mat conductor g) Shock duration 1.
8.11 The station platform surface is insulated for a width of 2.. c) It energises or de-energises the different electrical sections of the traction network in case of demand of traffic operator or maintenance staff. OPERATION & MAINTENANCE MANUAL Page 021 .10 All the structure parts are connected to station earth mats and for this purpose Structure Earth Cable (200 mm2 copper). temporarily short circuiting the running rails to earth in case of rise of running rail potential exceeds prescribed limits as per EN 50122-1. g) It issues and cancels the blocks on individual equipments and system for maintenance. is provided all along the corridor for both UP and DN lines (one on each of the parapet).8.9. 1. linking all mainline earth mats. e) It operates the system in such a manner to arrange alternative feeds from the healthy system. BANGALORE METRO RAIL CORPORATIOn limited Short Circuiting Devices at each station (located in ASS-TSS room) are provided for safety reasons i. k) It provides analysis of normal operations as well as events to the management. 1. The Operational Control Centre (OCC) is situated in the Baiyappanahalli Depot. ETS & Power Supply Protection System The purpose of the SCADA system is remote monitoring and control from the Operational Control Centre (OCC) and Backup Control Centre for all the power supply installations of the Phase I of Bangalore Metro Rail Corporation. The Engineering Controller (ECO) is stationed at OCC.) j) It prints a pre-determined log of events and data.8. l) It provides simultaneous maximum demand of all the 4 RSSs for revenue billing.9 1.. The Backup Control Centre is situated in the Peenya Depot.5 m from the edge of the platform.1 SCADA.2 a) It monitors the condition of the entire power supply network. b) It energises or de-energises the different electrical sections of the auxiliary network in case of demand. 1. h) It restores the entire system after attending to faults. which consists of both the corridors and the Depots.9 1. power energy .e. The ECO carries out the following main functions: 1. d) It segregates the faulty section in the event of a fault in auxiliary or traction network.9. f) It identifies and communicates the fault and faulty section to concerned maintenance staff. i) It monitors several electrical parameters (voltage.
which is a part of the SCADA System. is achieved through OFC network. 1. It monitors and logs the various voltages. it has an interface with signalling and the essential interlocking to prevent any train coming on directly or through a cross over leading to the affected third rail section where ETS is activated.9. The communication between OCC SCADA and the RTUs at the power installation ends viz. interlock and metering of the equipment.9.e. ASSs. It operates the vital components and works as the interface with the remote SCADA system. The SCADA also has the provision for plugging in a portable control console (laptop) with the RTU.5 1. power consumption and status of various equipments and provides automated control throughout the system at the OCC/BCC through the SCADA system. ETS consists of ETS stations (ETS Boxes) and the RTU. currents.9. protection control unit (PCU) i. RSSs. is achieved through integrating ETS with SCADA system. in case of emergency. Upon activation of ETS.3 For protection. maximum demand.9. Digital Protection Control System (DPCS) is installed on all switchgear panels. Further. TSSs and other location. An Emergency Trip System (ETS) is provided at the each end of the station platforms. BANGALORE METRO RAIL CORPORATIOn limited 1.9. cross passage in tunnels and in depots as per the requirement of NFPA 130. It can operate and monitor the status and alarm conditions of all equipments from this local control console.7 OPERATION & MAINTENANCE MANUAL Page 022 .4 1.6 1. Traction supply power-off. it proceeds through a pre-determined programme of operation of circuit breakers and relevant interrupters to de-energise the third rail sections. power factor.
1 2.1.1 Director (Operation and Maintenance) GM (Maintenance) DGM (Electrical) Manager (Traction) AM (SCADA) AM (Traction Line -1) AM (Traction Line -2) SSE/SE (SCADA) SSE/SE (Traction) SSE/SE (Traction) ASE/JE (SCADA) ASE/JE (Traction) ASE/JE (Traction) Maintainers (SCADA) Maintainers (Traction) Maintainers (Traction) Unskilled Unskilled Unskilled OPERATION & MAINTENANCE MANUAL Page 023 . BANGALORE METRO RAIL CORPORATIOn limited ORGANISATION OVERVIEW Organisation Chart The organizational chart of traction department is as follows: 2.0 2.
2. He is responsible for administration of the Electricity Rules in BMRCL. b) Inspection of the completed installations. In regard to electric traction installations. cadre controlling.2. traction as well as auxiliary substations.1. This includes all electrical high voltage installations in BMRCL including transmission lines.1. either personally or through his nominated representative in order to ensure compliance of all safety as well as statutory and subsidiary requirements.2 2. 2. f) Submission of annual report to Central Electricity Authority. The General Manager (Maintenance) also functions as Electrical Inspector to Government as defined in section 36(1) of Indian Electricity Act -1910.) and other hierarchy down below. feeder lines. in capacity to Electrical Inspector to the Government.1 2. c) Approval for energization of the installation.2.1. BANGALORE METRO RAIL CORPORATIOn limited Duties & Responsibilities GENERAL MANAGER (MAINTENANCE) General Manager (maintenance) is the head of maintenance related activities. He is overall responsible for all administrative as well as technical decisions.2. d) Statutory requirement of inspection of the installations periodically under rule 46 of the Indian Electricity Rules. establishment matters and also for the works to be executed by the department.) mainly performs the following activities: a) Approval of the layout and design of the substations.1 2. 33 KV network and 750 V dc systems.2 2. He will be assisted by DGM (Elect. GM (Maint. 750 V dc installations etc conforming to the Indian Electricity act and rules. e) Investigations of electrical accidents and taking remedial measures to prevent in future.3 OPERATION & MAINTENANCE MANUAL Page 024 . in respect of all high voltage electrical installations and equipment owned by Bangalore Metro Railway Corporation Limited (BMRCL).
4 2.2. Maintain liaison with the Power Supply Authorities in regard to tariff. promotions.2.2. safety and economic operation as well as scheduled/predictive maintenance of the traction system so as to maintain highest level of reliability and availability of the assets for regular operation of the trains.2. Arrange for standardization of stores as required including preparation of drawings.2.2. take prompt and energetic action to normalize the services at the earliest possible time and take up the enquiry to investigate the cause of the problem along with taking remedial measures to prevent the re-occurrence.2. however.8 2.11 2.14 OPERATION & MAINTENANCE MANUAL Page 025 .9 2. Co-ordinate effectively with officers of other departments in BMRCL in connection with the items of common interest.2.2.2.) for all the electrical maintenance related activities.2.6 2.1 2.10 2.2. Ensure timely initiation and procurement of stores required for proper operation and maintenance of Traction system. for the same. Development of vendors for stores supply Study and analyze the periodic statistical parameters and take measures to improve the same.2 Deal with all correspondence except those which involve policy matters and expression of opinion on behalf of BMRCL.2.2. His duties are to be assigned by GM (Elect.2. Initiation and effective technical scrutiny for items for inclusion in works.).7 2.2. Investigate the failures and take corrective measures to prevent in future.2.2 2.13 2. Monitor energy consumption. main duties will include the following: 2.12 2. Exercise administrative and technical control for efficient planning.2. training etc well in time. Keep close watch on day to day performance of traction system and initiate/implement preventive maintenance where ever required based on experience or otherwise.2.2.5 2.3 2. designing.2.2.) is answerable to GM (Maint. BANGALORE METRO RAIL CORPORATIOn limited DEPUTY GENERAL MANAGER (ELECTRICAL) Deputy General Manager (Electrical) designated as DGM (Elect. In case of breakdowns/accidents.220.127.116.11. close co-ordination with stores/finance department etc.program. continuity of supply and policy matters etc.2.2. 2.2. power factor and maximum demand at various installations on BMRCL and take appropriate measures for efficient utilization of electrical energy as well as to contain the energy cost. Plan the cadre requirements including recruitments. specifications etc.
16 2.2.2. efficiency.2.15 2.2. reliability and economy.17 OPERATION & MAINTENANCE MANUAL Page 026 .2. BANGALORE METRO RAIL CORPORATIOn limited Budgeting and control over expenditure on maintenance repair and staff costs. 2.2. Keep in touch with advance technical developments so as to identify for implementation on BMRCL for achieving further safety. Plan long term strategy in regard to maintenance/operation requirements.
3.10 2.3. in case the failures are attributable to design related or can be contained by way of adopting improved technology.6 2.2. tools/plants etc. d) To ensure compliance of the instructions issued by way of inspections and other directives 2.2. Monitor the progress and successful implementation of all the approved modifications and analysis of efficacy of such modifications. performance ratings.2.5 2.2. operation and maintenance schemes.2 18.104.22.168. BANGALORE METRO RAIL CORPORATIOn limited MANAGER (TRACTION) Manager (traction) is the officer who is direct in -charge of the traction distribution network system and responsible for all technical and organizational matters connected with the efficient maintenance and operation of power supply installations and SCADA system. Man power planning to ensure efficient and economical maintenance. Overall co-ordination with other departments to plan better utilization of the assets and planning of maintenance works including materializing the concept of integrated maintenance.1 2. His main duties are as follows: 2.2.3 2.8 2.9 22.214.171.124.7 2.3 2.2. Study of day to day technical and organizational problems related to operation/maintenance and initiate appropriate measures to deal with it. Analysis of failures and take remedial measures to control.11 Liaison with the power supply authorities in regard to the matters which can not be dealt at lower level Arrange adequate training of staff so as to adopt correct and effective maintenance and operational practices OPERATION & MAINTENANCE MANUAL Page 027 .3.4 General planning and supervision to ensure efficient and safe maintenance and operation of traction installations in accordance to the prescribed norms and schedules.2.3. He should be well acquainted with the technical details.2. at least one once in three months including test checks of stores. Inspections of his jurisdiction are as under: a) Detailed inspection of all the assets as per schedule b) Frequent surprise inspections including night inspections covering all the related installations c) General inspection of all the subordinate offices under his control.2.3.3. Monitor the performance of various equipment to assess their anticipated life and initiate timely proposals for their repair/replacement. Monitor and ensure availability of spare parts/ stores required for maintenance and initiation of procurement action well in advance.3. proposal to be moved accordingly to apprise higher authorities.2.
Close association for tests and trials in the area under his control and submission of reports Ensuring by surprise and periodical inspections that the provisions/ procedures laid down in general and subsidiary rules.126.96.36.199.14 2. BANGALORE METRO RAIL CORPORATIOn limited Careful preparation of budget for traction installations and control over expenditure Scrutiny and passing of traction power supply bills.17 OPERATION & MAINTENANCE MANUAL Page 028 . personal supervision of operations in the event of major failures affecting train operation or outage of essential equipment. departmental codes. Periodical meetings to review the performance and for enhanced co-ordination among traction maintenance staff. maximum demand readings and liaison with rolling stock section to keep these expenditures under effective control Special watch on the adequacy and alertness of the organization for dealing with failures and breakdowns.2.13 2. 2.12 2. study of the energy consumption .2. circulars and other orders are circulated down below at the earliest and are being implemented in true manner & sprit.3.16 2.3.15 188.8.131.52. manuals.3.
SCADA system and Third Rail system.2.9 2. Prompt implementation in true spirit the instructions received from time to time including those contained in inspection notes of superior officers and keeping record of the action taken against each of the item.1 Efficient and safe upkeep and operation of the traction system.2. In addition to assisting Manager (Traction) in discharging his duties. b) Frequent surprise inspections/checks of maintenance gangs at work including the working at night.11 a) Detailed scheduled. Inspections of assets/installations of his jurisdiction are as under: 2.10 2. Analysis of failure reports and statements generated through SCADA system and using the information for betterment.4. Monitoring of performance of various make of equipment for further follow up measures to improve the reliability and achieve economy.4 2.8 2.2. minimum once in three months inspection of all the assets including equipment in GSS.4.2.3 2.4.7 2.4. Personal and regular checking of breakdown organization to ensure that it is in good fettle condition to deal with all type of breakdowns & exigencies.4.2. OPERATION & MAINTENANCE MANUAL Page 029 .4. power supply installations and SCADA system under his control in accordance with the prescribed schedules including detailed planning of all maintenance work and also to ensure that proper maintenance records are maintained on the formats. Effective co-ordination with officers and staff of other departments in matters that warrant joint action and similar co-ordination with the officials of contiguous sections. Careful scrutiny of statistical and other periodical returns before submission to Manager (Traction) and taking appropriate corrective action.5 2.2 184.108.40.206 220.127.116.11.18.104.22.168. his main duties are as follows: 2. In-depth investigation of all the re-occurring type or major power supply interruptions & equipment failures and taking immediate remedial measures so as to prevent. TSS.4. Ensure that Traction Power controller (TPC) takes prompt and effective action to restore services in the event of power supply interruptions or other failures of the power supply distribution/control network affecting train services Close liaison with power supply authorities to ensure continuity of power supply. ASS.2.2.6 2. BANGALORE METRO RAIL CORPORATIOn limited ASSISTANT MANAGER (TRACTION) Assistant manager (Traction) is the immediate in-charge in the field for all the maintenance and operation activities so that those are followed timely in efficient and safe manner as per schedule as well as per requirement.
including their establishment/welfare matters. Skilled/Semi-skilled and helper staff. 2.4. d) Periodic inspection of sub-ordinate offices. OPERATION & MAINTENANCE MANUAL Page 030 . etc.2.12 Direct control and monitoring of performance of the sub-ordinate staff like SSE/SE (Traction). maintenance records covering all the installations at least once in six months. BANGALORE METRO RAIL CORPORATIOn limited c) Random checks of the procedures being followed for imposition of power blocks/shutdowns and also verify that the safety procedures are being adhered to strictly. including stores.
Disconnect power.1 SAFETY INFORMATION HEALTH AND SAFETY Fully comply with the legally recognized standards (IEC or local). Keep the instruction manual accessible to all personnel involved in installation. Pay special attention to the hazard notes in the instruction manual marked with this warning symbol. operation and maintenance. Make sure that the specified data are not exceeded under switchgear or switchboard operating conditions. BANGALORE METRO RAIL CORPORATIOn limited SAFETY 3. then earth and short circuit before proceeding with any work on this equipment. Always follow the instruction manual and respect the rules of good engineering practice! Hazardous voltage can cause electrical shocks and burns. The connection conditions of the local electrical utility and the applicable safety at work regulations.0 Safety First – Always! 3.1 3.1. Observe the relevant information in the instruction manual for all actions. OPERATION & MAINTENANCE MANUAL Page 031 .
commissioning. All relevant safety precautions should be strictly adhered to during installation. 3. always store this manual where it can be accessed easily. Note that some items described as CAUTION may lead to major results depending on the situation. important information that must be observed is described. Thoroughly understand the device. safety information and precautions before starting operation.4 OPERATION & MAINTENANCE MANUAL Page 032 . The user will determine the level of training required for the operatives in accordance with the work each will undertake. Even qualified persons must undergo periodic training. If operators are not familiar and/or confident with the equipment. ● Please read this instruction manual and enclosed documents before starting operation to ensure correct usage.1. testing and maintenance of the equipments.2 3. In any case. Only suitably authorized personnel should operate the equipments. Operation of the equipments will be in accordance with this manual.1. CAUTION: When a dangerous situation may occur if handling is mistaken leading to medium or minor injuries. PRECAUTIONS FOR SAFETY Items to be observed to prevent physical damage or property damage and to ensure safe use of the equipments are noted on the product and in this instruction manual. or physical damage. operation. BANGALORE METRO RAIL CORPORATIOn limited Voltages capable of causing death are used in the equipment. ! DANGER: When a dangerous situation may occur if handling is mistaken leading to fatal or major injuries. ● This manual is written on the premise that the user has an understanding of the operation & maintenance and inspection of the equipments must be done by a qualified person. taking particular account of the safety requirements. After reading.3 3.1. Personnel working near or with the equipments should be familiar with modern methods of resuscitation. ● The safety precautions are ranked as "DANGER" and "CAUTION" in this manual. this manual and any relevant user procedures should be reviewed.
maintenance and inspection of the products.1. inspection and repairs of the products. 3. and understands the possible dangers. a) The person has thoroughly read and understood the manuals. BANGALORE METRO RAIL CORPORATIOn limited Qualified refers to satisfying the following conditions.5 OPERATION & MAINTENANCE MANUAL Page 033 . e) He is in possession of a valid competency certificate issued by a nominated competent authority. c) The person has been trained on the maintenance. b) The person is well versed in the installation. d) The person has been trained on protective tools used to ensure safety. operation.
BANGALORE METRO RAIL CORPORATIOn limited CHAPTER – II OPERATION & MAINTENANCE MANUAL Page 034 .
Each RSS has two 66kV/33kV Power Transformers. The power from transformers is fed to 33kV main substation having 33kV switchgears for distributing power further to auxiliary and traction networks.2. Only one NGR is in operation during normal service. The substation is a single Bus system with the sectionlizer dividing the Bus into two sections. Baiyappanahalli. The system consists of 4 RSSs at east. Each section feeding 66/33. 66 kV substations are AIS.1 1. west. The RSS receives the power from the Grid Substation through two sets of cable feeders of 630 Sq.2. two outgoing 66kV transformer bays and one bus coupling bay. One feeder in each RSS location serves the system.6 OPERATION & MAINTENANCE MANUAL Page 035 .e.e. Peenya and Puttenhalli are Air Insulated Switchgear (AIS) type while the fourth i. During parallel operation of the power transformer the NGR is closed. three viz. The RSS has one indoor TSS (750 V dc) substation to cater to the Traction load of Depot area. mm Aluminium laid in ground in Trefoil formation. The 33 kV side neutral is connected to Earth through NGR to restrict the earth fault current to 1000 Amp.2 1. Out of these four RSSs. north and south areas.2. 20/25 MVA Power Transformer which caters to both Auxiliary & Traction loads. The power is provided at 66 kV level. During normal operation.4 1.1 RSS Scheme The Electrical energy is fed from Power Supply Authority grid at the nominated receiving sub stations. Transformers are provided with OLTC for regulating the secondary voltage. Mysore Road RSS is Gas Insulated Switchgear (GIS) type. 1.0 1. i.2.3 1. Each RSS has two incoming 66kV bays. whereas another feeder is kept as hot standby.2 1. the NGR is kept open. 1. Each feeder is capable of feeding the entire load of RSS and coupling switchgear is provided at the incoming level to facilitate the power transfer from one cable to the other. BANGALORE METRO RAIL CORPORATIOn limited RECEIVING SUBSTATIONS General RSS Types The Phase-I network of Bangalore Metro Rail has four Receiving Substations.2. with One Transformer in service & the other in hot standby. Two feeders are installed at each RSS with 100% redundancy for the system.5 1. while 33 kV is indoor metal clad switchgear.2.
three phase current transformer d) Two nos.3 Outgoing Section Each outgoing section consists of: a) One triple pole isolator b) One triple pole circuit breaker c) One current transformer in each of the three phases d) One lightning arrester in each of the three phases 22.214.171.124 Incoming Section Each incoming section consists of: a) One lightning arrester in each of the three phases b) One earthing isolator to earth in the incoming cable c) Two voltage transformer in each of the 3-phases d) One triple pole line isolator e) One triple pole incoming circuit breaker f) Two current transformer in each of the three phases g) One triple pole isolator 1.1 a) Two incoming sections b) One bus coupling section c) Two outgoing sections 1.3 1.3. three phase voltage transformers OPERATION & MAINTENANCE MANUAL Page 036 . BANGALORE METRO RAIL CORPORATIOn limited RSS Layout The 66 kV bays contain: 1.3.4 Coupling and Busbar Section The three phase busbar section consists of: a) One triple pole circuit breaker b) Two triple pole isolators c) Two nos.
e) Relay settings have been done as per the scheme. leading to undesired tripping.4. Similarly.3 1. Close HOIS-1 and HOCB-1 to charge the Power Transformer 1. 1.8 OPERATION & MAINTENANCE MANUAL Page 037 . Charge the 66 kV feeder cable one at a time from GSS end. Normally each 66 kV feeder feeds one section of the bus with the Bus coupler open.4.4. the 66 kV feeders have to be charged one at a time from the HAL/HOODY end.4.4 1. 1. HICB-2.1 1. HOCB-1 and HOCB-2 are open. c) DC supplies on protections are in service.6 1.4. close HOIS2 and HOCB-2 to charge the Power Transformer-2.2 Keep the Isolator HIIS-1 and HIIS-2 open. The two sections of the Bus charged from Feeder 1/ Feeder 2. Earth switch of HIES-1 and HIES-2 are open. In case of any fault in the service feeder. In case of Baiyappanahalli.4. 33 kV circuit breakers LBCB-1 and LBCB-2 are open and the Earthing isolator of these feeders are open.4. BANGALORE METRO RAIL CORPORATION LIMITED RSS Operation Logic Charging: Initial Charging: . Observe the voltage for any abnormality. it is essential that --a) Charging has been notified b) Busbars are meggered. Similarly. By closing the Bus coupler the two sections of the bus can be coupled. Also close circuit breakers HICB-1 and HICB-2 keeping HCCB open.5 1. or if it is desired to take one of the feeder for maintenance. For example.7 1.Before charging the substation.4. f) Interlocks have been checked and ready for charging. d) Necessary approvals have been obtained from statutory agencies. the Bus coupler can be closed for coupling of the two buses and one incoming feeder can feed the load of entire RSS. Ensure all the Circuit breakers HICB-1.4 1. In 66 kV switchyard. a Bus coupler is provided between two sections of bus to enhance selectivity and availability of power. Transformer should be charged one at a time preferably with time interval between charging of the other Transformer to avoid inrush current. Close Isolators HIIS-1 and HIIS-2.
11 Line Throw Over (LTO) A line throw over (LTO) is installed for the incoming 66kV feeders in control and monitoring panel.4.14 Inside each RSS.10 For 66 KV switchgear at RSSs.13 In the normal feeding scenario. one of the 66/33 kV power transformer feeds the line load while the other is in hot standby. both the transformers of another RSS of that line will cater to supply of the line. In case of a transformer fault or any other failure that causes no power at 33kV switchgear incoming bay.15 Then both busbar and the connected loads is fed by a healthy transformer bay. In case the energizing feeder is out of service. 1. the CTO gets activated again if the BTO is released in case of faulty or outage on a remaining transformer bay in that RSS. then the power will be switched-on by the BTO by automatic closing the JA07 (2 out-of-3 configuration). they will be operating in parallel and ―2-out-of-3‖ interlocking and BTO will be superseded. In this case (equivalent to outage of one RSS of a line). thus. 1. This transfer of power takes through an automatic device called Line Throw Over (LTO). the BTO at 33kV level is provided. JA07 and JA10 is applicable in the normal scenario. 1.4. then the related protection relay trips out (FA04 or FA05 and JA03 or JA10 for transformer bays).4.4.16 However.4.4. 1. The BTO will block the Circuit Throw Over (CTO) installed at Kempegowda TSS to avoid overload of a transformer on that RSS.4.12 Bus Throw Over (BTO) & Circuit Throw Over (CTO) 1.9 1. BANGALORE METRO RAIL CORPORATIOn limited Changeover: 1. 1.4. OPERATION & MAINTENANCE MANUAL Page 038 . there is a provision for transfer of power from one feeder cable to the other feeder in case of failure of power. the LTO automatically transfers from infected line to the healthy standby line within a certain setting time delay. Therefore ―2-out-of-3‖ interlocking among JA03.
d) Does not give false operation during normal load flow in bus bars.1 Line Differential Protection (Pilot Wire Protection 87C) The cable differential protection is the primary protection for the 66 kV incomer feeder cables. extremely inverse and long-time of the four inverse definite minimum time (IDMT) type characteristics. 1.2 High Voltage (66 kV) Protections Incomer Line Protection: 1.5.5. It gives hundred percent security up to 40 kA fault level.5. Bus Bar Protection: 1.2. very inverse. 1.2.5. c) Continuous supervision for CT secondary against any possibility of open circuit and if this occurs.4 Undervoltage Protection (27) The incomers are provided with undervoltage relay (27) to trip the circuit breakers in case of no voltage or low voltage.5.1 a) High voltage (incomer and busbar) protection b) Power transformer protection 1.5 Differential Protection (87B) It has the following features: a) Bus bar protection for each busbar has a main protection and check feature. BANGALORE METRO RAIL CORPORATION LIMITED 66 kV FEEDERS & RSS PROTECTIONS The various protections for RSSs are divided into the following: 1.5.2. b) Each bus bar protection scheme operates selectively for each bus bar. renders the relevant zone of protection inoperative and initiates an alarm.126.96.36.199 1. OPERATION & MAINTENANCE MANUAL Page 039 . 50N/51N) Over current tripping operates with selectable characteristics such as definite time inverse. 1.3 Backup Overcurrent Protection (50/51. The current and time setting are variable continuously over the range.2 Backup Distance Protection (21) The distance protection has characteristics that gives load encroachment discrimination and load current compensation of the reactance line in the first zone to avoid over reach.
BANGALORE METRO RAIL CORPORATION LIMITED e) Provides independent zones of protection.C. supplies supervision. j) LED for relay serviceability. f) Includes individual high speed electrically reset tripping relays for each feeder. OPERATION & MAINTENANCE MANUAL Page 040 . g) Transient free in operation. i) Does not cause tripping for the differential current below the load current of heaviest loaded feeder. h) Includes continuous D.
High winding temperatures gives tripping orders above the permissible limit.3 1.1 The power transformer is provided with various main protections.5. a) Differential protection (87T) b) Restricted earth fault protection (64R) c) Standby earth fault protection (51NS) d) Backup O/C protection e) Transformer Tank Protection 1. Activation of these protections will also lead to tripping of circuit breakers.188.8.131.52. which sound an alarm when the oil level drops below permissible limits.3. BANGALORE METRO RAIL CORPORATION LIMITED Transformer Protection 1.3. An automatic device will sound an alarm at failure of the cooling medium.3 Buchholz Alarm & Trip (80) The relay is sensitive to all types of faults inside the transformer tank which produce gas bubbles. 1. These protections include: 1.5.5 Thermal Protection Relays (49 OT & 49 WT) The protection includes detector coils embedded in the transformer cover to indicate oil (49 OT) and winding temperature (49 WT) at the control board.6 Protection against low oil level The transformers are equipped with devices.5. OPERATION & MAINTENANCE MANUAL Page 041 .5.4 Over Temperature Relay (26) The transformer is equipped with thermal image and dial thermometer with contacts that sound an alarm at excessive temperatures. The relay will be of the Buchholz type or the rate of pressure rise type. and gives tripping orders above the permissible temperatures.3. 1.3. certain other protections also exist in the system.2 Apart from the above main protections.5. 1.
BANGALORE METRO RAIL CORPORATION LIMITED Metering at 66 kV Level: The following metering arrangements are provided on the incoming feeders from KPTCL: 1. power factor.1 a) Ammeters (to read the value of current in each phase of each of the incoming feeders) b) Voltmeter (to read the value of line voltages R-Y.6 1.2 The energy meter is trivector type having Availability Based Tariff (ABT) feature and data ports. Reactive energy (kVARh). OPERATION & MAINTENANCE MANUAL Page 042 . 1.6. Y-B. B-R. to enable measurement of Active energy (kWh).6. apparent energy (kVAh). in each of the incoming feeders) c) Energy meter (Electronic energy meter. The meter has recording and memory facilities. phase angle. frequency. instantaneous maximum demand. integrated maximum demand etc.
0 i. vii. vi. iv. ii. 66/33 kV Power Transformer 66 kV SF6 Circuit Breaker 66 kV Isolator 66 kV Current Transformers 66 kV Potential Transformers Lightning Arrestors Neutral Grounding Resistor The Guaranteed Technical Parameters of the individual RSS equipments. iii. BANGALORE METRO RAIL CORPORATION LIMITED RSS EQUIPMENTS The Receiving Sub-Station includes the following equipments: 2. v. their operation mechanisms and maintenance schedules for Bangalore Metro Rail – Phase I Corridor are provided below: OPERATION & MAINTENANCE MANUAL Page 043 .
1 : 66/33 KV Power Transformer Technical Parameters SN A 1 2 3 4 5 B 1 2 3 4 5 6 7 8 9 10 11 12 Description GENERAL Manufacturer Place of manufacture Port of embarkation Manufacturer drawing reference Standards ELECTRICAL CHARACTERISTICS Type Coupling Rated frequency Rated secondary power Cooling mode Primary rated insulation voltage Primary operating voltage Rated short duration power frequency withstand voltage for primary winding Rated lightning impulse withstand voltage for primary winding Primary line ends Secondary rated insulation voltage Secondary rated operation voltage under load kV kV 36 33 kV kV kV rms Hz MVA Outdoor Dyn5 50 20/25 ONAN/ONAF 72.1. India Vadodara.5 66 140 ABB Ltd. India 1LIN600100 –ACU 1EC 60076 Unit Values kV peak 325 OPERATION & MAINTENANCE MANUAL Page 044 .1 below: 2.1 Technical Specifications Table 2. Vadodara.1.1 2. BANGALORE METRO RAIL CORPORATION LIMITED 66/33 KV POWER TRANSFORMER The Technical Parameters are provided in Table 2.1.
20 a.15% Tol.28 (Approx) kA(rms) 3.16 (Approx) kA(rms) 3.) V V 6.) 12.15% Tol. power factor Unit kV Values 70 14 15 16 a. b.54 (Approx) 56.) 11. BANGALORE METRO RAIL CORPORATION LIMITED SN 13 Description Rated short duration power frequency withstand voltage for secondary winding Rated lightning impulse withstand voltage for secondary winding Iron losses Short-circuit voltage On load tap changer on tap 1 On load tap changer on median tap On load tap changer on highest tap Voltage drop at secondary winding Rated secondary load (ONAN mode) Rated secondary load (ONAF mode) Copper losses 4/4 of secondary load (ONAN mode) 4/4 of secondary load (ONAF mode) Short circuit current at secondary On load tap changer on tap 1 On load tap changer on normal tap On load tap changer on tap 16 Transformation ratio On load tap changer on tap 16 On load tap changer on normal tap (tap 8) On load tap changer on tap 1 Power at primary winding 4/4 of secondary load.) at normal tap kA 3.1/33 66/33 72.5% (+/.6/33 25 MVA OPERATION & MAINTENANCE MANUAL Page 045 .8 pf (Approx) 8. c. 19 a. b.29 % at 0. c. b. 21 kV kW 170 18 (Max) % % % 13% (+/. 17 a.8 pf (Approx) kW kW 64 kW (Approx) at normal tap 100 kW (Max. 18 a.55 % at 0. b. c. b.5% (IEC Tol.
Temperature rise at thermal stabilization at secondary at 4/4 load For copper For magnetic sheets For oil CONSTRUCTION CHARACTERISTICS Winding type On load tap changer type Rating Number of taps Voltage corresponding to each tap Cooling system Number and type of fans Rated voltage AC Fan rotating speed Power per fan Fan starting current Total power drawn by cooling equipment V rpm kW A kW Continuous Disc High speed resistor type 123 kV.5 kW (Max) °C °C °C 55 55 50 OPERATION & MAINTENANCE MANUAL Page 046 . c. b. C 1 2 a. 3 ph.24 (Approx) As per fan manufacturer‘s standard practice 1. b. d. Axial flow type 415 V. power factor 0. b. 50 Hz. 4 wire 700 0.506 % 25 a. c.) at 25 MVA Base seconds 1 % 99.5 (IEC Tol. f. e. 250 A 16 1100 V ONAF (Oil Natural Air Forced) 6 main + 2 standby. c. 3 a. BANGALORE METRO RAIL CORPORATION LIMITED SN Description 0.95 % 12.95 Unit Values 22 23 24 Impedance voltage Duration of admissible short-circuit Efficiency (not accounting for the power drawn by the secondary) 4/4 of secondary load.
h. BANGALORE METRO RAIL CORPORATION LIMITED SN g. Description Air output per fan Total air necessary Unit m3/h m3/h Values 7900 (Approx) 47400 (Approx) D 1 2 DIMENSIONAL CHARACTERISTICS Transformer Overall dimension in cubicle -Length -Width -Height mm mm mm 6800 (Approx) 4850 (Approx) 5700 (Approx) 3 Weight -of transformer in operating condition -of oil -de tanked weight kg kg kg 555000 (Approx) 12600 (Approx) 31300 (Approx) 4 Rolling tracks (between inner faces of the rails) spacing -large axis -small axis m m 1.676 5 Preserver Dimensions -Oil weight -Installation height kg mm 800 (Approx) 4500 from rail level (Approx) 6 Main parcel OPERATION & MAINTENANCE MANUAL Page 047 .676 1.
i. under hooks height required for travelling crane to enable handling -Complete transformer Mm Lifting of completely assembled transformer is not applicable for power transformers.ACU E 1 2 NOISE LEVEL Transformer alone (per testing mode stipulated in IEC standards) Overall noise level -at rated voltage and no load -at 110% of rated voltage and no load -at maximum over-induction dBA dBA dBA 70 78 78 dBA 70 F 1 MISCELLANEOUS INFORMATION Thermal time constant -of oil -of transformer h h A peak 3-4 Hours 10-20 minutes 1. BANGALORE METRO RAIL CORPORATION LIMITED SN 7 Description Dimensions : -Length/Width/Height weight -with oil -with inert gas Unit Values mm 6000/2400/3900 (Approx) kg kg 47000 (Approx) 37500 (Approx) 8 Handling. 5200 (Approx) 9 Overall dimension drawing number 1LIN600100 .2 A (Approx) from HV side 2 Maximum value of energizing current OPERATION & MAINTENANCE MANUAL Page 048 .e.
5 (Approx +ve sequence impedance) -as seen from secondary terminals 4 Value of zero sequence impedance -as seen from primary terminals 80 % to 105 % of +ve sequence impedance (Approx) 80 % to 105 % of +ve sequence impedance (Approx) IP 55 -as seen from secondary terminals 5 Degree of protection for auxiliary circuit OPERATION & MAINTENANCE MANUAL Page 049 . BANGALORE METRO RAIL CORPORATION LIMITED SN Description at no load Unit Values 3 Value of direct and reverse impedance -as seen from primary terminals 37.72 (Approx +ve sequence impedance) 5.
OPERATION & MAINTENANCE MANUAL Page 050 . If the transformer has been stored more than two months after the assembly. d) The transformer. all sealing joints must be retightened. j) The covers have to be installed on the test taps and/or potential taps (if no potential device is connected) of the bushings to assure proper grounding of the taps.3 Energization Procedure: Prior to energization.1. l) All protective and alarm circuits have to be operational and placed into service before the transformer is energized. the transformer should be visually inspected and the following items should be checked and executed: Preparation for Energization a) The oil should be filled up to the indicated level in the oil filled compartments. Operation & Maintenance 2. 1LIN460022-STD) Title: Power Transformers – Manual for Erection.1. the control cabinet and all accessories are cleaned and touch up painted if needed.2 Operation of Transformer The Transformer has to be installed. Commissioning. n) The cooling controls should be set for automatic operation. f) The gas-operated relay must be purged of air. (Refer Manufacturer’s Manual – ABB Document No. commissioned and put into operation as per the instructions and guidelines given in the Manual. i) It should be checked that the clearances between phases and phase to earth is as specified. k) All temporary protective grounds must be removed from conductors. o) The control selector-switch for the on-load tap changer in the control cabinet must be set on REMOTE position. h) The connections to lines. m) It should be confirmed that there are no current transformer secondary open circuits. e) The heating element in the control cabinet must be connected and in operation. BANGALORE METRO RAIL CORPORATION LIMITED 2. b) The drying agent should be blue and the oil level in the dehydrating breather should be as per the indication. bus-bars and earth should be properly made. g) Any possible leakage should be checked. c) All valves must be set at the right position.
2. the transformer has to be kept under careful observation for the first 12 hours.2 184.108.40.206 2.1.5 2. The observation should continue on a daily schedule for seven days and then weekly for the first month of operation. d) The Ambient Temperature 2.4.4. OPERATION & MAINTENANCE MANUAL Page 051 .1.1.7 When the transformer is successively loaded. The following should be checked and monitored for 12 Hours: a) Oil Temperature.3 2. b) The Winding Temperature. the transformer may be connected directly to a live transmission line at no load. c) The Tank Pressure.4. all sealing joints have to be retightened. When the transformer has been in service at normal working temperatures.1. If it is not possible to use a generator.4.1 2.4.4 The transformer should be energized in such a way that the voltage is increased step by step up to the rated voltage.1.4. especially the temperature gauges and the gas relay. The transformer is now ready for service upon the successful conclusion of the tests and completion of the set time.1.1. the transformer has to be observed for a few hours. BANGALORE METRO RAIL CORPORATION LIMITED p) OLTC operation is ensured prior to energization of Transformer and the tap position to be normal.4 Energization 2. After energizing.
1 General In order to avoid faults and disturbances. insects. On alarm.5. and when required cleaned from dust.5. Possible rust should be removed and the surface treatment restored to original state by means of the primer and finish-paints that are dispatched with the transformer. a certain setting may appear in sealing joints.1.5. The indicator has alarm contacts for low and high. it is important that a careful and regular supervision and control of the transformer and its components is planned and carried out.1.5 Oil-level Indicator for Oil Conservator The oil conservator is provided with an oil-level indicator.1.5. 2.4 Rust Damages.1. the cause will be established and measures should be taken to reach the correct oil level. environment and service conditions etc.1. a more or less complete chemical analysis of the oil is recommended. BANGALORE METRO RAIL CORPORATION LIMITED 2.8 There are two types of Tests: OPERATION & MAINTENANCE MANUAL Page 052 .1.5. The correct oil-filling level is specified on an information plate.6 Gas in Oil Analysis Regular gas in oil analysis is recommended.5. 2.1. They should therefore be retightened after the transformer has been in operation for about a month and thereupon when needed. Note: Spare transformers are supervised and maintained according to the same schedule as transformers in service.5 General Supervision & Maintenance 2.3 Possible Oil Leakage After energizing.1. 2. The frequency and extent of such a supervision and control depends on climate. 2. 2. As a guiding value gas in oil analysis once a year is recommended. Touch-up Painting A regular inspection of the external surface treatment of the transformer should be carried out. 2. This applies especially to sealing joints with plain gaskets that are not placed in grooves. 2.1.2 Dirt and Dust The external transformer surfaces should be inspected regularly.5. leaves and other airborne dirt.5.7 Oil Analysis In addition to gas in oil analysis.
sludge and acid products develop. due to the aging processes. The moisture content and the dielectric withstands of the oil will be checked as part of the small and large test or whenever there is a suspicion that oil has been exposed to humidity.5. 2.11 Sludge. As a guiding value.15 mg potassium hydro oxide (KOH) per gram oil in inhibited oil. (alternatively larger than 0. Larger values on neutralization number or less inhibitor content than stated here will accelerate the ageing. The inhibitor works as an antioxidant (a preserving agent). 2. The inhibitor retards the ageing process and extends the utilization time of the oil.1%.12 When this occurs the oil will be analyzed and the neutralization number and the remaining inhibitor content will be determined.1.2 mg KOH/g in non-inhibited oil) and/or an inhibitor content less than 0.1 to 0. tan delta.1. The oil may also have been subjected to moist air.5.5.10 Moisture Some build-up of water content is inevitable. oil analysis should be done about once every year if not otherwise necessary depending on the outcome of other tests. The oil should be replaced or regenerated.9 These tests are in addition to the conventional gas in oil analysis. depending on the situation − Interfacial tension − PCB Content 2. BANGALORE METRO RAIL CORPORATION LIMITED a) The small test covers:− Color − Visual inspection − Moisture content − Dielectric breakdown withstand − Neutralization number b) The large test covers four more tests in addition to the above: − Inhibitor content established (GC-method) − Power factor. 2. if the neutralization number is larger than 0. Acid The transformers and reactors are filled with inhibited oil. OPERATION & MAINTENANCE MANUAL Page 053 . Such tests are recommended when gas in oil analysis has given indication of non-conformance of the transformer.5.1.1. When the oil is aging.
2. A separate current transformer in the winding circuit will provide the current. The measured oil temperature is "adjusted" by a temperature increase corresponding to the temperature difference between the oil and the winding conductor.5. However. 2.5.14 2. The winding absolute temperature has to be considered together with permissible current loading of accessories like bushings and tap-changer. In inhibited oil where only the inhibitor content has decreased the addition of new inhibitor is a possible option. the permissible overload must not be judged only with regard to the oil temperature. because old oil will infect the new one and thus speed up the ageing process. the thermometers should be checked first. However.15 Overload The transformer can normally be overloaded at low ambient temperatures.17 This temperature increase is obtained by a heating element carrying a current proportional to the winding current.13 2. The heating element and the shunt element may be located in the display instrument or at the sensor body in the thermometer pocket. cooling system functions etc. there may be a reduction of the ability of the cooling equipment due to dirt and dust.5.1. The calibration is normally based on the outcome of a heat run test. The exchange should preferably be carried out when the oil is warm and the oil viscosity is low. If the temperature in a transformer shows a tendency to rise without a corresponding increase of the load.1. 2.5.16 Winding Temperature Indicator The thermometer system has a sensor. BANGALORE METRO RAIL CORPORATION LIMITED The exchange of oil should be as complete as possible.1. The temperatures should be read regularly and the measured values registered.1.5.1. temperature signal transmission and display system similar to the oil thermometer. An adjustable shunt resistor in the current transformer heating element circuit facilitates the calibration of the thermometer to display a correct winding temperature. Temperature Supervision It is important to keep the oil and winding temperatures under continuous observation. These values will give guidance for judging of the service life of the transformer. OPERATION & MAINTENANCE MANUAL Page 054 .
Check whether there is any leakage of oil. 7 Monthly Maintenance 8 9 Checking of oil level in OLTC Conservator Checking condition of Silica gel in breather and re-condition if required Check electrical connections for its tightness if found loose tightened the same.1. No 1 2 3 4 5 6 Power Transformer M/s ABB Limited 66/33 KV Check List Checking of bushing oil level Checking of oil level in Conservator Cleaning of all Bushings with dry clothes. 12 13 14 15 Cleaning of Marshalling boxes. 10 11 Checking/Topping up of oil level in oil seal of breather Record maximum oil & winding temperature in a register. If required rectify. Check Pressure relief device for any damage. Check oil level in conservator tank. BANGALORE METRO RAIL CORPORATION LIMITED Maintenance Schedule Table 2.6 Equipment Make: System Voltage Schedule Sl. Cleaning of transformer and its other accessories. Tightening of terminals. OPERATION & MAINTENANCE MANUAL Page 055 .1.2: Maintenance Schedule 2. if it is below 1/4 level oil should be topped up. External cleaning of Radiators and other parts of transformer.
Check of current carrying contacts preferably by a thermo vision camera while the transformer is in service.5KV/5. 9 10 Check and measure tap changer motor winding resistance. by 2.Megger 5 Half-Yearly Maintenance 6 7 8 Check all alarms and trip circuits for proper functioning such as buchholz relay. LV + E =400 M ohms. Oil sample should be taken during day time in good weather..0KV .. 1 2 3 4 All checks from monthly schedules Checking of oil level in WTI and OTI pockets Check operation of tap changer. HV + LV = 2500 M ohms. BANGALORE METRO RAIL CORPORATION LIMITED 16 17 18 19 20 21 22 Checking of contactors. Check name and danger board Check for gas collection in Buchholz relay Clean tap changer box and tighten all electrical connections. HV + E=2000 M ohms. Measure and record insulation resistance of all windings to earth & primary winding to secondary. Test oil sample from tank bottom for crackle test. Check all the cable entry for the protection equipments are properly sealed. Check all SCADA signals. Measure IR value of tank and WTI CT and winding continuity. Retighten them if required as per torque specified in the instruction manual OPERATION & MAINTENANCE MANUAL Page 056 . If BDV is less than 50 KV. OLTC surge relay etc. Check all earth connections of transformer and tank CT. oil should be filtered. illumination etc. Check if there is any abnormal sound from transformer while energized. pressure relief device. acidity and BDV. space heaters.
OPERATION & MAINTENANCE MANUAL Page 057 . Trip: 95 deg C Collect oil sample in dry and clean bottle for DGA analysis. OTI Alarm : 80 deg C. b) Always follow the instruction and Maintenance Manual of the manufacturer. Trip: 90 deg C. WTI Alarm : 85 deg C. it should be more than 1.3 Checking/Replacement of the gaskets of the terminal box Paint transformer wherever required. Calibration of OTI. e) All Drawings and Manufacture‘s Instruction & Maintenance manual will be ensured at site for reference during Maintenance. Check voltage ratio at different tap. d) Standard tools and accessories as per Instruction and Maintenance Manuals will be ensured for facilitating the normal maintenance activities on the Equipment. Maintenance of OLTC driving mechanism Calculate Polarization index . BANGALORE METRO RAIL CORPORATION LIMITED 1 2 3 All checks from half yearly maintenance schedules. Earth them at both ends before carrying out any maintenance work. Overhauling of transformer in every 10/12 years Yearly Maintenance 4 5 6 7 8 9 Remarks: a) Ensure that the equipment is disconnected from all electrical supply. c) All safety precautions will be taken during Maintenance. WTI meter.
operating mechanism and link system.2. When the arcing contacts separate.2. The pole beams as well as the attendant two column support are both hot-dip galvanised. 2. the requisite extinguishing pressure is built up in the Auto-Puffer section through heating from the arc.2.2 2. 2. 2.1.2 Breaking Principle 2.3 When the short-circuit current is interrupted. Each circuit breaker pole consists of three main components: a) A mechanism b) A hollow post insulator with insulating pull-rod c) A breaking unit that consists of a breaking chamber insulator with attendant flanges and adapter plates.1.1. The circuit breaker poles are linked using torsion rods.One Auto Puffer section and other a Compression section.2.2.1 2.1. 2.2.1 2. The interior of the breaking unit consists of a fixed upper and lower current path with integrated contact system and a moving puffer unit.4 On closing. the gas in the compression section flows out and extinguishes the arc at a current zero passage.1.2 When the normal rating current is interrupted the SF6 gas is compressed in the compression section to an overpressure. OPERATION & MAINTENANCE MANUAL Page 058 . d) The circuit breaker poles are mounted on a pole beam.2.2.2. the contacts engage and the puffer cylinder is refilled with gas. the puffer cylinder slides upwards. BANGALORE METRO RAIL CORPORATION LIMITED 66 KV CIRCUIT BREAKER General Description Structure The circuit breaker consists of three separate circuit-breaker poles.2.2.1 The breaking unit works as per Auto-puffer principle with a puffer cylinder that is divided into two chambers: -.1. The pressure increase is achieved with energy from the arc and no extra energy is required from the operating mechanism.
No.2. Description Unit Values 1 2 3 4 Name of the manufacturer Country of manufacture Relevant Specification Type Substation type ABB Ltd India IEC 62271-100 & IEC 62271-1 Outdoor AIS 3 Hz kV kV 50Hz 72.2.2/50 micro second) Rated current kV peak 10 325kVpeak 11 12 13 14 15 16 A 1250Amp 40kArms 100kApeak 40kArms 100kApeak SF6 Rated short circuit withstand current (1 sec) kA rms Rated peak withstand current Breaking capacity Making capacity Breaking mode kA Peak kA rms kA Peak OPERATION & MAINTENANCE MANUAL Page 059 .2. BANGALORE METRO RAIL CORPORATION LIMITED 2.1 below: Table 2.1: Technical Parameters of SF6 Circuit Breaker Sl.2 Technical Specifications The technical parameters of 66 kV SF6 Circuit Breaker is provided in Table 2.5kVrms 66kVrms 140kVrms for 1 min 5 6 7 8 9 Phase numbers Rated frequency Rated insulation voltage Rated operating voltage Rated short circuit duration power frequency kV rms withstand voltage Rated lightning Impulse withstand (1.
5) a. 75ms d. d.No. 17 18 19 Rated operating cycle Rated auxiliary voltage Operating time from actuation to extinguishing of primary arc Rated transient recovery voltage (first pole to clear factor 1.0ms 7 bar (abs) at 20ºC 22 Rated SF6 pressure for operation OPERATION & MAINTENANCE MANUAL Page 060 . Opening actuation from current emission on the release coil up to Separation of contacts (opening time) b.At closing ms ms MPa ms ms kV s s V dc ms CO-15‖-CO 110VDC 65ms 20 1.At opening . c. Extinguishing of primary arc (breaking time ms at rated breaking capacity) Closing actuation from current emission on ms the engagement coil up to Establishment of current (establishment time) Start of connecting (closing time) Maximum operating difference between poles . BANGALORE METRO RAIL CORPORATION LIMITED Description Unit Values Sl. b. Test duty Transient recovery voltage peak value Time Time delay Operating times a.5 (first pole to clear factor) T10 272 39 6 21 50ms 65ms c.33ms 5. 75ms 3. e.
23 24 25 26 Rated SF6 pressure for breaking SF6 under-pressure first threshold alarm SF6 under-pressure blocking Operating system rated pressure minimum pressure maximum pressure MPa MPa MPa 7 bar (abs) at 20ºC 6.0 bar (abs) NA (we have provided spring operated mechanism) MPa % % 27 Operating and auxiliary cubicle protection degree Circuit breaker position auxiliary contact open position make contacts open position break contacts closed position make contacts closed position break contacts IP55 28 Will provide at the event of order during detail engineering OPERATION & MAINTENANCE MANUAL Page 061 . BANGALORE METRO RAIL CORPORATION LIMITED Description Unit Values Sl.2 bar (abs) at 20ºC Blocking provided at 6.No.
The tripping latch in the operating mechanism keeps the circuit breaker in closed position.3. BANGALORE METRO RAIL CORPORATION LIMITED 2. The circuit breakers comply with the requirements in the IEC 62271-100 standard and are restrike free when breaking capacitive load.2.1 below: 2. The transmission rod runs from the switching shaft of the operating mechanism to the mechanism of the circuit breaker pole and thereby transfers closing and opening travel to the circuit breaker.3 The circuit breaker is operated by a motor charged spring operating mechanism. The operating mechanism is connected to the circuit breaker poles‘ mechanism via a transmission rod and two torsion rods.5 2.2. When closing.4 220.127.116.11.1 2.2. the trip spring is charged which is also located in the operating mechanism. The detail labelling has been shown in Fig.2. only tripping of the tripping latch is required.3.6 OPERATION & MAINTENANCE MANUAL Page 062 . For opening. (Refer Manufacturer’s Manual – Title: SF 6 Circuit Breaker – Product Manual) 2.2 2.3 Operating Mechanism The Circuit Breaker has to be installed. The circuit breaker is closed using an operating mechanism that contains a closing spring.2.2. commissioned and put into operation as per the instructions and guidelines given in the Manual. 18.104.22.168.
2. BANGALORE METRO RAIL CORPORATION LIMITED Fig.1: Circuit Breaker Components OPERATION & MAINTENANCE MANUAL Page 063 . 2.
d) The gas density is larger than the blocking level.4. A closing operation using the ―Close/Open‖ control switch or electric remote impulse can only be done if: a) The ―Local/Remote/Disconnected‖ switch is in the ―Local‖ or ―Remote‖ setting.4 Closing & Opening Operations 2. 2. operation can only be executed using the ―Close/Open‖ control switch. the closing latch is released from the main shaft and the closing spring trips.2.4. via the main shaft and worm gear.4.4 2. c) The operating mechanism‘s closing spring is fully charged when the operating cycle begins. and thereby opens the circuit breaker. In the ―Local‖ setting. b) The closing spring is charged. 2. An opening operation for a closed circuit-breaker can be done when the ―Local/Remote/Disconnected‖ switch is in the ―Local‖ setting mode and the ―Close/Open‖ control switch is set to open. at the same time as the trip spring in turn is charged and locked.2. c) The circuit-breaker is in open position.5 Auto-Reclosing Auto-reclosing.4. Remote/Local Operation For normal operation.2. The motor then charges the closing spring following each closing operation. the ―Local/Remote/Disconnected‖ switch is in the ―Remote‖ setting for electrical remote control.3 2.2.2. OPERATION & MAINTENANCE MANUAL Page 064 . the circuit is broken by the limit switch. This implies that the cam disc rotates via the closing lever. The ―Disconnected‖ setting is used for maintenance.5 a) The circuit breaker is closed. the tripping latch device releases from the switching shaft and the trip spring trips.4. BANGALORE METRO RAIL CORPORATION LIMITED 2.2. When the spring is then charged. The switching shaft is put in motion and the circuit breaker closes.1 Closing: When the signal indicates that the circuit breaker will close. ―Open-0. (Tripping and protection type activated) b) The ―Local/Remote/Disconnected‖ switch is in the ―Remote‖ setting.2.2 Opening: When the signal indicates that the circuit breaker will open.3 Sec-Close-Open‖ is possible if: 2.
If any part of the interior is badly rusted indicating entry of moisture. Check local position indicator and remote semaphore indicator for operation. Examine leading pipe connection for proper sealing Check for any SF-6 Gas Leakage Check if all pins and checkouts are in place Check all tie rod nuts for tightness. Clean the bushing.2: Maintenance Schedule Equipment Make: Schedule Sl. Re-grease the shaft. Checking of shock absorbers for leakage or stuck up – position F&G Check the door gaskets. Checking of CB for Rack In & Out Tightening of cable terminations. Check the electrical connections for tightness Checking of fasteners tightness. Operate the mechanism twice manually and electrically by Remote/Local keeping the control box door open and check for any abnormal noise. BANGALORE METRO RAIL CORPORATION LIMITED 2. replace if required. plug the hole and repainted the rusted parts. 2 3 4 5 6 7 8 9 Quarterly Maintenance 10 11 12 13 14 15 16 17 18 19 OPERATION & MAINTENANCE MANUAL Page 065 . Any damage cubicle surface either inside or outside should be treated with touch up paint or protected against rust with their layer of grease.2. Clean the Bushing of the pole and check for any crack and flash of bushings Checking of Earth switch operation & its event in SCADA check that good connection is made. find out the cause.6 Maintenance Schedule Table 2. Check the heater in functioning properly Check interlock of the equipment. No 1 66 kV SF6 CIRCUIT BREAKER M/s ABB LIMITED Check List Remove the accumulated dust by Vacuum Cleaner.
000 operations. It should be less than 15 sec. Coupling knife catch gap -gaps should be 12mm Bottom TFM & Cap gap . BANGALORE METRO RAIL CORPORATION LIMITED 20 Carry out the following electrical checks . Proper operation of the motor. Checking of Top & bottom trip free mechanism cap & coupling. 104(terminals) Measure contact resistance of CB. close time< 75 ms & CO time <100 ms of CB . <100 micro ohm Check open time <45 ms.5 bar abs. 102(terminals) Terminals for tripping coil: Measure Resistance between 103.Few closing & opening operations and check for correct indications.Proper operation of service limit switch after few racking movements of The breaker from `Test‘ to `Service‘ and vice versa . Check tripping of CB on DC failure. Spring charge time. All checks of half yearly to be done IR value of CB bushing to be measured By 5 KV megger >1000 M ohm Check all signals on SCADA Check gas pressure low. Overhaul and lubrication of charging device and operating device 21 1 2 3 4 5 6 7 8 9 10 Half-Yearly Maintenance 11 12 1 2 3 4 5 6 Yearly Maintenance OPERATION & MAINTENANCE MANUAL Page 066 . check trip of CB on over current protection Check tripping of CB on under voltage. auxiliary circuits . Overhauling of CB after every 10. Gas Pressure at 200 C should be 3.Proper functioning of interlocks Check for any foreign material inside a breaker All checks of quarterly maintenance.gaps should be 1-2 mm Spring cut off micro switches. Check the resistance value of Opening & Closing Coil Terminals for Closing coil: Measure Resistance between 101.
2. Contact pressure meter 12. BANGALORE METRO RAIL CORPORATION LIMITED 66 kV CURRENT TRANSFORMER 2.3.1 The detailed labeling and description of the Current Transformer is shown and provided below: Fig. Entrance secondary box 13.3. Eye bolts OPERATION & MAINTENANCE MANUAL Page 067 . Current terminal P2 4. Porcelain insulator 2. Secondary core 10. Primary circuit 9.1 General Description 2. Gas SF6 filling plug 11. Current terminal P1 22.214.171.124 2.1: Current Transformer Structural Design 1. Secondary terminals 8. Bottom support 7. Primary diverting device 6. Pressure relief device 14. Aluminium alloy coffer-dam 3.
3. giving insulation between live part and earth.m. Current terminals (3) and (4) for connection to the external circuit. Bottom support (6). connectable one to each other with a diverting device (5). contacts (11) and SF6 filling (10) Molecular tightness of the envelopes is individually checked by means of appropriate SF6 detector inside pressurized cells. BANGALORE METRO RAIL CORPORATION LIMITED Description a) An envelope made with: 2. A device having a pre-set breakage provides the CT with a protection against possible overpressure. inside the head of CT. high voltage insulation is fully obtained with SF6 gas. An aluminium alloy coffer-dam (2). it has incorporated the secondary terminals (7). as well as toroidal core. if any. furthermore the specific features of sulphur hexafluoride are such to give very small consequences of discharges. Cores and secondary windings are located on the top. The secondary circuit of the CT made with secondary winding around magnetic core and its vertical earthed connection to the terminals. housing the longitudinal part of the secondary winding. This design has several and remarkable advantages: The dielectric quality is neither depending on long and complex treatments nor on delicate checks during life-time of the equipment. the pressure meter with a. The toroidal magnetic cores. linked with toroidal zone of the secondary winding (9) and having its ends connected to current terminals (3) e (4). supporting the insulator. the secondary winding and the pressure relief device (13). Internal insulation can be continuously monitored by means of a pressure-gauge fitted with alarm and trip contacts in case of gas pressure decrease.1. housing the primary winding (8). made with one or more coils. b) The active part consisting of: The primary circuit (8). OPERATION & MAINTENANCE MANUAL Page 068 . made with grain oriented steel sheets.2 A shredded porcelain insulator (1). Probability of internal discharge is none as a consequence of an insulation coordination of gaseous dielectric medium.
p. SF6 rated pressure b.3.5 66 50 140 13 kV peak 325 14 SF6 400 kPa 330 kPa OPERATION & MAINTENANCE MANUAL Page 069 .2 Technical Specifications 2.2. SF6 minimum pressure MPa % kV kV Hz kV rms Lodi. Italy Genova.A Unita Operativa ADDA 2 3 4 5 6 7 8 9 10 11 12 Place of manufacture Port of embarkation Manufacturer drawing reference Standards Type Type of substation Number of phases Rated insulation voltage Operating voltage Rated frequency Rated short duration power frequency withstand voltage Rated lightning impulse withstand voltage Insulation medium a.1 The Guaranteed Technical parameters for 66 kV SF6 Current Transformers is provided in Table 2.3.1 below: Table 126.96.36.199: SF6 Current Transformer (66 kV) –Technical Parameters SN Description Unit Values 1 Manufacturer ABB PT S. Italy 2GJA300199 IEC 44-1 Outdoor Open 3 72. BANGALORE METRO RAIL CORPORATION LIMITED 2.
005) 3. No.3 Operation Parameters Pressure Schedule Sl.05 (0.5 (0.005) 5. BANGALORE METRO RAIL CORPORATION LIMITED Description c.35) 2.2 x 800 (1600) 180 kg per CT 780 mm x 1525 mm IP 55 2.3 ± 0.3 ± 0. SF6 maximum pressure Unit % Values 1050 kPa (Rupture Disk Pressure Release) 40 SN 15 Short-circuit current allowable for 1 seconds Permanent operation without danger Overheating Total weight Overall dimension of one element Degree of protection for auxiliary circuit kA 16 17 18 19 20 In In kg 800 or 1600 A 1. 1 2 3 4 5 Description Rated Pressure Pn or Filling Pressure Bar (MPa) 2nd Ceiling Lock Pressure Bar (MPa) 1st Ceiling Alarm Pressure Bar (MPa) SF 6 Weight Filling Pressure during Transportation TG 72 4 (0.05 (0.60) 5.01 – 0.1 – 0.02 MPa) OPERATION & MAINTENANCE MANUAL Page 070 .53 ± 0.55) 4 Kg 0.3.7 Kg 0.40) 3.5 (0.2 Bar (0.2 Bar (0.01 – 0.1 – 0.02 MPa) TG 145-170 6 (0.03 ± 0.
OPERATION & MAINTENANCE MANUAL Page 071 .3.8% . v) Open the valve (1) completely (the manometer A will show about 20 bar).0. up to the achieving of the rated pressure Pn on the manometer B. each 3 meters pipe-length and keep the pipe upwards. b) Sulphur Hexafluoride must be 99. iii) Allow the gas SF6 to come out under reduced pressure by the valve (2) .for 5 sec. iv) Quickly connect the pipe (4) with pipe fitting to the filling plug (6) on CT bottom and allow gas to come out. BANGALORE METRO RAIL CORPORATION LIMITED 2. consequently increase gradually the opening of the valve (2) by several steps of about 1 bar. c) Filling procedure must be followed according to Fig.2/0.3. ii) Open the valve (1) partially and the valve (3) completely.3 bar. vi) Read the pressure by manometer fitted on the base of CT and close valves (3) and (1) as soon as the rated pressure Pn is reached. 2.4 Filling procedure of CT with gas --SF6 a) Fill the CT with SF6 up to the rated pressure given on the schedule accompanying the apparatus.2 Purge the pipe as follows: i) It should be made sure that pressure-reducing valve is completely close (no pressure at the output) and that pipe fitting is not connected.
e) This operation has to be performed after the temperature of the quantity of gas introduced is stabilized that is to say after 12 hours from the filling in operation.2: SF6 Gas Filling Procedure d) The pressure must be finally adjusted to its correct value. f) The value of the correct pressure has to appear on its schedule in order to make the checks easier.3. OPERATION & MAINTENANCE MANUAL Page 072 . 2. BANGALORE METRO RAIL CORPORATION LIMITED Fig.
by means of contact pressure meter. Periodical cleanings depend on the environmental conditions. Check and tighten terminals nut and bolts.6 Maintenance Schedule Table 2. so it is possible to clean insulators using high pressure water pump without risk of damage. some deposits on the insulator could produce a certain surface conductivity. c) After long time from installation. b) Monitoring of pressure can be done from remote control room continuously.2: Maintenance Schedule Equipment Make: Type Schedule Sl. top up with SF6 gas as per the instruction manual.3.3. Italy TG 72-145-170 Check List Check and clean the CT porcelain insulator for its cleanliness.5 General Supervision & Maintenance a) No periodical check is necessary. All checks from half yearly schedule Measure insulation resistance. If any SF6 alarm comes. Monitor the SF6 pressure from control panel as well as from the local gauge and record the readings. BANGALORE METRO RAIL CORPORATION LIMITED 2. 2. Washing of insulator is then advisable. The CT transformers are completely tight. Check and tighten the secondary terminals. No 1 2 3 Half-Yearly Maintenance 4 66 kV SF6 CURRENT TRANSFORMER M/s ABB Limited. Check the gasket for its wear and tear and replace even at slight damage. 5 6 1 2 Yearly Maintenance OPERATION & MAINTENANCE MANUAL Page 073 .3. especially in dusty or coast areas.
Earth them at both ends before carrying out any maintenance work. All PPE‘s (Personal Protective Equipment) shall be ensured at site during maintenance. Manufactures Instruction & Maintenance Manual shall be referred during Maintenance. 4. Ensure that the equipment is disconnected from all electrical supply. 2. 3. BANGALORE METRO RAIL CORPORATION LIMITED Remarks: 1. All safety precautions shall be ensured during maintenance. OPERATION & MAINTENANCE MANUAL Page 074 .
2. BANGALORE METRO RAIL CORPORATION LIMITED 66 kV POTENTIAL TRANSFORMER 188.8.131.52: General Arrangement of 66 kV Potential Transformer OPERATION & MAINTENANCE MANUAL Page 075 .1 GENERAL DESCRIPTION Fig.4 2.
2 2. The top chamber. 3.5 2.1. OPERATION & MAINTENANCE MANUAL Page 076 .1. 2.1 2. A Dome Shape Cover is provided to protect the pressure diaphragm and nitrogen filling valve from rainwater.1.4. 2. mounted on bushing. Oil Expansion chamber fitted with oil level indicator and pressure release diaphragm.1.4.6 Note: The Voltage Transformer after careful drying is filled with High Quality de-aerated oil under vacuum. Main Porcelain Bushing mounted on Bottom tank.3 The Voltage transformer bottom tank is fabricated from mild steel plates. The box is provided with suitable cable entry at the bottom. the space left for expansion on the top is filled with dry and pure Nitrogen through non-returnable valve at predetermined pressure. which acts as Oil Expansion Chamber is fitted with oil level indicator. Secondary Terminal Box forms an integral part of tank. 2.1. Pressure Release Diaphragm.4. To seal it. The High Voltage lead of voltage transformer is taken out through porcelain bushing mounted on bottom tank and is terminated at top chamber where a primary terminal is provided to connect the voltage transformer to external line.4.4. Oil filling plug and Nitrogen filling valve. It houses the core and coil assembly. Neutral point of primary winding is brought out through a suitable insulated terminal in a separate earthing box and provided with shorting links to keep neutral terminal shorted to earth in normal operating condition of VT. Bottom tank with mounting Channel and Integral Secondary terminal Box. BANGALORE METRO RAIL CORPORATION LIMITED The outdoor oil filled Voltage Transformer (VT) consists of the following: 1.1. It is important that the Voltage Transformer is always kept in a vertical position so that the gas forming a cushion at the top remains at top only.4 2.4.
of Secondary Winding Rated Secondary Voltage Winding – I Winding -. Outdoor Oil cooled IS:2705 Outdoor Bottom kV 66 kV/ √3 2 3 4 5 6 7 8 (i) (ii) Country Of Origin Manufacturer‘s Type and Designation Standards Applicable Type of Installation Mounting of Tank (Bottom) Rated Primary Voltage Secondary Winding Details No.4.1 below: Table 2.II (iv) Class of Accuracy Winding – I Winding -.4. BANGALORE METRO RAIL CORPORATION LIMITED 2.2 Technical Specifications The guaranteed technical parameters of 66 kV Potential Transformers is provided in Table 2.4.2 OPERATION & MAINTENANCE MANUAL Page 077 . Meerut India VISHAL make.1: Technical Parameters of 66 kV Potential Transformers SN Description Unit Values 1 Name of the Manufacturer M/s Vishal Transformers & Switchgears (P) Ltd.II V Two 110 V/√3 110 V/√3 VA 10 VA 10 VA (iii) Rated Burden Winding – I Winding -.2 0.II 0.
20 OPERATION & MAINTENANCE MANUAL Page 078 . BANGALORE METRO RAIL CORPORATION LIMITED Maximum Ratio Error with % rated burden and 5 % normal primary voltage Temperature Rise at 1.2 Continuous 325 13 One minute power frequency withstand test voltage on primary One minute power frequency withstand test voltage on secondary kV (rms) 140 14 3 15 16 17 18 Total Creepage distance of the bushing mm Sealing (Metal Bellow) provided Quantity of insulating oil Total weight including oil Litres Kg 1825 Provided 55 +/-5 220 +/.1 times rated voltage with rated burden Rated Voltage factor and time Impulse Withstand test voltage kV (Peak) Deg C As per IS 9 10 45 11 12 1.
1 If the insulation resistance of the Voltage Transformer is low. it may be little difficult to close the oil drain plug as oil is drained with higher pressure.4.4. it can be improved by oil filtration under vacuum.4 OIL FILTRATION: 2. However. b.30Kg/cm2).0.1 Nitrogen can also be filled by following procedure: a) Fill the oil in the tank up to the top plate so that no air remains in the tank.NITROGEN: a) Remove the oil filling plug. Remove the Nitrogen valve and connect suitable adaptor to connect incoming oil pipe of the filtration machine. e) After 5 minutes. close the oil filling plug with rubber ‗O‘ ring and cap. Note: This method of Nitrogen filling is most effective than the one mentioned earlier. b) Close the oil-filling plug. Check whether valve is leaking. Remove oil drain plug and connect other oil-outgoing pipe of oil filtration machine to it. c) The Nitrogen should be kept flowing at least for 5 minutes. f) Fill Nitrogen up to 5 psi pressure (approx. BANGALORE METRO RAIL CORPORATION LIMITED 2. 2. pushing air upward through oil filling plug.30Kg/cm2). d) Close the oil Drain Plug when oil level drops to minimum level (Normally half level in oil level indicator). Fill Nitrogen up to 5-psi pressure (approx.4.4.4. The procedure for oil filtration is as follows: a. g) The pressure inside the tank may be checked for confirmation after 24 hours for any leakage. b) Start filling Nitrogen gas through Nitrogen value with very low pressure by regulating pressure with pressure regulator provided on the Nitrogen Gas Bottle. c) Open the oil drain plug and start filling Nitrogen from valve provided on the top plate of the tank simultaneously. d) Nitrogen will slowly settle down at bottom.3.3 FILLING PROCEDURE OF PT WITH GAS -. 0. OPERATION & MAINTENANCE MANUAL Page 079 . 2.
iii) Remove rubber ‗O‘ ring. If IR of primary to earth and secondary to earth both show very low value and nitrogen pressure is not present in VT. check Nitrogen Pressure. ii) Remove the Pressure Diaphragm. provided along the periphery of the flange. d.4. except occasional cleaning of Bushing.5. 2.5 General Supervision & Maintenance 2. it may explode. Nitrogen may leak through defective/damaged diaphragm. close the drain Plug and Nitrogen valve and fill the Nitrogen as explained above. due to ageing is less than that due to moisture ingress. replace it with new one. If the IR values indicate decreasing trend. resulting in contamination of oil and subsequently lowering the IR values. Start the filtration machine and keep it running for at least 36 to 48 hours (It is always better to keep filtration for more than 36 hours.4. However. Following is the procedure for replacing diaphragm:i) Remove the flange by removing six nuts. c) Check the Pressure Diaphragm as per procedure explained in the Commissioning Manual. following checks are for trouble-free continuous operation:a) Check the IR value of each VT periodically preferably once in six months and keep record. If pressure diaphragm is defective. If such Voltage Transformer is kept in service.1 All Voltage Transformers are of ―Sealed Type‖ construction and do not require any maintenance. as it takes times to transmit the heat inside the insulation and remove the moisture). After filtration. IR value of primary will be low unlike Current Transformer. b) As primary winding is provided with graded insulation and neutral point is brought out through a 3 kV Bushing. Due to this there is always a possibility of moisture entering the oil tank through the leaking part. iv) Put new rubber ‗O‘ Ring (Old Rubber ‗O‘ Ring may be used if it is not defective). the rate of fall of IR value with respect to period. However. It is advisable to test oil sample taken from VT to confirm the healthiness of VT. BANGALORE METRO RAIL CORPORATION LIMITED c. OPERATION & MAINTENANCE MANUAL Page 080 . The IR value also decreases due to ageing effect.
Check and tighten terminals nut and bolts.2: Maintenance Schedule 66 kV POTENTIAL TRANSFORMER M/s Vishal Transformers & Switchgears (P) Ltd Sl. Check the earthing connection of the tank. 2. Check the CVT fuses and replace if found faulty. Check secondary bushings for leakages. If minor leak is there rectify it. Check and tighten the secondary terminals. Place other flange over it and tighten the nuts.4.4. Check for any leakages.6 Maintenance Schedule Equipment Make: Schedule Table 2. Check the gasket for its wear and tear and replace even at slight damage. Refer manuals. BANGALORE METRO RAIL CORPORATION LIMITED v) Clean the surface of both flanges . No 1 2 3 4 5 Quarterly Maintenance 6 7 Check List Check and clean the porcelain insulator for its cleanliness. Check the oil level All checks from half yearly schedule Measure insulation resistance. replace them with proper rating. Do not over tighten the nuts. Measure secondary winding resistances.Places the Diaphragm on the rubber ‗O‘ ring such that Hylum sheet exposes to the atmosphere. Refer test reports. 8 1 2 Half-Yearly Maintenance 3 OPERATION & MAINTENANCE MANUAL Page 081 .
4. Ensure that the equipment is disconnected from all electrical supply. Earth them at both ends before carrying out any maintenance work. OPERATION & MAINTENANCE MANUAL Page 082 . BANGALORE METRO RAIL CORPORATION LIMITED Remarks: 1. All PPE‘s (Personal Protective Equipment) shall be ensured at site during maintenance. Manufactures Instruction & Maintenance Manual shall be referred during Maintenance. 2. 3. All safety precautions shall be ensured during maintenance.
porcelain insulator stacks. (Refer part Drg ―C‖) 1 No.5.1 Isolator comprises of three identical single pole units consisting of: A galvanized rigid base made of distortion resistant structural steel having fixing arrangements to the supporting structure by means of drilling holes and also having two elevator plate/channels on both sides and a rotating bearing unit with interconnecting pipe (tandem pipe) fixing clamps. (Refer part Drg ―F‖) Operating Mechanism (Motor/Manual) (Refer part Drg ―G‖) Group operating pipe (Tandem pipe) for interconnecting three poles (Refer part Drg ―H‖) Operating Pipe (Down pipe) for interconnecting the top operating mechanism and operating mechanism (Motor/Manual) (Refer part Drg ―I‖) 2.1 General Description 2. Top operating mechanism for isolator (Refer part Drg ―E‖) or rotating bearing units with interconnecting pipe clamps and top operating mechanism.5 2.5.2 Earth Switch also comprises of three identical single pole units consisting of: Moving contact fixing assemblies with inter connecting pipe fixing clamps and interlock pipe with link assembly (Refer part Drg ―J‖) fitted to base.1. fixed contact assemblies with arcing horns for mounting on side insulator stacks. fixed contact assembly fitted to the isolator fixed contact (Refer part Drg ―K‖) 1 No.1. BANGALORE METRO RAIL CORPORATION LIMITED ISOLATOR 2. 1 No.5. moving contact assembly with arcing horns (Refer part Drg ―D‖) for mounting on centre insulator stack. (Refer part Drg ―A‖) 3 Nos. (Refer part Drg ―B‖) 2 Nos. moving contact assembly fitted with flexible (Refer part Drg ―L‖) 1 No. top operating mechanism (Refer part Drg ―M‖) Operating mechanism for earth switch (Motor/Manual) (Refer part Drg ―G‖) OPERATION & MAINTENANCE MANUAL Page 083 .
5. BANGALORE METRO RAIL CORPORATION LIMITED Group operating pipe (Tandem Pipe) for interconnecting earth switches (Refer part Drg ―H‖) Operating pipe (Down Pipe) for interconnecting the top operating mechanism and operating mechanism (Motor/Manual) (Refer part Drg ―I‖) Auxiliary coupler pipe which connects the earth switch inter connecting pipe with top operating mechanism (Refer part Drg ―N‖) Fig 2.1: General Arrangement of 66 kV Isolator OPERATION & MAINTENANCE MANUAL Page 084 .
5.2: General Arrangement OPERATION & MAINTENANCE MANUAL Page 085 . BANGALORE METRO RAIL CORPORATION LIMITED Fig 2.
3: General Arrangement of Operating Mechanism OPERATION & MAINTENANCE MANUAL Page 086 . BANGALORE METRO RAIL CORPORATION LIMITED Fig 2.5.
4: General Arrangement OPERATION & MAINTENANCE MANUAL Page 087 . BANGALORE METRO RAIL CORPORATION LIMITED Fig 2.5.
BANGALORE METRO RAIL CORPORATION LIMITED Fig 2.5: Mounting Arrangements OPERATION & MAINTENANCE MANUAL Page 088 .5.
India NA ―DB‖ Double Break IS 9921 Part I to V/ IEC 694.5 kV 66 kV 140 kV rms 10 11 12 13 Rated frequency Rated insulation voltage Rated operating voltage Rated short circuit duration power frequency withstand voltage Rated lightning Impulse withstand (1. BANGALORE METRO RAIL CORPORATION LIMITED 2.1: Technical Specifications SN Description Unit Values 1 2 3 4 5 6 7 8 9 Name of the manufacturer Country of manufacture Port of embarkation Manufacturer drawing reference Relevant Standards Type Substation type Phase numbers Two rotating columns GR Power Switchgears Limited Hyderabad. 129 Outdoor Open Three Centre Post Rotating Double Break ―DB‖ Hz kV kV kV rms 50 Hz 72.2/50 micro second) Rated short duration power frequency withstand voltage across isolating distance Rated lightning impulse withstand voltage across isolating distance 14 kV peak 325 kV peak 15 kV rms 160 kV rms 16 kV peak 375 kV peak OPERATION & MAINTENANCE MANUAL Page 089 .2 Technical Specifications The technical parameters of 66 kV Isolator are provided in Table 2.5.1 below: Table 2.5.5.
26 Making capacity OPERATION & MAINTENANCE MANUAL Page 090 . Isolator Earthing Switches (Class E0) are designed for short time withstand current and not for making capacity. If simultaneous operation of Earthing Isolator and Line E/S to be done at site through Electrical interlocking. BANGALORE METRO RAIL CORPORATION LIMITED Description Unit Values SN 17 18 Rated current A 1000 Amps 40 kA rms Rated short circuit withstand current (1 kA rms sec) Rated peak withstand current Rated auxiliary voltage Rated control motor auxiliary voltage Degree of protection for operating and auxiliary cubicle Rated mechanical terminal load Earthing Isolator N 19 20 21 22 kA Peak 100 kA peak V dc V dc 110 V dc 415 V AC IP 55 23 As per IEC: 62271-102/ IS:9921 24 25 Electrical values Earthing isolator operation simultaneous Yes/No with LIS As above Isolator and earthing switches are individual operated and a mechanical interlock provided in between.
184.108.40.206.4 220.127.116.11 2.5. Check few operations and keep the isolator in open position.3. Due care to be taken while fastening. After ensuring the proper alignment.8 2.3.5. 2.5 2. Check levels with spirit level or by water balance method. Keep all the three poles in close position and keep the top operating mechanism lever in parallel to the other levers of isolator pole.5. that the centre line of top operating mechanism coincides with the centre line of the operating mechanism. Adjust the poles individually to have proper entry of the moving contact arm (D) into the fixed contact © simultaneously at either end by adjusting the elevator (A of 1). Place the top operating mechanism (Motor/Manual) as per the layout drawings.3.5. Care should be taken that ll individual poles are to be closed in anti-clock wise direction only. Fasten the group operating pipe (H) through the fixing clamps to all levers. Fix the operating pipe (I) suitably by sizing the height and weld with the vernier flange. Fasten support insulator stacks (B) on rotating bearing unit (A of 2) and elevator plate/channel (A of 1) Check the insulator columns vertically (by plumb) and place moving contact arm (D) on centre support insulator and fixed contacts © on outer support insulator in opposite direction. Care should be taken that all poles are closing uniformly and simultaneously. Isolator supporting structure) in such a way that distortion forces cannot effect the frame. While connecting see that the operating mechanism is also in ON (close) position.11 OPERATION & MAINTENANCE MANUAL Page 091 .3 ISOLATOR INSTALLATION PROCEDURE 18.104.22.168 2. Adjust the centreline of isolator poles and see that the operating levers are at the same level. Connect one end to the top operating mechanism and the other end to the operating mechanism (G) (Motor/Manual) through vernier flange with two bolts. BANGALORE METRO RAIL CORPORATION LIMITED 2. see that the terminal pad (C of 2) should be in outer side adjust and tighten.3. If the poles are not closing properly loosen the fixing clamps of group operating pipe and re-adjust to achieve proper alignment.6 2.5.5. Place the operating mechanism (G). tighten all fasteners firmly.e.3. Check the operation manually (by means of operating handle).2 22.214.171.124.10 2.3.3 2.1 Fasten the base frame (A) horizontally and vertically levelled to foundation (i.
4.5. Connect the mechanical interlock link to the isolator lever arm (Y Phase) Check the mechanical interlock operation between the earth switch and the isolator properly by adjusting the link pipe (J of 3).126.96.36.199 Place the moving contact (L) in the moving contact fixing assembly and tighten the clamps.3 2.5.4 EARTH SWITCH INSTALLATION PROCEDURE 2. Keep all the three poles in ON (close) position and connect the group operating pipe (H).5.4. one end to the group operating pipe and the other end to the top operating mechanism.5. Place the operating mechanism (G).6 2.e.5. Place the top operating mechanism (M).4.4. Fix the operating pipe (I) suitable by sizing the height and weld with the vernier flange.2 2.1 2.5. Due care to be taken while fastening that the centre line of the top operating mechanism coincides with the centre line of the operating mechanism.8 2. 2.4.9 OPERATION & MAINTENANCE MANUAL Page 092 .4.7 2. Check the operation manually (by means of operating handle) to make sure that all poles are closing uniformly and simultaneously.5 2.4. Keep the lever at convenient angle and connect the auxiliary coupler pipe (N) i. Adjust the moving contact to have proper entry in the fixed contact by adjusting check bolts.5. Connect one end to the top operating mechanism (M) and the other end to the operating mechanism (G) through vernier flange with two bolts. BANGALORE METRO RAIL CORPORATION LIMITED 2. See that the operating mechanism also in ON (close) position while connecting.5.4.
5. BANGALORE METRO RAIL CORPORATION LIMITED 2. Operating mechanisms are to be cleaned and tightness of screws and wires are to be checked.2 2. While operating the isolator with manual operating mechanism. Don‘t operate the isolator when the breaker is in ON position. open the pad lock and take the operating handle into horizontal position. Apply contact lubricant (petroleum jelly) for isolator and earth switch contacts.4 2. Check the contacts of isolator.5. Now the mechanism is free to operate the isolator/earth switch to close or open. and Deenergise the isolator. No special tools and tackles are required. Apply lubricant (grease or oil) in all rotating parts like rotary bearings.6.6.3 2.5.5. replacement has to be made. Check the fasteners tightness in all points.5. By pressing the push button remove the castle key by rotating and insert the key in top castle lock and rotate. If any deep burnings observed.188.8.131.52.5.6 MAINTENANCE After performance of 500 operations few random checks are to be done. 2. clamp joints and turn twist mechanism etc.4 Don‘t operate the isolator when the interlock conditions are not satisfied.184.108.40.206. earth switch and arcing contact for contacts wear and tear and arcing effects.5.1 2. 2. After completion of the operation remove the castle key by rotating and keep the key inside the cubicle and rotate.5.5 220.127.116.11.6 Switch off the control/auxiliary supplies to the operating mechanism. OPERATION & MAINTENANCE MANUAL Page 093 .3 2.6.5 OPERATING INSTRUCTIONS 2. While checking the following important points are to be taken care.1 2.2 2. keep the handle in the same position and pad lock it.
BANGALORE METRO RAIL CORPORATION LIMITED Lubrication: All points are to be greased as follows: LUBRICATING POINTS a) b) c) d) Rotary Bearings Bush Bearings at clamps Turn and Twist mechanism Isolator/Earth switch contacts 2. 6 7 66 KV ISOLATOR M/s G R Power Switchgear Ltd. OPERATION & MAINTENANCE MANUAL Page 094 .6.5. Clean the contacts and apply a thin layer of petroleum jelly to the contact surfaces. Check and tighten the control wirings.7 MAINTENANCE SCHEDULE Equipment Make: Schedule Sl.7 LUBRICANT TO BE USED a) b) c) d) Grease by grease guns Grease and Oil Grease and Oil Petroleum jelly or silicon grease 435 GR 2. No 1 2 3 4 5 Quarterly Maintenance Operate the Isolator a few times and check for proper operation locally. All other rotating parts to be lubricated with mobile oil. Hyderabad Check List Check and clean the isolator‘s porcelain insulator for its cleanliness. Check and tighten terminals nut and bolts. Main bearings to be lubricated with grease through the nipple provided.5.
BANGALORE METRO RAIL CORPORATION LIMITED 8 9 1 2 Half-Yearly Maintenance 3 4 1 Yearly Maintenance 2 Check limit switch & auxiliary switch & contacts. Manufactures Instruction & Maintenance Manual shall be referred during Maintenance. Observe for any signs of overheating All checks of half yearly maintenance. Measure insulation resistance. Measure and record insulation resistance of motor winding and contactor coils using 500 v megger. Earth them at both ends before carrying out any maintenance work. Check Movement of Operating Rod All checks from quarterly schedule. Ensure that the equipment is disconnected from all electrical supply. 2. 3. 5 KV megger Checking condition of fixed and moving contacts. 4. All PPE‘s shall be ensured at site during maintenance. All safety precautions shall be ensured during maintenance. OPERATION & MAINTENANCE MANUAL Page 095 . Remarks: 1.
the resistors can withstand many onerous environmental conditions without any protection. The outdoor enclosure for resistor warrants certain consideration.6. 30 and 60 sec. NGR / NER is normally rated for a very short duration of 5.1.6. The ceramic glazed insulators are not affected by exposure to condensation and repeated heating cycle of resistive elements.8 OPERATION & MAINTENANCE MANUAL Page 096 . 2. 10. The individual elements are connected by bolt and nut instead of welding.3 2. Sometimes a set of resistor banks will be mounted on post insulators. The heating of resistor elements requires well-ventilated enclosure and at the same time no rainwater should enter inside. For certain applications they are also rated for continuous current ratings.6.6.2 2. The resistor unit will consist of many resistor banks.1.1 The Neutral Grounding / Earthing Resistor (NGR/NER) is passive device to limit earth fault current. BANGALORE METRO RAIL CORPORATION LIMITED NEUTRAL GROUNDING RESISTOR 2. The stainless steel resistor units are virtually corrosion proof and immune to progressive pitting and rusting. The resistive material is stainless steel. taking place out of consideration should be drained off from the bottom.6 2. The Punched Plate type offers non-inductive characteristics.7 2. In the assembly of the resistors only hardwares of stainless steel are used. The resistors are of Punched plate type grids.1. They are invariably non-magnetic and non-corrosive.6. The operation of the resistor will not be affected by moisture or fine dust or sand provided they are not unduly conductive.4 2. This will facilitate easy replacement of individual resistance elements. Stainless Steel elements are adequate for normal applications.18.104.22.168.6.5 2.1.1 General Description 2. Also the entire assembly can be reconstructed for any desired ohmic values but for same current rating at site.6. Because of the usage of stainless steel and ceramics in the construction of NGR.6 2. The type of resistive element will be identical in all the resistance banks of NGR‘S of same ratings.1.6. The NGR‘S conform to IEEE – 32 standards which is universally followed and it is also a most comprehensive specification for NGR. But the enclosure is designed to minimize the ingress of undesirable material and conforms to IP 54 specifications. Support insulators support each bank independently. Any water accumulation.
2.1: NGR General Arrangement OPERATION & MAINTENANCE MANUAL Page 097 .6.5.1 below: 2.9 Fig.5. 2. BANGALORE METRO RAIL CORPORATION LIMITED The general arrangement of Neutral Grounding Resistor has been shown in Fig.1.
10 minutes Heating-up at I-1000 A.2 Technical Specifications The technical parameters of Neutral Grounding Resistor are provided in Table 2.5.1: NGR Technical Parameters Description Unit Values General Manufacturer Place of manufacture Manufacturer drawing reference NGR Type Nature of the active part Rated insulation voltage Rated value Allowable tolerance on measurement (at 20°C in DC) Rated frequency Rated operating cycle thermal stabilization at In=5A Heating-up at I-20 A. at 45°C ambient temperature Protection degree Dimensions Length Height mm mm 1800 2200 °C °C °C 47 55 550 19 kV % Metal in Air Stainless Steel 24KV 19 ± 5% NATIONAL SWITCHGEARS Chennai-600098. Nil SN A 1 2 3 B 1 2 3 4 5 6 7 Hz 50 9 10 IP 55 OPERATION & MAINTENANCE MANUAL Page 098 . 30 seconds 8 Value of the resistance after operating cycle.5.1 below: Table 2. BANGALORE METRO RAIL CORPORATION LIMITED 2.6.
22.214.171.124.1 The switch has base frame (1) and two cast resin epoxy insulators (2) per phase for support. the main contact closes and opens first and then the arcing contact. The flat arc chute quenches the arc by the gas emanating in the arc chamber.1 Operating Conditions Maximum ambient Temperature: 50C Maximum Humidity Maximum altitude : 95% : 1000m from sea level 2.6.3 An arcing blade (7) is fixed along the main blade and it will operate inside the flat arc chute (8) the mechanical arrangement is so assembled using spring mechanism.2 The switching are has two identical fixed contacts (3) ( for incoming and outgoing) and moving contacts (4) of adequate capacity and it is operated by specially designed insulating material called lifting arm (6) standard provision is available for fixing HRC Fuses by extending the base frame with one more cast resin insulator added on it.3 Operation 2.6. BANGALORE METRO RAIL CORPORATION LIMITED Depth Weight mm kg 1800 1550 126.96.36.199.6. 2. 2.6.2 General Operating Mechanism 2.3.3. OPERATION & MAINTENANCE MANUAL Page 099 .2.
the following maintenance instructions are given. 2.3.3. Take appropriate action to replace damaged bushings and clear the defects. High speed switching of the blades follows immediately.6.6.3 CAUTION for Manual Operation 2. to close the Disconnector manually.4 The stock of torsion springs (9) are housed in between the main driving shaft (10) and the fixed shaft (11) which is bolted to the hollow shaft (12) stores the energy when the operating handle is operated.e.5 The switch has cam latches mounted in the base frame for closing (13) and opening (14).2 OPERATION & MAINTENANCE MANUAL Page 0100 .4. and then the handle has to be operated in the clockwise direction.3. soaring temperature coupled with humidity prevailing at the site where the NGR is installed.2. the springs are energized and the energy is transferred to the hollow shaft through the fixing shaft. BANGALORE METRO RAIL CORPORATION LIMITED 2. In view of hazardous nature of the terrain with lots of thunderstorms harsh and unpredictable climatic conditions with heavy rains. 2. The cam coupling is restricted to rotate by opening and closing latches. 2.2 The doors should not be opened when the switch is operated electrically. 2. The performance reliability is guaranteed without any routine maintenance for considerably a long time.1 When the switch is in tripped condition. a) Inspect the High end and Low end bushings for any damage.6 When the main operating shaft is operated.2.2. the handle must be rotated in the anti-clockwise direction till the nosed lever locks with the grooved shaft. 2.3. 188.8.131.52. If it happens in the middle of the operation the Disconnector has to be operated manually to close or open. looseness of fasteners or any foreign material sticking to the bushing.) either left or right side easily by shifting the opening and closing latches.184.108.40.206.6.4 General Supervision & Maintenance 2. The operating side can be changed (i.6.3.1 The design of the NGR the quality of the materials and the skilled workmanship are such that it requires practically no maintenance whatsoever.6.6. Shut tip mechanism is not possible in this arrangement. The main driving cam coupling (15) is in the left and right side.
OPERATION & MAINTENANCE MANUAL Page 0101 . b) The interconnecting fasteners of the elements are to be removed and the elements should be made free for removal.T. are to be loosened and the side trays are to be removed. the re-assembly of the bank can be carried out and put back in its assigned place. Now the elements can be replaced easily. 2. the tie-rods. e) After carrying out the visual inspection and repair. Insulation Resistance Test (Using 5 KV Megger) Ohmic value measurement by Digital Micro Ohm Meter or Wheatstone bridge.6.3 Methods to be followed to replace the resistor elements. which are holding the elements. d) Finally use a hot blower to remove the ingress of moisture and dust accumulated in the enclosure. a) The particular resistance bank where the element got damaged is to be removed by loosening the fasteners at tray end. By sliding the bank the same can be pulled out. Loose nuts and bolts on the grids will invite arcing. c) For taking out the burnt-out elements. the grid connecting stainless steel bushes and the associated hardware‘s are to be tightened properly to avoid the change in ohmic values and heating up of contacts. c) After carrying out the replacement of grid separator ceramic bushes. BANGALORE METRO RAIL CORPORATION LIMITED b) Remove covers and inspect the resistance grids. d) After replacing the elements. the following routine tests are to be conducted to ascertain the proper functioning of the equipment.4. the connections from the H. bushings down to the Low-end bushings and the copper bus bars. If anything is found loose or damaged the same should be replaced / tightened.
It should be 20 ohm. Check pedestal insulator and clean them with dry cloth. CT and earth.2: Maintenance Schedule Equipment Make: Schedule Sl. 8 1 Half-Yearly Maintenance 2 3 1 Yearly Maintenance 2 OPERATION & MAINTENANCE MANUAL Page 0102 . All checks from half yearly maintenance schedule.5. Measure total resistance of NGR circuit. Check gasket for water proofing.5. NEUTRAL GROUNDING RESISTOR M/s NATIONAL SWITCHGEAR Check List Check for general cleanliness of the equipment. All checks from quarterly maintenance schedule. Check all connections of resistance in panel. Measure IR value of CT & LA with 500 V megger as per the specified value. BANGALORE METRO RAIL CORPORATION LIMITED 2. Check neutral connection of transformer to NGR and tighten them. if loose tighten them. No 1 2 3 4 5 Quarterly Maintenance 6 7 Check isolator and clean the contacts with kerosene oil and apply Vaseline lightly. Touch up paint if required. Check connections with LA. Check all earth connections and tighten them.6 Maintenance Schedule Table 2.
3. All safety precautions shall be taken during Maintenance. BANGALORE METRO RAIL CORPORATION LIMITED Remarks: 1. Standard tools and accessories as per Instruction and Maintenance Manuals shall be ensured for facilitating the normal maintenance activities on the Equipment. 4. Always follow the instruction and Maintenance Manual of the manufacturer. OPERATION & MAINTENANCE MANUAL Page 0103 . All Drawings and Manufacture‘s Instruction & Maintenance manual shall be ensured at site for reference during Maintenance. 2.
BANGALORE METRO RAIL CORPORATION LIMITED CHAPTER – III OPERATION & MAINTENANCE MANUAL Page 0104 .
Peenya. while all the underground stations are provided with two ASSs each having 1 x 2000 kVA transformer.1 Each auxiliary substation consists of 33 kV circuit breakers. Mysore Road and Puttenhalli stations.1.2. is transmitted to the Auxiliary Substations (ASS) located at the passenger stations and depots. This type of ASS is applicable for elevated stations Baiyappanahalli. one 2 x 500 kVA ASS is provided for the Operation Control Center (OCC) physically located in Baiyappanahalli Depot. 1.3 Both the depots are provided with one ASS having 2 x 2000 kVA transformers. BANGALORE METRO RAIL CORPORATION LIMITED AUXILIARY SUBSTATIONS Overview The power at 33 kV level from the 33 kV switchgear room located in the Receiving Substations (RSS). 1.2 ASS Types 1.2.2 All the ASSs of elevated stations are provided with one ASS having 2 x 500 kVA transformer.1. 1.1 1.3 Type C: 1 x 2000 kVA This type of ASS is for underground stations and will be applicable to all underground stations with the exception of Kempegowda station. Puttenhalli and Peenya Village. 1.0 1.2 Type B: 2 x 500 kVA with 33kV Incoming Feed This configuration is similar to Type-A with the addition of an incoming 33kV feeder from the Receiving Substations. 33 kV interrupters. 1. The 33 kV power is transformed to 415 V power by means of 33 kV / 415 V Cast Resin Dry type transformers of suitable capacity installed in the ASS‘s.1 Type A: 2 x 500 kVA This type of ASS is applicable to all elevated stations and at-grade stations (and OCC-ASS) except Mysore Road. auxiliary transformers and AC/DC control power supply system. through 33 kV cables. 1. In addition. Each transformer at these ASSs receives power from separate two ring main 33kV feeder cables. Two such auxiliary substations are provided for each underground station (except Kempegowda). OPERATION & MAINTENANCE MANUAL Page 0105 .1.2. The transformers at these ASSs receive power from the two ring main 33kV feeder cables. Baiyappanahalli.
2. BANGALORE METRO RAIL CORPORATION LIMITED 1. OPERATION & MAINTENANCE MANUAL Page 0106 . Each transformer at these ASSs receives power from the separate two ring main 33kV feeder cables. This type of ASS is applicable to both the depot ASSs.2.5 Type E: 2 x 2000 kVA This is similar to Type-A with the exception that each auxiliary transformer is 2000 kVA rating instead of 500 kVA. 1. This type of ASS is applicable to the underground Kempegowda stations of both the corridors.4 Type D: 1 x 2000 kVA with Interconnection Cables This configuration is similar to Type-C with the addition of 33kV interconnecting cables between the EW and NS Corridors.
ac/dc control source and systems. the systems in depots are negative earthed one.0 2. 2850 kVA rectifier transformers.4 The traction system for mainlines is that of floating negative / return system so that stray currents are controlled. with all accessories and auxiliary equipment. in the premises of passenger stations and depots. 2. so as to facilitate isolation of depot traction power supply from mainline in order to prevent the leakage of return currents to main line.1 2. Remote operated sectionalizing switches are provided to feed power from depot to main line equipment and vice-versa in case of failure of TSS.5 A separate traction substation is therefore provided in depot. OPERATION & MAINTENANCE MANUAL Page 0107 .1 The rolling stock is provided with traction power at 750 V dc. through feeders of 33 kV insulated cables.1.1.2 The 33 kV power is transformed to 750 V dc power by means of 33 kV / 292-292 V Cast Resin Dry type rectifier transformers and rectifier of suitable capacity installed in the TSS‘s. Therefore. 2. indication and metering arrangement. protective provisions related to electrical safety and earthing etc. power at 33 kV level from the 33 kV switchgear room is transmitted to the Traction Substations (TSS) located along the corridors. 33 kV ac and 750 V dc switchgears (including high speed circuit breakers).3 TSS includes 33 kV/292-292 V. However for safety reasons. 2500 KW rectifiers. protection and control unit. For this purpose. 2.1. BANGALORE METRO RAIL CORPORATION LIMITED TRACTION SUBSTATIONS Overview 2. 2. 750 V dc positive and negative cables.1. the mainline tracks are isolated from depots tracks through insulted rail joints in order to minimize the stray currents.1.
2. One of the sections feeds the two rectifier-transformers in addition to acting as closing the concerned 33kV ring. as this station being an integrated one. the feed can be extended from other RSS through the additional interconnecting 33kV cable. thus requiring closing of the 33kV ring.1 Type-A: With two 33kV Ring Main Cables This is the most common type of TSS and this is applicable to all TSSs except . The 33kV busbar is provided with a bus coupler dividing the busbar into two sections. and The 33kV interconnection between EW and NS corridors are provided at this location. These are the TSSs which are located on either side of RSS. 2. from other RSS).e. interconnecting 33kV cable is provided to interconnect 33kV network of EW and NS Corridors. The two (presently one and are to come in future) rectifier-transformers are fed from 33kV busbar in the TSS like in the Type A. and Jalahalli & Peenya Industrial Area.2. One end of these interconnecting cables is normally open and only in emergency case. BANGALORE METRO RAIL CORPORATION LIMITED TSS Types 2. TSS at these stations normally receives power from the two ring main 33kV feeder cables. This design is applicable to two TSSs viz.two depot TSS. two Majestic TSSs (one each for EW & NS corridor respectively).3 Type-C: Majestic TSSs Majestic TSSs (both for EW and NS Corridors) are different for two reasons: Majestic TSSs are the end of 33kV traction ring in normal feeding scenario. TSS at these stations receives power from the two ring main 33kV feeder cables and two rectifier-transformers are fed from 33kV busbar in the TSS. From both these sections of 33kV busbar.2. 2. In an emergency case of RSS being in outage.2 Type-B: With two 33kV Ring Main cables and one Interconnecting Cable This type of TSS is similar to Type-A with an additional 33kV switch. the 33kV supply is extended from one corridor to another. This ensures extension of 33kV feed without the necessity of routing it through the 33kV busbar in faulty RSS. Jalahalli and Peenya Industrial Area TSSs. OPERATION & MAINTENANCE MANUAL Page 0108 .2 2. The other section works to close the other side 33kV ring with the bus coupler (normally open) providing the possibility of emergency feed extension from other 33kV ring (i. one of which is coming directly from RSS. which connects to the adjoining TSS.
BANGALORE METRO RAIL CORPORATION LIMITED 2. their operation mechanisms and maintenance schedules for Bangalore Metro Rail – Phase I Corridor are provided below: 2. 2. their operation mechanisms and maintenance schedules for Bangalore Metro Rail – Phase I Corridor are provided below: OPERATION & MAINTENANCE MANUAL Page 0109 . Depot TSSs receives power from separate two ring main 33kV feeder cables and two rectifier-transformers are fed from 33kV busbar in the TSS.2.4 Type-D: Depot TSS As RSSs are physically located in both the depots.3 ASS EQUIPMENTS The Auxiliary Sub-Station includes the following equipments: a) 33 kV Switchgear b) Dry Type Auxiliary Transformer (200 kVA. the depot 33kV supply for TSS and ASS is directly drawn from respective RSS in the 33kV ring main feeding formation.4 TSS EQUIPMENTS The Traction Sub-Station includes the following equipments: a) 33 kV Switchgear b) HSCB (High Speed Circuit Breaker) c) Rectifier d) Rectifier Transformer e) Short Circuiting Device f) Negative Return Panel The Guaranteed Technical Parameters of the individual ASS equipments. 500 kVA & 2000 kVA) c) ACDB d) DCDB The Guaranteed Technical Parameters of the individual ASS equipments.
BANGALORE METRO RAIL CORPORATION LIMITED 33 kV SWITCHGEAR General Description The basis for the design of switchgear panel is the incoming/outgoing feeder panel with vacuum circuit breaker using insertion technology. The three high voltage compartments (busbar compartment.1. circuitbreaker compartment and the cable connection compartment) are equipped with top-mounted and secured pressure relief flaps.1. apply: 2. In case of internal overpressure.5 2. cable compartment and control cabinet for the secondary equipment.1.5.5. The enclosure and internal partitions of the panels are of 2mm thick high quality steel sheets. OPERATION & MAINTENANCE MANUAL Page 0110 . The circuit breaker compartment and cable connection compartment doors are pressure resistant and can either fitted with screws or manual closing system.5. The circuit-breaker compartment is equipped with inspection window made of security glass.3 2.5.2 2. The following limit values. Door and rear walls as well as cover plates are thoroughly cleaned and treated against corrosion before receiving a high quality double coating of paint. Panels are partitioned from one another by the side walls of each panel.1.1.1. circuit-breaker compartment. are made of sheet steel with wire mesh or plain sheet steel. It is divided into busbar compartment.5. the plastic screws are the point of rupture. Normal operating conditions: The switchgears are basically suitable for normal operating conditions for indoor switchgears and switchboards in accordance with IEC 60694/ IEC 62271-1.4 2.1 2. among others. The pressure relief flaps are secured with steel screw on one longitudinal side with plastic screws. Cable and circuit breaker compartments have independent doors.7 Ambient temperature: a) Maximum + 40 °C b) Maximum 24 h average + 35 °C Minimum (according to ―minus 5 indoor class‖) .6 220.127.116.11 2. The front of the panel is closed by pressure resistant doors.5 °C The maximum site altitude is 1000 m above sea level.5. These open in the case of over pressure due to an internal arc fault.5. according to the rated branch conductor current. The enclosure is provided above by top-mounted pressure-relief flaps which.1 2.
2.2 Circuit Breaker Compartment The circuit breaker compartment contains all the necessary equipment for reciprocal operation of the withdrawable part and the panel.2 2. using lever when inserting into the service position. and are closed when the latter is removed.5.5. The ON/OFF pushbutton located on the CB. The moving part with the circuit breaker is moved manually by means of a spindle.2.5. BANGALORE METRO RAIL CORPORATION LIMITED 2. It is metallically partitioned on all sides.5. the withdrawable part is still completely inside the panel with door closed. b) Other Withdrawable Parts The withdrawable part can also be fitted with the following trucks: Metering voltage transformers trucks with fuses Earthing truck without making capacity (for main busbar system and power cables) Earthing truck with making capacity (for main busbar system and power cables) Power cable testing trucks Isolation trucks Isolation truck with fuses OPERATION & MAINTENANCE MANUAL Page 0111 . These are held by flat branch conductor. 2. 2. which is form coded on both sides.2. The earthing connection between the withdrawable part and the panel is established by its roller and travel rails which are bolted on to the panel. The shutters are opened by means of actuating bars of the withdrawable circuit breaker part. between the service or test/disconnected positions with the front doors closed.1 Structure & Design of Panel Compartments Bus Bar Compartment The bus bars have 3 tubular cross-section made of copper and are laid in sections from panel to panel. and the mechanical indicators for ON/OFF and CHARGED/DISCHARGED can be observed through an inspection window. Bus bars & branch conductors are insulated and connections are shrouded. The fixed part is connected to the panel by forking. No special connection clamps are needed. In the Test/Disconnected position.3 Withdrawable Parts a) Withdrawable Circuit Breaker Parts The withdrawable assembly establishes the mechanical connections between the panel and the circuit breaker.
Fixed & Withdrawable Voltage Transformers and Earthing Switch. BANGALORE METRO RAIL CORPORATION LIMITED Cable Connection Compartment The cable compartment contains Current Transformers.2.5. The removable voltage transformers are fitted with HRC fuses. The cable compartment is constructed for installation upto three current transformers.2. The earthing switch can be used with either a manual or motor-operated mechanism. The voltage transformer mounted fixed are connected on the primary side with connectors.5. 2.1: Complete Cubicle Assembly OPERATION & MAINTENANCE MANUAL Page 0112 . Its switching position is indicated both mechanically and electrically by means of the auxiliary switch.5 The structure of 33 kV switchgear panels is shown below: Fig 1.2.4 2.
BANGALORE METRO RAIL CORPORATION LIMITED
Technical Specifications Table 1.2.1: Technical Parameters for 33 kV Switchgear
SN A 1 2 3
Description General Manufacturer Place of manufacture Standards
ABB Nasik, India IEC 62271-100 / 200
B 1 2 3 4 5
CUBICLE (FIXED PART) Class Rated insulation voltage Rated operating voltage Rated frequency Rated short time duration power frequency withstand voltage Rated lightning impulse withstand voltage Cubicle rated current All CB except aux. transformer CB Aux. transformer CB A A A kA rms kA peak 1250 400 1500A 14KA 35KA 2 NO + 2 NC kV kV Hz kV rms Indoor 36KV 33KV 50Hz 70
8 9 10 11
Bar set rated current Allowable over current for 1 second Instantaneous over current
Number of flip-flop contacts for circuit- Minimum breaker plugging-in and plugging-out
OPERATION & MAINTENANCE MANUAL Page 0113
BANGALORE METRO RAIL CORPORATION LIMITED
Description monitoring Unit Values
Number of flip-flop contact for earthing Minimum isolator open/closed position monitoring Number of flip-flop contacts for isolator open/closed position monitoring Maximum dimensions of the cubicle Minimum
2 NO + 2 NC
a. Width b. Depth c. Height
mm mm mm
1000 mm 2800 mm 2600 mm 3700 IP41 for Switchboard
d. Depth with circuit breaker plugged out mm 15 16 Protection degree Earthing isolator making capacity kA
CIRCUIT-BREAKER (MOVABLE PART) Type Rated insulation voltage Rated operating voltage Rated frequency Rated short time duration power frequency withstand voltage Rated lightning impulse withstand voltage kV kV Hz kV rms Three Pole 36 33 50 70
1 2 3 4 5
OPERATION & MAINTENANCE MANUAL Page 0114
BANGALORE METRO RAIL CORPORATION LIMITED
Description Rated current All CB except aux. transformer CB Aux. transformer CB A A kA rms kA peak kA rms kA peak 1250 400 14KA 35KA 14KA 35KA Vacuum ms ms ms ≤ 70 ≤ 80 ≤ 100 O-0.3sec-CO-3min-CO A O/O O/C V dc V dc 110 110 +10%, -15% As per IEC 8 NO + 8 NC Unit Values
8 9 10 11 12 13 14 15 16 17 18
Allowable over current for 1 second Instantaneous over current Breaking capacity Making capacity Breaking mode Opening time Breaking time Closing time Rated operating cycle Breaking capacity of cable at no load Number of auxiliary contact for open/closed position of the circuitbreaker Auxiliary supply voltage Supply voltage for motor drive circuits Allowable variation range of supply voltage Coils consumption: - engagement coil - release coil
19 20 21
200 W A A A 350 W
Consumption of arming motor
OPERATION & MAINTENANCE MANUAL Page 0115
BANGALORE METRO RAIL CORPORATION LIMITED
Description Maximum noise level during opening and closing actuation Degree of protection for auxiliary circuit Trolley design (Will be suitable for direct withdrawal on Floor) Unit Values Within Audible Limits dB IP 41 for Switchboard
Offered switchgear is with Cassette Mounted Circuit breaker. Breaker transport trolley separate.
D 1 2 3 4 5 6 7 8
CURRENT TRANSFORMER Type Manufacturer Place of manufacture Standards Rated insulation voltage Operating voltage Rated frequency Rated power frequency short duration withstand voltage Rated lightning impulse withstand voltage Actual transformation ratio (As required for different purposes to be indicated. The value provided in ‗required‘ column is indicative only) Protection secondary - Accuracy class kV kV Hz Cast resin Pragati/ECS Mumbai/ Vadodara IEC 44-1 / IS 2705 36 33 50 70 kV kV 170
As per Approved RSS SLD
As per Approved RSS SLD
OPERATION & MAINTENANCE MANUAL Page 0116
Rated output (Burden) Unit VA Values SN 12 Measuring secondary .2 Continuous °C As per IEC / IS E 1 2 3 4 5 6 7 8 VOLTAGE TRANSFORMER Type Manufacturer Place of manufacture Standards Primary insulation voltage Operating voltage Rated frequency Rated short-time duration power frequency withstand voltage Rated lightning impulse withstand voltage Actual transformation ratio .Rated output (Burden) VA kA 14 As per Approved RSS SLD 13 Short-circuit current allowable for 1 seconds Permanent operation without danger Over current class Temperature rise over 40 °C ambient 14 15 16 In 1.Accuracy class .2*In 1.Primary winding kV kV kV Hz Cast Resin Pragati/ ECs Mumbai/ Vadodara IEC 44-2 / IS 3156 36 33 50 70 kV kV 170 9 10 As per Approved RSS SLD OPERATION & MAINTENANCE MANUAL Page 0117 . BANGALORE METRO RAIL CORPORATION LIMITED Description .
Zero Halogen OPERATION & MAINTENANCE MANUAL Page 0118 .secondary windings 11 Accuracy class Protection core Measuring core 12 Rated output (minimum) Protection core Measuring core (As required for different purposes to be indicated.5 VA VA 50 100 (For Bus PTs) 50 (For LPTs) Metering Winding & Graded Insulation V 660 Copper 30 x 10 mm 14 15 16 Secondary winding voltage grade Secondary winding conductor material Earth bus F 1 Finish of Switchgear Inside and outside the panel Only Front Doors are with epoxy powder painting. The value provided in ‗required‘ column is indicative only) 13 Secondary winding type and insulation V 3P 0. G 1 2 Internal wiring of panel Elevated / at-grade sections Underground sections FRLS FRLS. BANGALORE METRO RAIL CORPORATION LIMITED Description Unit Values SN .
BANGALORE METRO RAIL CORPORATION LIMITED Description NUMERICAL RELAYS Manufacturer Place of manufacture Relevant Standards Protections Communication Protocols Auxiliary Supply V DC ABB ABB Vadodara IEC 255 / IS 3231 As per Approved RSS SLD IEC 61850 110 Unit Values SN H 1 2 3 4 5 6 OPERATION & MAINTENANCE MANUAL Page 0119 .
4.2 Circuit Breaker a) Charging the stored energy system: On the circuit breaker with charging motors. Note: The force normally applicable to the insertion/withdrawing lever is 260 N. BANGALORE METRO RAIL CORPORATION LIMITED Operating Mechanism 2. Remove hand crank. 2. 2.5. OPERATION & MAINTENANCE MANUAL Page 0120 . the maximum applicable force must never exceed 400 N. Observe the position indicator.4 The switching operations must be carried out with the front doors closed.1 Withdrawable Apparatus Connect control wiring plug. This ensures that the rear part of the pin head has been shifted onto the hexagonal cap of the spindle and prevents unintentional wrenching of the spindle during panel service. The withdrawable part must not be stopped in any intermediate position in the travel range between the service and test/disconnected position. Turn the crank clockwise (30 Turns) until the stop is reached and the withdrawable part is in the service position. Close the front door Ensure that the apparatus is in OFF position. In any case. Reverse the procedure described above for insertion into the service position.4. charging is carried out automatically. It must be considered that the spring loaded pin head will lie completely on the rear side of the panel door when the hand crank is moved from square spigot of spindle mechanism. Manual withdrawal from the service position into the test/disconnected position: Ensure that the apparatus is in OFF position.5.5. Fit hand crank on square spigot of the spindle mechanism after opening the hole for them by turning slide.
Observe the switch position indicator 2.5. Observe the switch position indicator. open the door with the withdrawable part in the disconnected position. An earthing switch allocated to a circuit breaker is only enabled for switching when withdrawable part is in the test/disconnected position or removed from the switchgear panel.5.4. b) Opening & Closing of the Circuit Breaker Opening and Closing operations with the withdrawable part in the service position should only be performed with the door closed. having previously turned knob anti-clockwise to the stop if the withdrawable part is in the service position. the charging mechanism is automatically disengaged and any further strokes of the lever have no effect.3 Earthing Switch The earthing switch has a snap closing mechanism which is independent of the rotation of the drive shaft. Press the relative mechanical pushbutton. They reach their service position immediately and engage in the panel earthing by means of the racking frame at the sides. If the lever is moved in the angle of 90 degree. BANGALORE METRO RAIL CORPORATION LIMITED For manual charging. Pumping is effective.4. When the charged condition is reached. Only turn earthing switches on when the doors are closed. and therefore HRC fuses can also be used along with the voltage transformers. The voltage transformers used correspond to the type used in the metering panel. Operate the local or remote electrical control.4 Withdrawable Metering Parts Withdrawable metering parts in incoming & outgoing feeder panels are put into the cable compartment using a ramp. pump the integrated charging handle approx 10 times until the charged condition is indicated. 2. OPERATION & MAINTENANCE MANUAL Page 0121 .
No partial discharge must occur on the surfaces of equipment at operating voltage.5. interlocking. Correct condition of the switchgear should be monitored by regular inspections. corrosion and moisture.2 Servicing Where necessary. This can be detected by characteristic noises. BANGALORE METRO RAIL CORPORATION LIMITED General Supervision & Maintenance Inspection Where necessary. application of a thin silicone film on the surface concerned is often effective as a temporary remedy.5. the working area must be switched off and secured against reconnection.5 2. Inspection is primarily to carry out a visual check for grime. using clean water. it is recommended to turn the system alternately in order to clean the inner contact points of the contact system. the working area must be isolated and secured against reconnection. Inspection must also to include correct mechanical/electrical operation of the parts viz.1 However. Visually checking the contact system.5. a clearly perceptible smell of ozone. switching devices. Clean insulating surfaces and conductive components with Ethanol F 25 M. 2. Clean the surfaces in general: Weakly adhering dry dust deposits: with a soft dry cloth. The contact points should be cleaned if signs of overheating (discoloured surface) are visible. and dry properly.5. OPERATION & MAINTENANCE MANUAL Page 0122 . or visible glowing in the dark. Effects of high temperature on the main circuits Traces of partial discharge on the insulating material parts Traces of leakage current on the insulating material parts Surfaces of the contact system 2. protection and signaling devices. Wipe down after cleaning.5. Should partial discharges occur as a result of condensation. actuating. More strongly adherent grime: with mildly alkaline household cleanser or with Ethanol F 25 M.
gaskets Check the Mechanical Interlocks Check and inspect visually the Current Carrying contacts Check the Tightness of guide rail and connections for MVCBs Check the Insulation Resistance by 5000 V megger value should be >1000Mohm Check the Earthing connections Check the rack in and rack out of the CBs Check the CTs and PTs if meters were found not working. Check the Hinges. Check all the selector switches for proper operation. 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Half-Yearly Maintenance OPERATION & MAINTENANCE MANUAL Page 0123 . grease or dust.5.2: Maintenance Schedule 2. Check for Presence of dirt. No 1 33 kV Switchgear Panel M/s ABB Limited Check List Before shutdown note down the readings of the meters and check all the indicating lamps after shutdown if abnormality is found Check after shutdown the Metal structures.6 Equipment Make: Schedule Sl. Check the relays and inform the service personnel if any abnormality is found. Check the operation of the U/V relays Check the PT compartment for any abnormalities visually. BANGALORE METRO RAIL CORPORATION LIMITED Maintenance Schedule Table 1. Locks. Check the signals from SCADA Check the operation of the CBs locally and from SCADA Check the mechanical indications of the CBs Check the incoming and outgoing cables. then check the PT fuses.2. If voltage is missing.
5. Always follow the instructions laid down in the Instruction and Maintenance Manual of the equipment manufacturer. BANGALORE METRO RAIL CORPORATION LIMITED 1 2 Yearly Maintenance 3 4 5 Remarks: - All checks from quarterly maintenance Any touch up paint required to be done. 3. OPERATION & MAINTENANCE MANUAL Page 0124 . 4. PTs Check the Bus bar tightness 1. All Drawings and Manufacturer‘s Instruction & Maintenance manual shall be ensured at site for reference during Maintenance. Ensure that the equipment is disconnected from all electrical supply. CTs Secondary resistance of CTs. All safety precautions shall be taken during Maintenance. IR value of PTs. 2. Standard tools and accessories as per Instruction and Maintenance Manual shall be ensured for facilitating the normal maintenance activities on the equipment. Earth them at both ends before carrying out any maintenance work.
6 2.1: General Arrangement of Auxiliary Transformer (200 KVA) OPERATION & MAINTENANCE MANUAL Page 0125 .6. BANGALORE METRO RAIL CORPORATION LIMITED DRY TYPE TRANSFORMERS General Description Auxiliary Transformer (200 kVA) 2.3.1 Fig 1.
IS 11171 Cast resin 3 50 Dyn11 200 Air 36 33 1.3.6. BANGALORE METRO RAIL CORPORATION LIMITED Technical Specifications The technical parameters of Dry Type Transformer are as below: Table 1.1kV 415/240 70 18 kV 170 OPERATION & MAINTENANCE MANUAL Page 0126 . IS 2026.2 SN Description Unit of Measur ement Values 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Type Name of the manufacturer Country of manufacture Port of embarkation Manufacturer drawing reference Relevant Specification Insulation type Number of phases Frequency Vector group Nominal rated power Cooling Mode Primary rated insulation voltage Primary operating voltage Secondary system highest voltage Secondary rated operating voltage Rated short duration power frequency withstand voltage for primary winding Rated lightning impulse withstand voltage for primary winding kV kV V V kV kVA Hz Dry type cast resin ABB Korea Busan ABB IEC 76.1: 33 KV/415V Auxiliary Transformers GTP (200 kVA) 2.
21 31 % 1. -2.35 OPERATION & MAINTENANCE MANUAL Page 0127 .0 23 24 25 26 Winding material Max. +18.104.22.168 75% at pf 1.0 30 % 1.05 27 Copper loss at rated voltage (refer to ITT for capitalization of losses) (at 75℃) kW 2.0 1. BANGALORE METRO RAIL CORPORATION LIMITED Description Unit of Measur ement kV Values SN 19 Rated short duration power frequency withstand voltage for secondary winding Rated lightning impulse withstand voltage for secondary winding Percentage Impedance Voltage setting (off load tap changer) 3 20 kV 3.5 28 Total loss at rated voltage (refer to ITT for capitalization of losses) (at 75℃) kW 3. +2.5 21 22 % % 4. efficiency % loading at maximum efficiency No load loss at rated voltage (refer to ITT for capitalization of losses) kW aluminium 98.55 29 Impedance at rates current and frequency Reactance at rated current and frequency Voltage regulation at full load % 4.0 -5.5. 0.
Winding c. Height d. Core b. BANGALORE METRO RAIL CORPORATION LIMITED Description Unit of Measur ement Values SN 32 33 Type of core Weight a. Total(TR + Enclosure) Kg Kg Kg Core type(step-lap) 1050 320 2450 34 Dimensions(enclosure) a. Length b. Overall for packages Mm Mm Mm Mm dB 2300 1800 2100 2700x2200x2500 65 IP31 35 36 Max Noise level Enclosure housing OPERATION & MAINTENANCE MANUAL Page 0128 . Width c.
3.2: General Arrangement of Aux. Transformer (500 kVA) OPERATION & MAINTENANCE MANUAL Page 0129 .6.3 Fig 1. BANGALORE METRO RAIL CORPORATION LIMITED Auxiliary Transformer (500 kVA) 2.
IS 11171 Cast resin 3 50 Dyn11 500 Air 36 33 1.6.4 The technical parameters of Auxiliary Transformer (500 kVA) are as below: Table 1.3.3: 33 KV/415V Auxiliary Transformers GTP (500 kVA) SN Description Unit of Measure ment Values 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Type Name of the manufacturer Country of manufacture Port of embarkation Manufacturer drawing reference Relevant Specification Insulation type Number of phases Frequency Vector group Nominal rated power Cooling Mode Primary rated insulation voltage Primary operating voltage Secondary system highest voltage Secondary rated operating voltage Rated short duration power frequency withstand voltage for primary winding Rated lightning impulse withstand voltage for primary winding kV kV V V kV kVA Hz Dry type cast resin ABB Korea Busan ABB IEC 76. IS 2026. BANGALORE METRO RAIL CORPORATION LIMITED Technical Specifications 2.1kV 415/240 70 18 kV 170 OPERATION & MAINTENANCE MANUAL Page 0130 .
950 28 Total loss at rated voltage (refer to ITT for capitalization of losses) (at 75℃) kW 6.0 -5. +5. BANGALORE METRO RAIL CORPORATION LIMITED Description Unit of Measure ment kV Values SN 19 Rated short duration power frequency withstand voltage for secondary winding Rated lightning impulse withstand voltage for secondary winding Percentage Impedance Voltage setting (off load tap changer) 3 20 kV 3.0 30 % 1.0 23 24 25 26 Winding material Max. 0. efficiency % loading at maximum efficiency No load loss at rated voltage (refer to ITT for capitalization of losses) kW aluminium 98.0 1.5. +2.2 OPERATION & MAINTENANCE MANUAL Page 0131 .0 31 % 1. -2.79 50% at pf 1.68 29 Impedance at rates current and frequency Reactance at rated current and frequency Voltage regulation at full load % 4.0.73 27 Copper loss at rated voltage (refer to ITT for capitalization of losses) (at 75℃) kW 4.5 21 22 % % 4.5.
Overall for packages Mm Mm Mm Mm dB 2400 2000 2400 2800x2400x2800 65 IP31 35 36 Max Noise level Enclosure housing OPERATION & MAINTENANCE MANUAL Page 0132 . Core b. Winding c. Length b. BANGALORE METRO RAIL CORPORATION LIMITED Description Unit of Measure ment Values SN 32 33 Type of core Weight a. Total(TR+Enclosure) Kg Kg Kg Core type(step-lap) 1800 490 3600 34 Dimensions(enclosure) a. Width c. Height d.
BANGALORE METRO RAIL CORPORATION LIMITED Auxiliary Transformer (2000 kVA) 2.3.5 Fig 1.6.3: General Arrangement of Aux. Transformer (2000 kVA) OPERATION & MAINTENANCE MANUAL Page 0133 .
6.4: 33 KV/415V Auxiliary Transformers GTP (2000 kVA) 2.6 SN Description Unit of Measure ment Values 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Type Name of the manufacturer Country of manufacture Port of embarkation Manufacturer drawing reference Relevant Specification Insulation type Number of phases Frequency Vector group Nominal rated power Cooling Mode Primary rated insulation voltage Primary operating voltage Secondary system highest voltage Secondary rated operating voltage Rated short duration power frequency withstand voltage for primary winding Rated lightning impulse withstand voltage for primary winding kV kV V V kV kVA Hz Dry type cast resin ABB Korea Busan ABB IEC 76.3. BANGALORE METRO RAIL CORPORATION LIMITED Technical Specifications The technical parameters for Auxiliary Transformer (2000 kVA) are as below: Table 1. IS 2026. IS 11171 Cast resin 3 50 Dyn11 2000 Air 36 33 1.1kV 415/240 70 18 kV 170 OPERATION & MAINTENANCE MANUAL Page 0134 .
efficiency % loading at maximum efficiency No load loss at rated voltage (refer to ITT for capitalization of losses) kW aluminium 99.25 30 % 0. +5.0 27 Copper loss at rated voltage (refer to ITT for capitalization of losses) (at 75℃) kW 15. +2.20 50% at pf 1.0 23 24 25 26 Winding material Max.0 4.3 28 Total loss at rated voltage (refer to ITT for capitalization of losses) (at 75℃) kW 19.5 21 22 % % 6. 0.3 29 Impedance at rates current and frequency Reactance at rated current and frequency Voltage regulation at full load % 6.25 -5.5.0 OPERATION & MAINTENANCE MANUAL Page 0135 .0. -2. BANGALORE METRO RAIL CORPORATION LIMITED Description Unit of Measure ment kV Values SN 19 Rated short duration power frequency withstand voltage for secondary winding Rated lightning impulse withstand voltage for secondary winding Percentage Impedance Voltage setting (off load tap changer) 3 20 kV 3.5.7 31 % 1.
The following protections are essential to ensure the reliability and operation of the transformer.6.7. Overall for packages Mm Mm Mm Mm dB 2800 2400 3000 3200x2800x3400 65 IP31 35 36 Max Noise level Enclosure housing 2. For this purpose there should be an automatic diverter switch or short-circuit fuses which take into account the possible overloads and are calibrated to prevent currents from passing that are 1.7 Transformer protection.5 or 2 times greater than the specified current. Total(TR+Enclosure) Kg Kg Kg Core type(step-lap) 3990 1200 7100 34 Dimensions(enclosure) a. The transformer must be protected from the thermal and dynamic effects caused by over currents and short-circuits.6. 2. BANGALORE METRO RAIL CORPORATION LIMITED Description Unit of Measure ment Values SN 32 33 Type of core Weight a. Width c. Height d. Length b. Winding c. OPERATION & MAINTENANCE MANUAL Page 0136 .1 Protection from over currents and overheating. Core b.
6. 2.8 CONNECTIONS Coupling When the transformer is connected to the H. BANGALORE METRO RAIL CORPORATION LIMITED Ventilation of the transformer cell. it should be ensured that it is well-ventilated and that it is of the correct size to allow air to pass in and out. P = The sum of the no-load and full-load losses of the transformer in kW. NOTE: This formula is valid for a maximum room temperature of 40ºC and a max. The input E and output S surfaces should have at least the surface areas in m given by the following formulas: E = P / (5. If the transformer is mounted inside a cell. forced ventilation should be used. If the transformer cannot be installed in premises with sufficient natural ventilation. and L.2 The ambient air temperature should not exceed that indicated by the standards.4 x √H) Where: H = Distance between the centers of openings. Altitude of 1000 m. There is suitable ventilation to stop the transformer from overheating above the limits established by the standards.6.V. circuits the connections should be carried out in such a way that they do not exert any strain on the terminals and should have a large enough section to prevent excessive heating. steam generators. expressed in meters. The transformer should not be installed in small rooms with blinds or metallic walls exposed to direct sunlight. etc.7. The transformer should not be installed in premises that are destined for other uses. The transformer must be located at least 100 mm away from the cell walls and its bushing must be at least 350 mm from the cell roof and walls. OPERATION & MAINTENANCE MANUAL Page 0137 .V. in particular in those in which there are machines that work at high temperatures: boilers. The air for cooling the transformer should not be aspired or expelled in the same room in which it is installed. They should also be able to dilate.15 E 2 2. The following should be avoided: S = 1.
BANGALORE METRO RAIL CORPORATION LIMITED
It is important to make sure of a suitable connection and tightening of all the bolts.
Using an ohmmeter check the continuity of the circuit with the tap changer in all of the positions as well as checking that the bridges are correctly fixed in the working position. The enclosure or lower flange of the transformer should be securely and permanently connected to earth by means of the earthing screws on the bottom right of the two larger, lower, opposite faces of the enclosure or flange.
If the transformer has to be parallel-coupled to other transformers, check that it fulfills the voltage compatibility conditions established by the standards, check the position of diverter switches, impedance voltage and connections unit. As per standards no. IEC 60076-4 and IEC 60606-4.
Identical rated voltages and frequencies (voltage tolerance 0.5%). The transformers should belong to the same vector group. Identical short-circuit voltage (tolerance +/- 10%) Power ratio of (maximum) 1/3 at continuous load.
Permanent and adequate grounding is essential for the enclosure, core and coil assembly of transformers. Grounding is required to remove static charges that accumulate, as well as protect the equipment should the transformer windings accidentally come in contact with the core or enclosure. To ensure a solid core ground, transformers have copper straps embedded in the core laminations and securely connected to the lower flame. The transformer is equipped with two ground terminals, one on each side of the lower flame. Main grounding must be connected to one of these ground terminals or ground pads as shown in following fig.
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BANGALORE METRO RAIL CORPORATION LIMITED
Voltage regulation (± change over) must be done by the no load tap changer which is attached to the high voltage winding. Following fig. is the general type of tap changer. Before changing tap make sure transformer to be de-energized. The voltage steps are indicated on the nameplate. On dispatch, the transformer is connected in the rated position. When changing the voltage the tap connector must be moved to the required position. The tap connections should be re-tightened and locked in such a way that they do not exert any strain on the terminals and should have a large enough section to prevent excessive heating. Using an ohmmeter check the continuity of the circuit with the tap changer in all of the positions as w ell as checking that the bridges are correctly fixed in the working position.
The cable is connected to the insulator on the upper yoke, or connection terminals on the coil. To ensure good connection between terminals and the connecting cables, the contact plates must be cleaned for anti-oxidization. This is very important in order to ensure a low connecting resistance and to avoid the heating of the screw connections. When dispatched from the works the contact plates are cleaned. When connecting terminals, confirm the sign of each phase. When connecting transformer terminals with cable, the cable should be supported to cubicle or other place solidly.
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BANGALORE METRO RAIL CORPORATION LIMITED
When transformer terminals are connected with bus duct, it is necessary to use flexible bus bar. If transformer terminal with bus duct is connected directly without flexible bus bar, vibration of transformer may cause damage to bus duct or increasing of noise. To ensure good connection between the low voltage bushings and the bus bars or the connecting cables, the contact plates must be cleaned for oxidization. This is very important in order to ensure a low connecting resistance and to avoid the heating of the screw connections. When dispatched from the works the contact plates are cleaned and covered with silicone grease as a protection against oxidization. For the first connection it is therefore sufficient to remove the silicon grease immediately before the connection is carried out. Table 1.3.5 Conical Washer No. M10 M12 M16 Ф 10.5/21 x 1.1 Ф 14.2/28 x 1.5 Ф 16.3/34 x 1.5 2 2 3 Dimension (mm) Ф 10.5/23 x 2.5 Ф 13.0/29 x 3.0 Ф 17.0/39 x 4.0
SizeBolts & Nuts
Flat Washer (mm)
Current Per Screw (A) One-side Connection 250 500 800 Both-side Connection 400 750 1250
CHECKS TO BE CARRIED OUT BEFORE PUTTING THE TRANSFORMER INTO OPERATION
Checks The transformer is supplied ready for installation but before proceeding to put it into operation, following checks should be carried out:
All of the recommendations indicated in Topics – Installation & Connections
should be checked.
The transformer should be cleaned with a vacuum cleaner to eliminate any dust. Check the thermal protection device Check insulation resistance according to the following table:
OPERATION & MAINTENANCE MANUAL Page 0140
BANGALORE METRO RAIL CORPORATION LIMITED
Insulation Between: HV / LV HV / Earth LV / Earth Test Voltage 5.000 Volt 5.000 Volt 2.000 Volt Minimum Value in MΩ (≥) 1 per kV Ampere Turns 1 per kV Ampere Turns 2
Putting the Transformer into operation:
Once the transformer has been connected to the H.V. mains:
Voltage will be applied in a non-load state and observed for one hour. No anomalies should occur during this period of time. Afterwards charging, after storage or disconnection during a prolonged period, first it is recommendable to connect the transformer during four hours in no-load for loss of the possible damp with the core heating. After this period it can be put into a normal operation. The voltage will be measured at the L.V. terminals to check the corresponding output voltage depending on the transformation ratio. To apply the load progressively until the rated power is reached and check the increase in temperature.
OPERATION & MAINTENANCE MANUAL Page 0141
415 kV Check List Visual inspection of the complete unit for any abnormality. Alarm: 90 Deg C Trip: 120 Deg C Check the tap changer links and tighten them if required. and the monitoring Units are in working condition. Nitrogen bottles as normally supplied. BANGALORE METRO RAIL CORPORATION LIMITED MAINTENANCE SCHEDULE Maintenance Schedule: 2. IR values: Primary winding with 5/2.5 KV megger P-E = 250 M ohm P-S = 200 M ohm Secondary winding with 500 V megger S-E = 50 M ohm Earthing check for tightness Check the ventilation/cooling of the Transformer Check the control devices such as thermometer temp. No 1 Dry Type Transformer M/s ABB Limited 33/0.6. 2 3 4 5 6 Quarterly Maintenance 7 8 9 10 OPERATION & MAINTENANCE MANUAL Page 0142 . Clean any dust from surfaces using a vacuum cleaner or by blowing with dry air or nitrogen (maximum pressure 3 Kg/cm2).16 Equipment Make: System Voltage Schedule Sl. can also be used. equipped with a pressure reducer. The tapping must be same for all the MV coils. Check the alarm and trip settings. Tightening of bolts & nuts HV/LV of Incoming/Outgoing cables Tightening of clamps of Aux Box Check the transformer temperature Cleaning of transformer enclosure for dust removal with a low pressure electric Blower.
All Drawings and Manufacture‘s Instruction & Maintenance manual shall be ensured at site for reference during Maintenance. 5.17 Precautions The following measures are amongst the most important ones. 1. 2. Any touchup paints required to be carried out. 2. 4. Standard tools and accessories as per Instruction and Maintenance Manuals shall be ensured for facilitating the normal maintenance activities on the Equipment.6. and L. 3.8 Outdoors Stainless Steel A2 or A4 Molybdenum Bisulphide Grease (Mo S2) Grip Torques (Nm) 10 20 40 80 15 30 60 120 20 40 75 140 OPERATION & MAINTENANCE MANUAL Page 0143 . Earth them at both ends before carrying out any maintenance work.V.6.V. Using an insulating rod the transformer bushings should be earthed to ensure that there is no remaining static charge.18 Disconnect the H. The bushings are then short-circuited and earthed. Ensure that the equipment is disconnected from all electrical supply. switches so that the transformer is deenergized and out of service. Always follow the instruction and Maintenance Manual of the manufacturer.8 Oil SAE 30 or 40 Vaseline Grease 8. All safety precautions shall be taken during Maintenance. Before examining or carrying out maintenance on the transformer: 2. Tightening torque of connections INSTRUCTIONS TO MAKE SCREWED JOINTS IN LOW AND HIGH VOLTAGE HV & LV SCREWED CONNECTIONS Indoors Quality of Nuts & Bolts Lubricant for Nut & Bolt Nuts/Bolts M8 M 10 M 12 M 16 8. BANGALORE METRO RAIL CORPORATION LIMITED Yearly Maintenance Remarks: - 1 2 All points of quarterly inspection.
the layer of aluminum oxide must be removed by brushing or sandpapering. BANGALORE METRO RAIL CORPORATION LIMITED When one or both of the bars to be joined together are aluminum. This operation must be repeated if the connection bars are dismounted for any reason. so its presence prevents making a good contact. HV SCREWED CONNECTIONS Nuts/Bolts Grip Torques (Nm) M6 5 M8 10 M10 20 M12 40 M16 100 H. Aluminum/copper joints must have a bi-metal plate. apply a very fine coat of special grease for electrical contacts. correspond to greased bolts.V. indicated on the table. The grip torques. Molybdenum bisulphide grease must be used for stainless or hot galvanized nuts and bolts. This layer is practically invisible and extremely resistant. bolts must not be greased because are screwed in brass. Once clean. OPERATION & MAINTENANCE MANUAL Page 0144 . Any excess must be cleaned after tightening. Greasing oil or white Vaseline grease can be used. in order not to soil the area around the connection.
BANGALORE METRO RAIL CORPORATION LIMITED CHAPTER – IV OPERATION & MAINTENANCE MANUAL Page 0145 .
A) Installation of the brackets for horizontal fixing.1.0 1.6 1. 1. The torque value must be such as the bracket can manually be moved for adjustments.1. Put the bracket in position to have in alignment the two holes of the bracket and the two plastic dowels of the sleeper. Put the bracket in position to have in alignment the four holes of the bracket and the four plastic dowels of the sleeper.1.1. Add 2mm HDPE pad between base plate and slab.8 Put the bracket in position & fix the base plate to the slab.1.1 Concrete Sleeper and Plinth B) Installation of the brackets for lateral fixing 1. The torque value must be such as the bracket can manually be moved for adjustments. Add 2mm HDPE (High-Density Polyethylene) pad between base plate and slab. Push 4 screw spikes with double coil spring washers through the base plate in the plastic dowel of the slab. OPERATION & MAINTENANCE MANUAL Page 0146 .1. For all types of sleeper.1.1 1.4 1.1 THIRD RAIL Installation of Brackets Brackets are differentiated by their height and their base plate.1.3 Fix the base plate to the slab.1. Fig. 1.2 1.7 1.5 1. BANGALORE METRO RAIL CORPORATION LIMITED 1. the two screws spike are then inserted and pre-bolted.
1.2 Bracket Adjustment Positions OPERATION & MAINTENANCE MANUAL Page 0147 . BANGALORE METRO RAIL CORPORATION LIMITED Fig 1.
1.5 Height of the insulator must be then positioned in reference to the running rail using Rail setting gauge. Another mobile jaw cannot be mounted in place of the original mobile jaw delivered with the fix jaw.1 1.3 1. This can be achieved by bolting & unbolting the M10 screws simultaneously or one after the other. The galvanized brace must be inserted in the brace support and must be inserted then.2. Jaws are delivered in assembled condition. Fig 1.2. These must be mounted as delivered. These must never be unmatched.4 Fig 1. Ensure torque value for the bolt must be 80Nm.2. BANGALORE METRO RAIL CORPORATION LIMITED Installation of Insulator Each mobile jaw is drilled for one fix jaw. inside the top of the bracket.2.2.2. from the bottom.2 1.1: Bracket Insulator 1. Fasten the composite body to bracket by means of one M16x75 screw with flat & spring washer under its head.2 1.2.2: Height adjustment of Insulator OPERATION & MAINTENANCE MANUAL Page 0148 . Put the M16 screw going inside the brace.
BANGALORE METRO RAIL CORPORATION LIMITED 22.214.171.124: Methods of Lateral Adjustment OPERATION & MAINTENANCE MANUAL Page 0149 .6 Check & confirm lateral adjustment( the edge of the bottom of the bracket shall be strictly perpendicular to the running rail) using Rail setting gauge and bolt the screw spikes at 200 to 245 Nm for concrete sleeper and plinth. Fig 1.
1. to fit the existing adjoining rails.3.3.5 OPERATION & MAINTENANCE MANUAL Page 0150 . BANGALORE METRO RAIL CORPORATION LIMITED Installation of Conductor Rail Place the rail in correct position of the slot of the fix jaw.1 Fig 1.2 This is done with four persons lift the rail at each end while a 5th and a 6th person assist lifting in the middle. On each side of the fix jaw.3. one people will introduce the mobile jaw into the fix jaw. The foot of the rail must be properly set in the slot of the mobile jaw. Once the mobile jaw is in position. To ease this procedure. 1. The orientation of the insulator is then checked by means of 5mm thick wedges. Be careful and be aware of the ends of the conductor rail which are overhung 2.3 1. lock it with the two pins. thereby securing the rail in place. tilting or twisting. A person should guide and act as signalman to forklift or crane operator and push in conductor base into the fixed jaws of the insulators. The ends shall be restrained with properly tied ropes to guide and prevent the section from spinning.3.4 1. a boom or hydraulic crane with spreader bar could be used.1: Third Rail 1. one people must check that a 5mm wedge can be inserted between the top of the rail and the fix jaw.8 meters.3. the 5th and 6th person slides the clamps along the rail web and tightens the insulator clamp.3.3 1. sliding and pushing the rail in such a manner that the base of the conductor rail will be slotted on the fixed jaw of the insulator. While the four persons are holding the conductor rail in position.
BANGALORE METRO RAIL CORPORATION LIMITED
Fig 1.3.2: Methods of Orientation of Insulator 1.3.6 Check height of the conductor rail using track gauge by means of unbolting insulator screw and adjusting the height of the insulator by moving up and down using 2 no. M10 screws on the top of the bracket.
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BANGALORE METRO RAIL CORPORATION LIMITED
Fig 1.3.3: Checking Height of Third Rail using Track Guage
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BANGALORE METRO RAIL CORPORATION LIMITED
Ensure third rail contact surface should be in the range of -4 to +4 indicated on the special tool.
Bolt the insulator screw at 80Nm and ensure the two bracket screws for a torque of 200 to 245 Nm with lateral adjustment. The orientation of the insulator is then again checked by means of 5mm thin wedges.
1.3.10 To cut the rail at right length, use rail cutting band saw and cut must be square at +/10.The vertical cut aluminium surface and the contact surface must be abraded and burrs removed. After the rail is cut it is necessary to drill two holes (16mm dia). Use the Rail End Drill Jig to do the holes , make sure that template is seated properly at the web and drill the two holes. Remove the burrs and clean the holes.
OPERATION & MAINTENANCE MANUAL Page 0153
BANGALORE METRO RAIL CORPORATION LIMITED
Installation of Splice Assemblies Apply a thin layer of contact grease after cleaning thoroughly and abrading the surface of the conductor rail and the splice plates with a steel brush for optimum electrical conductivity. Install the splice plates to both sides of the web of the conductor rail end to be joined keeping a minimum distance of 200mm away from the jaws of the closest insulator.
Tighten the outer two Huckbolts, make sure that the rail ends are touching each other and then install the rest two Huckbolts. Use appropriate equipment for installation of Huckbolts.
Fig 1.4.1: Splice Assemblies
OPERATION & MAINTENANCE MANUAL Page 0154
4. Ensure that all the Huckbolts and collars dismounted must be replaced and never be used again. Lightly polish (with an emery disc) the stainless steel surfaces at the rail junction to obtain a smooth transition between the two conductor rails.5 1.7 OPERATION & MAINTENANCE MANUAL Page 0155 . BANGALORE METRO RAIL CORPORATION LIMITED 1. The maximum gap between the two conductor rail shall be 2mm.4.4.6 1. 1.4.4 Clean the joint of any excess contact grease and securely cover the contact grease container to prevent any contamination. Put corrosion resisting paint on broken side of each Huckbolts.
5 1.6 Check the height and the alignment of the expansion section assembly using track gauge. Set the right gap opening of the expansion joint by sliding on end of the expansion joint with adjustable screw by using table below which is arrived through the calculation note.3 1.5. sliding and pushing the rail in such a manner that the base of the conductor rail of the assembly will be slotted on the fix jaws of the two insulators.5. 1. To ease this procedure. The ends shall be restrained with properly tied ropes to guide and prevent the section from spinning. A person should guide and act as signalman to forklift or crane operator and push in conductor base into the fixed jaws of the insulators.2 1.7 1. Be careful and be aware of the ends of the adjoining installed conductor rails.5. Extreme caution must be exercised in lifting the assembly. adjust if needed.1 1. 1. tilting or twisting.5.5.4 1.5. at bottom web and top surface of the conductor rail using digital thermometer.5 1.5. Record and take the average of the temperature with the sensor point at base. a boom or hydraulic crane with spreader bar could be used. BANGALORE METRO RAIL CORPORATION LIMITED Installation of Expansion Joints Bring the expansion joint assembly to the vicinity of the installed insulator chairs. Ensure the length between the expansion joint and insulator will be the same on the two sides. Two persons should be able to lift the assembly while the third person assists lifting near the middle.8 OPERATION & MAINTENANCE MANUAL Page 0156 .5.
5. BANGALORE METRO RAIL CORPORATION LIMITED Fig 1.1: Expansion Joint Gap CR Temp in 0 C at the time of Installation 6 7 8 9 10 11 12 13 14 15 16 17 18 Gap in mm 149 147 146 144 142 140 138 136 134 132 130 129 127 CR Temp in 0 C at the time of Installation 19 20 21 22 23 24 25 26 27 28 29 30 31 Gap in mm 125 123 121 119 117 115 113 112 110 108 106 104 102 CR Temp in 0 C at the time of Installation 32 33 34 35 36 37 38 39 40 41 42 43 44 Gap in mm 100 98 96 95 93 91 89 87 85 83 81 79 77 OPERATION & MAINTENANCE MANUAL Page 0157 .
1.15 After the expansion section installed protective cover must be specially cut near the expansion joint with the formula RFIX = 0. then the radii in any case should not be less than 300 m. 1.5.14 Expansion sections are not desirable in radii under 300mtrs and it is not recommended to avoid installation of an expansion on a curve.9 1. 1. if it is unavoidable.5 X GAP + 80 in mm & RMOBILE = -0. 1. Then remove the expansion joint special tool. 1.13 The brackets on either side of the expansion joint assembly should be marked by red paint to ease the maintenance control. install the expansion joint at half of the recommended distance and go to the second anchor at the other side of the expansion joint to install the rest of the third rail. Put the 4 plastic washers in the holes of the expansion joint cover and fasten it with 4 slotted flat head screw M8x25 (2 Nm) in the cover fasteners of the expansion joint.11 The installation of the two anchors and the adjustment of the expansion gap must be made at the same time of the day to get constant ambient temperature.12 Power feed cannot be installed on the 4m long expansion joint section.10 For installing of expansion joint.5.5.16 Fasten the two upper and the four lateral cover fasteners for expansion joint with CHC screws M8x35 (8 Nm) and put on the expansion joint cover.5.5. OPERATION & MAINTENANCE MANUAL Page 0158 . However.5. BANGALORE METRO RAIL CORPORATION LIMITED Recheck the contact surface alignment and temperature readings.5 X GAP + 180 in mm 1.5.5. start from one anchor. 1.
BANGALORE METRO RAIL CORPORATION LIMITED Fig 1.2: Expansion Joint Assembly OPERATION & MAINTENANCE MANUAL Page 0159 .5.
5. BANGALORE METRO RAIL CORPORATION LIMITED Fig 1.3: Expansion Joint Covers OPERATION & MAINTENANCE MANUAL Page 0160 .
check gap setting as per chart before drilling second anchor in place.1 Fig 1. Go to expansion section.6.6 1.6.1: Anchor Blocks OPERATION & MAINTENANCE MANUAL Page 0161 . BANGALORE METRO RAIL CORPORATION LIMITED Installation of Anchor Blocks Installation of the anchor assembly can be done after the conductor rail had been installed from end to end. 1.
6.2: Installation of Anchor Blocks OPERATION & MAINTENANCE MANUAL Page 0162 .6. locate the nearest insulator bracket. Install and fit the anchor blocks on both sides of the insulator jaws and tighten with two Huckbolts using the prescribed equipment.6.4 1.6.5 1.6 Apply a thin layer of contact grease on the contacting surface of the conductor rail and the anchor blocks for optimum electrical conductivity. Drill a 13mm dia hole on each side of the insulator jaws using the mid anchor rail drill jig ensuring rails are secured and the insulator support bolts are tightened properly so that it will not topple over.3 1.2 1. Ensure the clearance between the edges of the jaw to the edge of the anchor block is less than 3mm.6.6. BANGALORE METRO RAIL CORPORATION LIMITED Identify the location where the anchor blocks to be installed. Fig 1. 1.
1.8 Two anchor sets must be installed on two consecutive insulators for every length of rail up to 90 meters.7 Clean the joint of any excess contact grease and securely cover the contact grease container to prevent any contamination. BANGALORE METRO RAIL CORPORATION LIMITED 1.6. OPERATION & MAINTENANCE MANUAL Page 0163 .6. Put corrosion resisting paint on broken side of each Huckbolts.
BANGALORE METRO RAIL CORPORATION LIMITED The bracket on which the anchor assembly is mounted should be marked by red paint.10 Ensure that all the Huckbolts and collars dismounted must be replaced and never be used again.9 1.6. OPERATION & MAINTENANCE MANUAL Page 0164 . 1.6.
7. BANGALORE METRO RAIL CORPORATION LIMITED Installation of Cover Fasteners ( Clips) Descend the cover fastener up to the top horizontal surface of the conductor rail till the foot of the rail comes in contact with the internal surface of the cover fastener.1 1. check the teeth are correctly in position under the foot of the rail. 1. The cover fastener is then turned by 300.2 1. If necessary use a soft hammer to put the cover fastener at the right position and to block it on the foot of the conductor rail. The two teeth of the cover fastener must then be under the level of the foot of the rail.7 1.7.3 OPERATION & MAINTENANCE MANUAL Page 0165 .7.
7. 1.4 1.7. Minimum distance between the conductor rail clamp and the closest part of the cover fastener is 200mm.e 12 cover fasteners between two insulators.5 OPERATION & MAINTENANCE MANUAL Page 0166 . BANGALORE METRO RAIL CORPORATION LIMITED Cover fasteners must be set every 420mm maximum i.
Secure the ramp by tightening the jaws hardware while one person holds the ramp to prevent the assembly from tilting.7 1. OPERATION & MAINTENANCE MANUAL Page 0167 .4 1.6 1.8.8. locate the nearest insulator bracket. The mask is removed and the opening is made with a plastic saw. The opening has to be marked on the cover by using the mask. The dimensions should be as specified in the drawings. Slide the adjoining conductor rail to be spliced to the butt of the ramp. Splice the ramp as explained in installation of splice assemblies. insulator to insulator and left end of ramp (splice side) to insulator.8 1. BANGALORE METRO RAIL CORPORATION LIMITED Installation of Ramps Identify the location where the ramps to be installed.2 1. Install ramp by slotting its base in to the jaws of the insulators. Conductor rail contact surface height should be in the range of ±4mm.8.5 1. Set the height of the ramp using the Rail Track Gauge in regards to the height of the ramp as per drawing.1 126.96.36.199 1.8 Ramp cover must be cut in a specific manner in the area of the first bracket for the insulator using the ramp cover cutting jig.8. Locate the three insulators and check the dimensions from right end of the ramp (bent side) to insulator.8. 1. Ramp cover must be cut to the correct length to join the insulator cover of the second bracket and have a minimum recovery distance of 100mm.8.
e.8. at 550mm from the end of the ramp-spliced side.10 Put the specific cover on the two other standard covers and drill the two standard covers using the drilling of the specific cover.8. OPERATION & MAINTENANCE MANUAL Page 0168 .11 Ensure minimum recovery of 100mm at cover junctions.8. M5 plastic screws near from the first bending axis of the ramp i. 1.9 Two lengths of the standard protective cover have to be adjusted and joined by a specific cover with 8 Nos. BANGALORE METRO RAIL CORPORATION LIMITED 1. 1.
8. OPERATION & MAINTENANCE MANUAL Page 0169 .12 The cover fasteners of the end of the ramp need to be modified to respect the structure gauge. The cutting profile should be the same as the top of a complete cover fastener. It‘s necessary to cut the cover fasteners at the correct height to get the ramp cover horizontally at the end of the ramp. BANGALORE METRO RAIL CORPORATION LIMITED 1.
8.13 Installation of special cover fasteners should respect the rules explained in cover fasteners installation.8.1: Ramp Assembly OPERATION & MAINTENANCE MANUAL Page 0170 . BANGALORE METRO RAIL CORPORATION LIMITED 1. Fig 1.
of Assemblies. 1.4 1.9. make sure that the collar shall be at the opposite side of the cables lugs bolting area and then install the last Huckbolts. BANGALORE METRO RAIL CORPORATION LIMITED Installation of Connector Plates.7 OPERATION & MAINTENANCE MANUAL Page 0171 . Cut the cover at the location of the power feed using power feed cutting mask designed for the protective cover.9.9 1.5 1. 1. Put the bimetallic plate between lugs and power feed and set the contact grease for mating between the two surfaces.9.9.Put corrosion resisting paint on broken side of each Huckbolts. and clean the area of any debris.6 1.9. clean the holes.9. remove the burrs. Drill the three 16mm holes using the power feed rail drill jig . Clean the area of any excess contact grease . Tighten the outer two Huckbolts.3 Apply a thin layer of contact grease after cleaning thoroughly and abrading both the sides of web of the conductor rail and the connector plates with a steel brush for optimum electrical conductivity.9. Put the jig at the right position on the protective cover and cut the cover following the jig. Power feed Locate the point where the power feed is to be installed and identify the no. Install the connector plates to both sides of the web of the conductor rail ends.1 1.2 1.
9.9.11 Each power feed assembly can accommodate two 500 sq. washers and nuts to the protective cover through the 8mm holes drilled previously.9. OPERATION & MAINTENANCE MANUAL Page 0172 .9. BANGALORE METRO RAIL CORPORATION LIMITED 1.8 1. 1.9.12 Ensure no power feed to be installed on the expansion section.9 Drill the four 8mm Dia holes.10 Ensure a minimum distance of 500mm between two power feed covers and edge of the power feed must be at least 1 meter away from the closest insulator‘s jaw. 1. 4 helical spring lock washers and nuts M6. Put the special cover on the power feed and fastened it by four plastic screws. fasten the cover fasteners for power feed on the plate with 4 CHC screw M6x40 at 9Nm. mm copper cables and not more than 3 power feeds installed between two brackets. 4 flat washers. 1.
a boom or hydraulic crane with spreader bar could be used. 1.10.5 Ensure the length between the insulated joint and insulator will be the same on the two sides. 1. 1. 1.10.10. OPERATION & MAINTENANCE MANUAL Page 0173 . 1.1 Bring the insulated joint assembly to the vicinity of the installed insulator chairs.4 To ease this procedure. adjust if needed. sliding and pushing the rail in such a manner that the base of the conductor rail of the assembly will be slotted on the fix jaws of the two insulators. Three other cover fasteners should be cut and put on the insulated joint. A person should guide and act as signalman to forklift or crane operator and push in conductor base into the fixed jaws of the insulators.10. 1.10. 1.2 Extreme caution must be exercised in lifting the assembly. tilting or twisting.9 Standard protective cover must be put on the insulated joint.10.6 Check the height and the alignment of the insulated section assembly using track gauge. Two cover fasteners should be put to the closest of the ends of the insulated joint splices.10. The ends shall be restrained with properly tied ropes to guide and prevent the section from spinning. BANGALORE METRO RAIL CORPORATION LIMITED Installation of Insulated Joint Assemblies 1.10. Be careful and be aware of the ends of the adjoining installed conductor rails.3 Two persons should be able to lift the assembly while the third person assists lifting near the middle. Screws should be between the legs of 3 these cover fasteners. 1.10 1.7 The brackets on the either side of the insulted joint assembly should be marked by red painted to ease the maintenance control.8 Insulated sections are not desirable in radii under 300mtrs and it is not recommended to install an insulated joint on a curve.10.
10.10 Clip the protective cover on the insulated joint pushing on the top of the cover at the position of the two nearest cover fasteners. OPERATION & MAINTENANCE MANUAL Page 0174 . BANGALORE METRO RAIL CORPORATION LIMITED 1.
5 The cover is clipped on the cover fasteners by pressing on the top of the cover.11. Clip one of the legs of the cover correctly on the cover fastener and push on the top of the cover at the position of the cover fasteners to clip the other leg.1: Protective Cover OPERATION & MAINTENANCE MANUAL Page 0175 .11. make sure that the conductor rail components are rightly installed.850mtr) must be presented in a vertical position. 1.11.4 The accuracy of cut must be [0. 188.8.131.52 Installation of UPVC & GRP Protective Covers 1. it is necessary to cut the cover at the adequate length L=E-150(in mm) where E stands for the length between the insulators. opening down with each end of cover must be located at an equal distance from the closest insulator.-10mm] and cutting of the cover must be square to the cover axle with an accuracy of [-2. Fig 1.3 In case the length between consecutive insulators is less than 5mtr .1 Before installation of covers. 1. 1.2 Cover (4. +2] and debur the ends. BANGALORE METRO RAIL CORPORATION LIMITED 1.11.
6 The bottom of the cover must be around 20mm above the contact surface.11. OPERATION & MAINTENANCE MANUAL Page 0176 . BANGALORE METRO RAIL CORPORATION LIMITED 1.11.11. 1.11.9 Take special care when installing UPVC covers radii less than 94mtr.7 Correct mounting of the cover must be checked by means of 20mm thick wedge applied at the bottom of the rail and verifying the bottom of the wedge is at the same level than the contact surface of the rail.8 On ramps the cover must be cut in such a manner to let the space required for the passage of the insulator. 1. Mirror can also be used to check the cover is correctly clipped on the cover fastener. 1.
12. 1.12.12 1. the warning label shall be put on. the standard cover is interrupted and the insulator cover is used to against the conductor rail under tension.3 Take special care not to go beyond the elasticity and not to crack or break the insulator cap.12.5 Press on the top of the insulator cover to clip the second leg. 1.1: Insulator Covers 1.1 At the location of the insulator. This operation can be facilitated in pressing the insulator cap against the insulator and rising slowly the leg of the adjacent covers. BANGALORE METRO RAIL CORPORATION LIMITED Installation of UPVC & GRP Insulator Covers 184.108.40.206 Insert the leg of the insulator cover located against the insulator by increasing the opening of the cover by spreading the legs of the insulator cover.12. OPERATION & MAINTENANCE MANUAL Page 0177 .4 The leg of the adjacent covers must be inserted both side inside the bent end of the leg of the insulator cap.6 When the covers are rightly installed. 1. Fig 1.12. 1.
1 At the end of the conductor rail installation. OPERATION & MAINTENANCE MANUAL Page 0178 .13 1. check the conductor rail system dimensions to ensure the installation is not out of the structure gauge using structure gauge which represents the maximum authorized dimensions of the conductor rail system. BANGALORE METRO RAIL CORPORATION LIMITED Structure Dimensions Control 1.13.
Contact surface width: 75 mm Rail height: 105 mm Ramp pick up height: 96 mm c) Mechanical _ Weight of rail: 17 kg/m _ Admissible load on rail at mid span: 1500 N d) Thermal Maximum rail heat rise at 4. BANGALORE METRO RAIL CORPORATION LIMITED MAINTENANCE OF THIRD RAIL GENERAL 2. The rail conductor maintenance should be a part of the end-user overall system maintenance program.0.2 This maintenance program is a recommended procedure and formulated in the premise that the system components are installed properly to the specifications of the Power Rail conductor System Installation.000 A.1 The maintenance of the Power Rail Conductor System must be carefully planned and executed so that the system will achieve its highest performance at the most economical cost.000A and 40°C external: 45°C above ambient OPERATION & MAINTENANCE MANUAL Page 0179 . 220.127.116.11. _ Nominal amperage: 4.1.0 2. 2.0.1 2.3 DESIGN DATA a) Electrical _ Nominal voltage: 750 V. _ System resistance: inferior to 7 mW/m b) Geometrical _ _ _ _ _ _ _ _ Distance of contact surface above running rail: 200 mm Horizontal distance of middle contact surface to track axis: 1 402 mm Contact surface horizontal adjustment (via oblong holes): 50 mm Contact surface vertical adjustment (via an oblong hole): 100 mm Distance between supports: 5 m max.1.
2. BANGALORE METRO RAIL CORPORATION LIMITED TROUBLESHOOTING Probable Cause Loose Splice Assembly (Connection between rails) Possible Remedy Rectify by disassembling the splice assembly. The anchor assemblies and the expansion joint (around the deficient part) should be inspected in order to rectify. Check the conductor rail contact surface plane with the special tools (running rail as reference – Rail Track Guage). by disassembling. No. Rectify. 2. If damage. Uneven wearing Of the conductor bar stainless steel contact surface.0. 2.0. cleaning. Rectify and re-torque to the specific torque. the surfaces in contact will be significantly reduced and localized heating resulting in electrical erosion can be experienced. applying Contactal grease on the mating surface and set the three Huck bolts. change the insulator support. Distortion Vertical or/and horizontal buckling of the third rail system.1 Conductor Rails Trouble Overheating: If overheating has occurred. Check insulator surface. Clean and wire-brush the mating surfaces. 1. if none is found. Check the electrical loading by doing a load survey. OPERATION & MAINTENANCE MANUAL Page 0180 .2 Sl. Adjust the level of the insulators near the rails affected. Assemble the splice assembly with four Huck Bolts. Contactal grease on the mating surfaces and abrade with a wire brush. Thoroughly inspect all components for arcing damage. apply. Specific remedial repairs will depend on the extent on the damage. 3. Rectify if not according to system parameters. If the angle between contact surface and collector shoe is not plane. Check insulator mounting hardware for looseness. Overloading Loose Power feed (Connector Plates) 2. Accidental Impact Buckling Upto a distortion of 3 mm the rail should be replaced or cut to change the deficient part at the first opportunity. there is high possibility that arcing or burning has damaged some or all components in the vicinity. The horizontal distance of the contact rail center should be 1480 mm from the track axis. Misalignment of conductor rails with respect to the collector shoe operating plane envelope.
there is high possibility that arcing or burning has damaged some or all components in the vicinity. No. If the angle between contact surface and collector shoe is not plane. Use anti-seize lubricant to prevent stainless steel from galling. Check loading by load survey.0. Overheating If overheating has occurred. Coat the mating surfaces of the splice plates and the rail with Contactal grease and bolt the two shunts. Micro-arcing At the conductor butted ends of the splice joints. Assemble the plates and Huck bolts. Uneven wearing Of the stainless steel contact cap.0. there is high possibility that arcing or burning has damaged some or all components in the vicinity.2 Splice Assemblies Trouble Probable Cause Loose Splice Assembly (Connection between rails) Possible Remedy Open up the assembly and clean and abrade the mating surfaces with a wire brush. No. The horizontal distance of the contact rail center should be 1480 mm from the track axis. Sl. Overloading Misalignment of conductor With respect to the collector shoe operating plane envelope. Rectify if not according to design.2. Specific remedial repairs will depend on the extent on the damage. Specific remedial repairs will depend on the extent on the damage. cleaning and then applying Contactal grease on the mating surface.2. 1. Probable Cause Loose Splice Assembly (Connection between rails) Bad contact Possible Remedy Rectify by re-installing the splice assembly. OPERATION & MAINTENANCE MANUAL Page 0181 . Check the expansion conductor rail sections contact surface plane with the special tools (running rail as reference—Rail track guage). 1.3 Expansion Section Trouble 2. Clean and abrade the mating surfaces. Set the four Huckbolts. 2. the surfaces in contact will be significantly reduced and localized heating resulting in electrical erosion can be experienced. Overheating If overheating has occurred. Adjust the level of the insulators near the rails affected. Dismount the copper shunts. 2. Coat the mating surfaces of the splice plates and the rail with Contactal grease. Sl. BANGALORE METRO RAIL CORPORATION LIMITED Loose splice Assembly hardwares Rectify by disassembling. 4.
Trouble Excessive Arcing At the Conductor Probable Cause Vibration Possible Remedy Check the base plate of the insulator mounting screw Spikes. apply Contactal grease and tighten the hardware to specified torque values. 1. Rectify by re-installing the splice assembly. Loose splice assembly (connection between rails) 2. Loose jumper cables OPERATION & MAINTENANCE MANUAL Page 0182 . BANGALORE METRO RAIL CORPORATION LIMITED Check the insulator mounting hardware to the bracket for looseness.0.4 Ramp Sl. Micro-arcing At the conductor butted ends of the splice joints. 3. Check the insulator mounting bolt. No.2. Rectify by tightening the bolts according to the specified torque. Rectify by cleaning the Contactal surfaces. Tighten according to the correct torque value. Clean and coat the mating surfaces with Contactal grease and abrade with wire brush.
After the first year. Uneven wearing of conductor stainless steel contact.3 2.3.3. Overheating to check the abnormal discoloration of the aluminium or the stainless steel contact surface. Basis: During the first year of operation.1 Conductor Rails Sl. the conductor rails must have current running for at least 30 mins. Basis: During the first year of operation. After it is recommended to switch off the section where inspection has to be performed and to use the short circuit device. Infrared inspection—During the inspection using non-contact infrared devices. 4. inspection interval could be adjusted based on history of the system. Sl. Interval or Frequency Weekly in a rotating basis to cover the total length of the guideway on three months.2 Splice Assembly Inspection Procedure Overheating to check the abnormal discolouration of the aluminium body. 6.0. Infrared inspection.0. No. Check for loose splice hardware by performing random verification (this must be done during the non-revenue period). Overheating can be identified by infrared scan when an adjoining conductor rail end of the splice assembly or the splice plate temperature exceeds the adjacent conductor rail end temperatures by at least 10 deg C. Distortion of the conductor rail system. BANGALORE METRO RAIL CORPORATION LIMITED INSPECTION AND MAINTENANCE SCHEDULE 2. Inspection Procedure 1. 2. 2. Overheating can be identified by infrared scan when a portion of the stainless steel contact cap temperature exceeds the adjacent conductor rail contact surface temperatures by at least 10 deg C. 4. No. After it is recommended to switch off the section where inspection has to be performed and to use the short circuit device. Infrared scanner should be used as required when loose connections are suspected. 1.0. 2. during inspection using noncontact infrared devices. Infrared scanner should be used as required when loose connections are suspected. 3. the conductor rails must have current running for at least 30 mins. Micro-arcing at the conductor ends. 3. After the first year. and the stainless steel contact surfaces of the joint. OPERATION & MAINTENANCE MANUAL Page 0183 . Interval or Frequency Weekly in a rotating basis to cover the total length of the guideway on three months. 5. inspection interval could be adjusted based on history of the system.
After the first year. BANGALORE METRO RAIL CORPORATION LIMITED Sl.3. Check the tightness of the base plate mounting bolts. Check the bracket alignment with the running rail. Inspection Procedure Check if each half anchor is in correct position around the dedicated insulator jaws. 3. OPERATION & MAINTENANCE MANUAL Page 0184 .4 Anchor Assembly Sl. change the Contactal grease. Basis: During the first year of operation. Uneven wearing of conductor stainless steel contact can be identified by chatter marks where the collector shoes are skipping. Infrared scanner should be used as required when loose connections are suspected. After the first year. the expansion joints shall be dismounted to check the splices. shall be made during the maintenance inspections. Every 5 years. 4. Long Term Work Interval or Frequency Weekly in a rotating basis to cover the total length of the guideway on three months. Check hardware for their correct torque values and shown in correct places as per location drawing. 2. including but not limited. inspection interval could be adjusted based on history of the system. and be examined in totality.3. 2. 2. 3. Check all components in contact with the collector shoes for sign of wear. Interval or Frequency Weekly in a rotating basis to cover the total length of the guideway on three months. No.0. stainless steel contact surfaces and the copper laminated jumper conductors. 5. Micro-arcing at the conductor ends. 1. 1. No. 6. Basis: During the first year of operation. Overheating can be identified when the splice connections or the copper bar (at the expansion sections) exceeds the adjacent conductor rails by at least 10 deg C. inspection interval could be adjusted based on history of the system. 2.3 Expansion Section Inspection Procedure Overheating to check the abnormal discolouration of the aluminium body. Infrared inspection— the following observations.0.
3.3. spring washers and all elements of the insulator assembly are present. Inspection Procedure Check the insulator mounting screw spike. 1. No. 2. Check the shrink on bolts for any breaks or deterioration. 1. No. and no delamination causing danger – Change if necessary. Interval or Frequency Weekly in a rotating basis to cover the total length of the guideway on three months. Check the lay of the power feed cables. 2. The power conductor rail movement must not be restricted during the changes of rail temperature due to changes in ambient temperature and/or electrical loading. be adjusted based on history of the system. Inspection Procedure Interval or Frequency Inspect the cover system. OPERATION & MAINTENANCE MANUAL Page 0185 . 3. No.6 Power Feed Sl. After Inspect the surfaces of the covers. inspection interval could lug terminations or power feed bolts. There shall be no cracks the first year. Discoloration of the surfaces can indicate loose cable After the first year. BANGALORE METRO RAIL CORPORATION LIMITED 2. the base of the conductor rails. Inspection Procedure Interval or Frequency 2. After the first year. Check the clamp. There shall be no loose and Weekly in a rotating basis to cover the total no displacement causing a danger – Change if length of the guideway on three months. Basis: During the first year of operation.3. inspection interval could be adjusted based on history of the system.5 Insulator Support Sl. Basis: During the first year of operation. necessary.0. 2. 1. 2. inspection interval could be adjusted based on history of the system. Basis: During the first year of operation.7 Cover System Sl.0. Visually check for any discoloration of surfaces around Weekly in a rotating basis to cover the total the area where the power feed plate is connected to length of the guideway on three months.0.
a discoloration of the bar will occur.0. Yearly systematic washing. This powder may provide an electrical path to ground. flings may denigrate performance. BANGALORE METRO RAIL CORPORATION LIMITED 2. Remove any iron flings using compressed air. No. Clean the web with compressed air at time of rail grinding. Remove any iron flings using compressed air and/or spraying distilled water then drying with compressed air. Iron OPERATION & MAINTENANCE MANUAL Page 0186 . If electrical arcing is evident. After the first year. There is no need to dismount protective covers. Inspect weekly in a rotating basis to cover the total length of the guideway on three months.8 Conductor Rail System Cleaning Sl.3. 2. Clean insulator composite body with tap water under pressure then dry with compressed air and wait one hour before setting voltage. Interval or Frequency Check weekly around the vehicle wash area. replace the insulator. inspection interval could be adjusted based on history of the system. 1. although. Remove the powder by washing with distilled water then drying with compressed air. the contaminants need to be removed. Contaminants on the web of the conductor will be removed through normal oxidation. iron flings may grind the insulator material. Clean as required. Basis: During the first year of operation. Inspection Procedure Inspect the conductor and insulator for a white powder build-up. 3. Inspect expansion sections for iron filling accumulation. Iron flings accumulating on the insulator may create a path between positive and negative rails or to the pedestal base. Clean at rail grinding and as required. If excessive. Inspect the conductor for filling accumulation caused by rail grinding. Inspect the insulator support for iron filling accumulation.
BANGALORE METRO RAIL CORPORATION LIMITED CHAPTER – V OPERATION & MAINTENANCE MANUAL Page 0187 .
1. Login When WS500 is started.1. Picture call up A default picture is automatically presented after login. it is required to log in with a SCADA operator user name and password.1 Start of WS500 1. From that.1: WS 5000 Graphical User Interface OPERATION & MAINTENANCE MANUAL Page 0188 .1 Basic Operation WS500 is started from the Start menu in a Microsoft Windows PC.1. navigation can be performed to other pictures. 1. 1.2 The graphical user interface Fig. BANGALORE METRO RAIL CORPORATION LIMITED SCADA (Supervisory Control & Data Acquisition System) 1.
1.2: Examples of Poke Points OPERATION & MAINTENANCE MANUAL Page 0189 . Poke points Poke points (push buttons) are presented within pictures using a text or icon and can be used for picture call up. A menu.1.1. BANGALORE METRO RAIL CORPORATION LIMITED The graphical interface consists of a Microsoft Windows styled application window. Menu bar picture call up The menu bar contains selections for both program functions and for picture presentation. The Toolbar The toolbar is used for frequently used functions and are represented by an icon. toolbars and an area for picture presentation can be found in the application. Up to 4 pictures can be presented in one WS500.1. The tooltip function presents a textual explanation of the icon. Process information is presented in process pictures and in lists.5 Fig 1.3 1.2. 1.4 1. Both pictures and dialogues can be selected by shortcuts. The normal usage of the menu bar picture navigation is for subsystem overview picture presentation.2 1.1.2. Dialogues are selected from menus and performed with the help of dialog boxes.2.1.2. a combination of keys on the keyboard and/or the mouse. for program start. and function start up.1 1.2.
1. for program start.2. 1. Pan is made in a zoomed display. Declutter and layer settings. More information may also be added to the Declutter levels (DCL). providing this function has been selected during picture engineering. or by using the vertical and horizontal scrollbars. Panning can also be done by pressing MB1 + Ctrl + Shift. The possible selectable items in the pop-up depend upon the type of object selected when MB2 is pressed. Pressing MB2 presents a pop-up menu. The zoom-functions are used to enlarge and reduce the size of the information of the pictures. BANGALORE METRO RAIL CORPORATION LIMITED Dynamic Function Keys (DF-keys) Each picture in the system has 10 Dynamic Function Keys (DFKs or Soft keys).6 1.4 Locate The Locate function enables the location of network components within graphical pictures. OPERATION & MAINTENANCE MANUAL Page 0190 . and function start up. Using the Zoom Area function. The Zoom back and Zoom forward functions save the previous zoomed in area. Information zooming can also be performed in steps using the Up and Down Declutter functions. The object can also be picked from the list in the dialog box after a filter action has been performed. The identity of the network component to be located can be entered manually in the selection field or selected from pictures. either by pressing MB2 and dragging the cursor when MB2 still is pressed. DFKs can be used for picture call up. Zoom Home will return the picture to the zoom and Declutter level it had when it was originally selected. the selected part of a picture will proportionally be enlarged to the window size. created by the mouse movement. moving the cursor. "Zoom in" will then give an "Information zooming".1.7 Using the right click popup menu A two-button mouse is used to operate the cursor.3 Using the mouse to Zoom and Pan Zoom is easiest performed by pressing MB1 and while MB1 is pressed. 18.104.22.168. With Mouse Button 1 (MB1) functions and objects can be selected. but then the area of the picture should be clicked that is to be focused upon. The new-presented area of the picture will be the rectangle.1.
BANGALORE METRO RAIL CORPORATION LIMITED Fig 1. Fig 1.3: Locate Dialogue Box 1.1. using the cursor and pressing MB1 select an object. Pressing MB2 makes retrieving detail information for this object and then selecting info in the popup menu while the picture element still is selected. In the dialogue that is displayed. the identity of the network component (object name) has to be entered manually.5 Getting more object information from a process picture Pointing at a picture element.4: Info Dialogue Box OPERATION & MAINTENANCE MANUAL Page 0191 .1.1.
6: Stop Audible Alarm OPERATION & MAINTENANCE MANUAL Page 0192 . Fig 1.6 The Alarm Window The five latest incoming unacknowledged alarms for total SCADA are presented in a special Alarm Window. Fig 1.1.7 Audible alarm reset The audible alarm is stopped by pressing the button labeled with a deleted horn icon in the Toolbar next to the Alarm icon.1.1. Click on the button to open the Alarm Window. An Alarm button to the left in the Toolbar indicates by a red color the presence of an unacknowledged alarm. The Locate function can be used to quickly select a station or overview picture showing the object in alarm.1.5: Alarm Window 1. BANGALORE METRO RAIL CORPORATION LIMITED 1.
8.Alarm precipitated by manual action S -. 1.1.1 Event List The event list is circular and contains a number of messages. for example.g. Bottom. If only events or alarms from the actually selected Station. In the parameter field to the right of the list.. the alarms should be acknowledged. the SOE or the Alarm lists. may be made if the station is selected prior to the selection of the Event list. Subsystem and System are required. BANGALORE METRO RAIL CORPORATION LIMITED 1.g. A selection of alarms may be made by pre-selection of. • Event list. from a certain station. Unlike the event list. to make room for additional events without scrolling. the alarm list is not circular in that it may be topped up with new alarms.8.Event precipitated by manual action S -.Alarm noticed by the standby server OPERATION & MAINTENANCE MANUAL Page 0193 . The alarm list contains a number of messages. An extract of events. Navigation is also possible by using the internal scroll bar of the list.Event noticed by the Standby server P -. Page down. event caused by local operation M -. the first page is presented.1. Page up. Event and Sequence of Event Lists There are a number of lists with event and alarm messages: • Alarm list.1. A DFK Extract is also available. When the warning "Alarm list full" is obtained. The letters in the parameter field to the right of the list are as follows: M -. the following letters may occur: L -.8 Alarm.Digital relay. containing status changes of breakers.. Navigation by selecting Top. When an Event list is selected for presentation. a station.2 Alarm List The alarm list contains unacknowledged and persistent alarms. A new message replaces the oldest message in the list. start/stop and trip signals from overload relays and messages from disturbance analyzers. 20000.Event initiating a disturbance recording 1. select the station picture before selecting the Event. e. the last page is presented only half filled. e. scroll up (3 lines) and scroll down (3 lines) as well as time selection can be performed in lists. When the Alarm List is selected. • Sequence of Event List (SOE). The same keys are used for scrolling and paging as in the Event List.
The time tagging is carried out in the RTU. Trend pictures are selected in the same way as process pictures using menu. Tabular pictures are selected in the same way as process pictures using menu.1.9 Creating. DFK and poke point selections. Depending on the accuracy of the time stamp the seconds can be presented with one.3 SOE/Sequence of Events The Sequence of Events List contains messages from the process with a more accurate time tagging than the event list. Only signals collected by special process communication terminals have this possibility. changing and navigating in trend curves Trend curve presentation is used for presentation of the history of analog values.Alarm initiating a disturbance recording Messages marked with a * are unacknowledged. DFK and poke point selections. The numeric data can be presented in numerical tabular and different graph formats such as histogram. The following colors are used: Green the message disappears after acknowledgment Yellow the message remains after acknowledgment. toolbar. pie.10 Creating.1. two or three decimals.8. 1. BANGALORE METRO RAIL CORPORATION LIMITED P -. changing and navigating in reports Tabular displays can be used for presenting data in tabular form.1. OPERATION & MAINTENANCE MANUAL Page 0194 . scatter plot etc. 1. 1. toolbar.
2 1.2. • Authority for the action has been established.1 Basic Authority concept The authority assignment is carried out in the context of the Operator's login. • The object is not controlled from any other workplace. • Contact has been established with the remote terminal unit concerned. • Any Interlock rules for the object are fulfilled. If no command acknowledgment has been returned within a certain time. A comment can be made in the dialog box. An object selection. An alarm is also issued on a command sequence error. BANGALORE METRO RAIL CORPORATION LIMITED Control of Objects 1. 1. which is not allowed. • The object is marked as updated. For each operator account. The command is then issued from the dialog box that appears. if defined. • Remote control is not blocked. If any of these prerequisites is not met. • The object is not marked as update blocked.2. a message explaining the situation is output. It is shown when the dialog box is presented again and in the information-picture for that object. There are default interlock checks that can be used with the command dialogue. The prerequisites for on/off or continuous control commands are: • The workplace is connected to the on-line application server. results in one error message in the error message box and one in the Event list. OPERATION & MAINTENANCE MANUAL Page 0195 .2 To Open and Close Breakers Selecting a picture element representing the object to control and then selecting command. a specific authority for actions and/or picture selection in the power and control systems is defined. The color for 'pending command' is displayed. • The object is not waiting for the response to a previously entered command. an alarm is issued. issue a command. The dialog is also used to switchover between Auto and Manual control modes of regulatory objects.
1: Command Dialogue Box 1. where at least one load will be de-energized • Closing network loops In addition there can be other default interlock rules associated with tags.2.1 Interlock rules: Bypass If the Interlock rules for an object are not fulfilled the bypass function can be used under special circumstances. Fig 1. OPERATION & MAINTENANCE MANUAL Page 0196 .2.2. BANGALORE METRO RAIL CORPORATION LIMITED These default interlock checks include the following three checks: • Connecting grounded and energized devices • Connecting two network groups • Opening critical path.
a message explaining the situation is output. These default interlock checks include the following three checks: • Connecting grounded and energized devices (Can NOT be bypassed) • Connecting two network groups (Can be bypassed) • Opening critical path. This means that the event handling works as normal. Manual data entries are logged in the event list. a dialog is started to manually enter a new value of the selected status indicator/analog value/text or time. It is shown when the dialog box is presented again and in the information picture for the object. points with manually entered values are marked in cyan (light blue). BANGALORE METRO RAIL CORPORATION LIMITED 1. Manually entered values are processed in the same way as ones acquired from the process or the control system. together with the initiating operator name. In the pictures. A comment can be made in the dialog box.2. The prerequisite for a status change on/off by manual data entry is that any Interlock rules for the object are fulfilled. if defined.3 Manual Data Entry By selecting the Data Entry alternative. There are default interlock checks that can be used with manual data entry. If these prerequisites are not met.2. where at least one load will be de-energized (Can be bypassed) • Closing network loops Fig 1.2: Data entry dialogue box for Object Status OPERATION & MAINTENANCE MANUAL Page 0197 .
transmission lines and stations. has the authority to set and remove tags for that object. where setting and removing of tags is recorded. When a tag is issued for an object.4 Tagging A tag is a method of bringing to the attention of other operators and the system itself that an object currently has a special status e. Each operator.2. section under test.3: Tagging Dialogue Box Tag information is presented in the following ways: a) In single-line diagrams. This may relate to work in progress or other abnormal conditions in the process. Fig 1. worker's name and a comment text can be entered.2. BANGALORE METRO RAIL CORPORATION LIMITED 1. who has control authority for an object also. job identity. time. the date.g. in the position specified during picture editing b) In dedicated lists showing all tags currently defined c) In the event list. operator identity. A number of tags can be set for the same object but only the tag with the highest priority will be displayed. An interlock can reject the issue of a tag. Tags can be set for the following types of objects: objects represented as indications. OPERATION & MAINTENANCE MANUAL Page 0198 .
e. A plausibility check is performed on the new limit values. i.3 1.3. is the limit values correctly related to each other etc. OPERATION & MAINTENANCE MANUAL Page 0199 . is the value within the measuring range of the transmitter. Fig 1. BANGALORE METRO RAIL CORPORATION LIMITED Limit Supervision 1.1: Limit Dialog Box Change of limits used for supervision of measured values can be made if the workplace has the authority to do so.3.1 Using Alarm Limits Alarm limits are set and changed using the Limit dialog. A limit transition results after a dead band filter in an alarm state for the object.
This may not necessarily mean that a function using the unit is notified thereof. Printers and Remote Terminal Units can be switched in and out of service. this unit becomes the printout unit.4. connects the process with the SCADA system. Printers can also be taken in and out of service. OPERATION & MAINTENANCE MANUAL Page 0200 . 1. The Info pictures are used for Manual switchover and stop/start of servers. The COLI1501 picture displays any status and controlling capabilities for one COM line.2 Operator Workplaces Operator workplaces can be taken in and out of service in the control system overview picture from another workplace with authority to take control system units in and out of service. 1. The change is logged in the event list of the control system. all reports of this type are re-routed to the new printer specified. The COM line device represents one or several physical lines that can be used to connect RTUs. The change is logged in the event list of the control system. com ports) The Process Communication Unit device. 1. PCU.4 RTU-s (line units. the data acquisition from it is suspended and the signals concerned are marked as not updated in the central database. taking a unit out of service often has to be accompanied by re-allocation of the input or output concerned. The PCU1501 picture displays any status and controlling capabilities for one PCU. represents one H/w unit that contains physical communication lines connecting the RTUs.3 Printers and Hardcopies A unit number can be assigned to each type of printout.4 1.1 Application Servers Overview pictures as well as individual Info-pictures for each application server are available. The Remote Terminal Unit. The printers have a backup device.4. BANGALORE METRO RAIL CORPORATION LIMITED Control system A faulty unit may be taken out of service until the fault is corrected. 1. Note that when the unit number is changed. In case of failure. Note: An application server has to be stopped before it can be restarted. For this reason. If an RTU is taken out of service.4.4. RTU.
2. controlling and supervision of one RTU. AI card and power supply card. tightness of cable terminations. interrupters and BMs Check close/open operations and SCADA permissive of circuit breaker. BANGALORE METRO RAIL CORPORATION LIMITED The RTU1501 picture displays any status. Take the back up of RTU files through the RTU configuration tool by Laptop. Power supply card. DI card. 3. Check the configuration of RTU rack and error log through RTU diagnostic tool by Laptop. Checking the auto change-over function of L. No 1 2 3 4 5 Quarterly Maintenance 6 7 8 9 10 RTU M/s ABB Limited Check List Visual inspection of LED status of CPU card. All safety precautions shall be taken during maintenance.5 MAINTENANCE SCHEDULE OF RTU Equipment Make: Schedule Sl. 1. if any. controlling and supervision of one Line Unit. Check the voltage at every DI-TB and DO-TB Check the working and performance of power supply units and communication convertors Cleaning of RTU panel using vacuum cleaner Check the tightness of all cable terminations at the RTU panel Checking of Interposing relay. DO card. The Line Unit device represents one physical line either single or redundant. The LINU1501 picture displays any status. Check the working of heater and lightning arrangement inside the RTU Check the functioning of Local SCADA permissive of circuit breaker isolator. relay markings. 1 Yearly Maintenance Remarks: 2 1. OPERATION & MAINTENANCE MANUAL Page 0201 . Always follow the instruction & maintenance manual of the manufacturer. isolator. breakers through SCADA Check the earthing connections and seal the holes.T. interrupters and BMs Check indications and alarms of sub-station equipments in SCADA along with PSI team at the time at the time of CB maintenance. All drawings and manufacturer‘s instruction & maintenance manual shall be ensured at site for reference during maintenance.
A measured point that assume to values .Application Servers are those servers that perform functions without direct dual communication except via the LAN. an abnormal state persists. after some event. AVANTI contains a database as well as tools for access and maintenance of the database. See Dialogue. the execution of calculations and the printout of reports.0 and 1 for single indications .Conditional check before executing commands. The number of servers that are needed depends on the total functionality of the installation and the performance and availability requirements imposed with this. Picture -.The active state of a server in a redundant computer system. Operator's console -.1 Glossary Application server -.6.The persistent fault marking indicates that.An operator or system initiated command changes the status or value of a power system object or a control system device. It is possible to block the acquisition of data. either in the process. BANGALORE METRO RAIL CORPORATION LIMITED Glossary and Abbreviations 1. OPERATION & MAINTENANCE MANUAL Page 0202 . On-line server -.6 1.01 and 10 for double indications (the intermediate states 11 and 00 may also occur).Dynamic information from the database. Command -. combined with static graphic information and general information that can be presented in a window on a CRT. Indication -.Changes of state in the power or the control system that requires some action of the operator. or in the control system.Comprises the equipment by which the operator controls the process. Interlocking -.A database system developed by ABB. Single or double computers can build up each Application Server. the control of power system devices. the processing of alarms. AVANTI -. Measured value -.A concept covering numeric values representing real or imaginary measuring points in the process.The function is used to inhibit specific types of processing of acquired data. Blocking -. Commands may be of the types: *One-step command (immediate execute) *Two-step command (with check-back before execute) Events -. Persistent faults -.
g. Tagging -. BANGALORE METRO RAIL CORPORATION LIMITED Each picture has an identity and belongs to a (sub) system and a picture type. used for 'work permits' on power system equipment. OPERATION & MAINTENANCE MANUAL Page 0203 . Some tags may be used as condition for interlocking.Marking of objects to display important information. E.
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