An introduction to switchyard system

High Voltage system for hydro power plant

• This training module consists of following :-

• Introduction to basic electric quantities.
• Electrical main and auxiliary's subsystem.
• Switchyard equipments main and auxiliaries.
• Panels
• Control and measurement units
• Sensors, transducers
• Protective relaying and logic interlocks
• Safety and illumination

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 Typical
double bus
bar
arrangement

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 While discussing about electrical power transmission to grid from
a power generating unit we shall familiarize ourselves with basic
electrical quantities.
• Voltage
• Current
Basic electrical • VA
• watt
quantities • Frequency
• Phase sequence
• Phase angle
• Impedance
• Insulation and resistance

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Electrical main and auxiliary's subsystem

Transformer for step

Busbar for power
up and stepdown of Switching and Control and Alarm and
receiving and
voltage. The unit and isolation system . monitoring system. annunciation
transmission
station transformers.

Communication
Auxiliary monitoring
system/ carrier Metering and
Protection system. control measurement Plant illumination.
current measurements.
system
communication

Pump house, sewage . DC Supply

Fire fighting system. Power distribution .
and disposal system Distribution

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 • Power Transformer
• Circuit breakers

Switchyard • Isolators.
• Instrument transformers. Current and voltage transformers.
equipments • Bus bars

main and • Lightning arrester

• Wave trap
auxiliaries. • Control and relay panels.
• Cables (power control and communication)
• Cable trench, bus duct .
• Earthing and grounding

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Control and • Distribution boards- ACDB, DCDB, Lighting DB

relay Panels • Battery bank- DC power source , Float and boost

charger

and DB and • Control and relay panel

• Alarm and annunciation system.

other • Protective relaying.

• Motor control centers .
equipments • LV Distribution board
• Fire fighting system panels

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 • Various type of sensors used in a switchyard
system consists of
Sensors, • Signal transducers for current and voltage.
transducers, • Pressure transducers.
relays , • Temperature transducers.
contactors etc. • Temperature sensors
• Pressure sensors
• Main and auxiliary relays.
• IED

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Protective relaying and logic interlocks

Various types of
Operational logic Status
protective Bay control unit.
circuits. communication.
relaying.

Abnormalities
Measuring and alarm and
Synchronization
protection units. annunciation and
trip logics

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 • Electrical system uses various types of conductor and
each has a method for its packing, storage, handling,
installation , jointing and termination.
Conductors • Few are as listed below:-
• Bus bar – Hollow circular / rectangular flat type. (
and cables without insulation)
• For flat bus bar depending upon application, rating and
space available various type of arrangements are used.
• ACSR Conductors of various denomination and size.
• EHT, HT and LT Power cables varying with size and type
of insulation.
• Control cables of varying core size and insulation type.

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 • In a typical electrical system for generation , transmission
and distribution insulation is one of the most vital
component. The insulating materials are in all possible
form solid , liquid and gas. Due to advancement of
insulating materials that meet stringent operation
requirement transmission at extra high and ultra high
Insulators voltage became possible. Combination of different type
of insulation is selected based on voltage rating nature
and and space available for different applications. At a typical
site we are using many different insulators and
insulation insulations which need to be handled as per instruction
of supplier / manufacturer of the equipment, component
medium or insulating material. Storage, handling, processing,
utilizing and testing methods are explained through the
instruction manuals supplied with the material. Every
current carrying element is isolated from ground or
structure by the insulation, hence its importance is
critical.

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 • Clean SF6 gas is an inert, stable, colourless, odourless, nontoxic, non-flammable
gas. It is approximately five times heavier than air and will displace air in confined
areas. SF6 gas contains no oxygen and will not support life. Confined areas must be
force ventilated when working with SF6 gas. SF6 gas has no adverse effects when
inhaled in the air at a Threshold Limit Value (TLV) of 1,000 ppm

Handling of SF6 • The Environmental Protection Agency has identified Sulphur Hexafluoride as a
greenhouse gas with a global warming potential 23,900 times the effect of an

gas •
equal mass of Carbon Dioxide and an atmospheric lifetime of 3,200 years
Under no circumstances should equipment pressurized with SF6 be voluntarily
vented to atmosphere. If discharge of small quantities is necessary for test purposes
(i.e., contamination or moisture analysis, etc.), such discharge is to be kept to the
minimum required to obtain a reading
• Decomposition Gasses and Solid By-Products
• When exposed to sustained or intense electrical arcs, SF6 gas decomposes to form
sulphur-fluoride gases and metal-fluorides which are toxic. If moisture is present,
the decomposition by-products may also include sulphur-oxyfluorides and
hydrofluoric and sulfuric acids. The presence of these by-products can be readily
detected by a white or grey powdery substance or a very pungent odour similar to
rotten eggs.

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Handling of SF6 gas contd-1

• Keywords:- [protective equipment. Greenhouse gas, log record. Gas handling cart , leakage test, weight. Gas
pressure.
• All employees shall wear the protective equipment specified in this procedure when removing gas or solid by-products
• All employees wearing respiratory protective equipment be properly trained in the use of this equipment.
• SF6 gas shall not be voluntarily discharged into the atmosphere
• The Maintenance or Construction Supervisor is responsible for maintaining a log for each cylinder provided.
• a) This log shall be retained with the cylinder, and indicate the location and
• nomenclature of the equipment being filled and weight of the cylinder before and after filling.
• b) The log shall be returned with the cylinder to the central facility when work is complete or the cylinder is empty
• Partially used or full cylinders may be retained at the work centre at the discretion
• of the Authorised designated supervisor- Substation Equipment. The supervisor is responsible for maintaining the
required logs and forwarding usage reports to the central facility upon request.

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Handling of SF6 gas
• Filling Equipment with Sulphur Hexafluoride Gas
• 1. Obtain a SF6 Gas Processing or Transfer Cart as needs dictate.
• 2. Connect SF6 source to gas compartment valve.
• a) Processing cart (preferred method):
• (1) Connect hose to gas compartment valve and tighten all fittings. (2) Evacuate hose using vacuum pump.
• (3) Break vacuum using SF6 gas. (4) Open gas compartment valve.
• 3. Fill and pressurize the equipment per manufacturer’s instructions.
• 4. Using an approved halogen leak detector, check the gas compartment and associated devices for any SF6 gas leaks into the
atmosphere. 5. Repair all leaks to prevent discharge of SF6 gas.
• 6. Close gas compartment valve and source valve. 7. Disconnect hose from gas compartment valve and cap hose fitting.
• 8. Weigh all SF6 gas cylinders used to fill the equipment. a) Record final weight on cylinder log. b) Record date, location, and
equipment nomenclature on cylinder log.
• 9. Return all empty cylinders and appropriate logs to the central facility.

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 • Various types of disconnectors/ isolators and earth switches are used in
HV/EHV/UHV switching system. The disconnectors are no load devices. They are
to be operated during no load and are properly interlocked. The position that is
Disconnectors open/close condition is registered through auxiliary cam operated contact
multipliers. They are required for various control, logic indicator etc. systems.

and Earth • Generally for all application 132 KV and above the disconnectors and earth
switches are motor operated. There is mechanical and electrical interlocks as
required. It prevents accidental operation on load.

switches • Control box houses necessary electricals and drive mechanism including motor
and gear arrangement to be coupled with operating road.
• Different type of isolators are used in field few name as, single break , double
break, centre break, tandem , pentagraph , disconnectors and earthing switches
can be single-pole or three-pole operated by means of different motor-operated
drive mechanisms or manual-operated drive mechanisms or both .
• In gas insulated switchgear the insulating medium is SF6 gas, whereas in
switchyard air is insulating medium.
• Other accessories are mounting structure, insulators, arcing horn .

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Some very important check list
• During construction period ensure proper isolation , switch , fuse as required and grounding of electrical equipments body
control box such as welding machine. Compressors, vibrators, pumps, grinders, etc.
• While studying erection key diagram check matching of all critical dimension with civil drawing for structure foundation.
• For Electrical control wiring check entire cable schedule for interconnections for accuracy before starting ferruling.
• Check phase sequence and polarity before mounting of equipments wherever applicable.
• Check for physical damage even to packing during receiving and unloading.
• Prepare deviation report for engineering’s advice in a defined format.
• Make proper record of documents received in a proper format including its description, source, number if any, quantity, date and
time with revision number wherever applicable.
• Any shortage or damage of received material be promptly reported for timely corrective action.
• Check list for each activity from receiving till commissioning for each equipment, accessories , consumables and facilities for
safety and construction tools and plants be properly stored at point of use and be made available for person responsible.
• Ensure safety to person at all stages of activity . It may include safe working process, use of safety appliances and tools , personal
protective equipments such as welding glass, mask shoes etc.

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 • Foundation bolt :-In a plant , switchyard , or control station number of
stationary or rotating equipments are installed and nearly each equipment
is placed on some foundation. For fixing of these equipments, panels base
structure with base plate of different types is used. This are tightened in
place through foundation nut and bolt. The layout defines their placement

Check list For vis a vis dimension. Before grouting of this bolts wherever applicable it is
necessary to ensure that they are not damaged during entire operation,
placed at right place and checked for its level and coordinates.
major activities • Earth mat:- In a High voltage switchyard earthmat is a large activity and vital
for effective earthing of all structures, junction and control boxes and

(E&M) equipment earthing points, cable trenches, fencing etc. for safety of person
working and safety of plant and equipments. Welded joints are large in
number and there is pre-requisite for overlap of earthmat rod or auxiliary
earthmat for effective cross section for release of earthing current during
fault condition or abnormal conditions of lightening. Proper bitumen
coating of welded area to be ensured to prevent from damage due to rust
over its long life span within ground where it is placed. The depth of the
earthmat is to be checked .
• Riser :- Risers are connected to two different direction of earthmat from
nearest points or auxiliary earthmat as the case may be. Check that these
risers are laid near structure in a manner that indicates good workmanship.
• Details for earthing can be discussed in detail technical specifications for
each electrical installation indoor and outdoor, trench and wiring.

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 • Another major activity in a generation, transmission distribution system or in one-
word electrical system is cabling , this include receiving, storage, handling, laying,
dressing, terminating, jointing wherever required.
• Different cables used are varying on current carrying capacity, voltage rating,
insulating materials used and number of cores sheath and type of armor wherever
applicable.
• Mostly cables are received wound in drums having drum number, size and length.
Cables are having mark of length on each meter and both ends are properly sealed
to prevent entry of moisture while transporting and storage.
Check list for • While receiving the cables the description of supply details be verified with
received material. Check for any damage to drum or outer sheath of insulating
cables material.
• Instruction of manufacturer be followed for storage.
• For handling of cable drums it shall be ensured that drum is not damaged. During
laying proper cable drum stand be used. For HT and EHT cables laying special
instructions be adhered.
• LT power and control cables shall be tested for continuity and insulation resistance
before laying. Control cable continuity of each core shall be ensured.
• While laying it shall be ensured that the cable insulation is not damaged fue to
rubbing or friction with rough surface or any sharp object.

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Check list for Cables continued.

• Cable schedule with required cut length and cable number, size be checked and rechecked for desired length on actual layout
length. For best use length of each cable with cable drum number be listed and cut length is managed in a manner that
wastages are minimized. Normal practice is to pull cable from drum and cut only when it reaches to the end. Near end points
some length is left for maintenance.
• A detail log be prepared for each cable as per cable schedule and record be maintained in soft and/or hard copy.
• Bending radius shall be as per specification.
• To the extent possible there should not be any joint in between cut length. If unavoidable then location of joint should be
visible and a suitable junction box to be made as per cable type.
• Cable racks placement and welding of earthing work be completed before cable laying.
• From cable trench where cable is to be taken out for field equipments such as marshalling kiosk, equipment control box
provision be made i.e. opening of suitable diameter be left in cable trench wall at proper location during casting. This shall help
in reducing time for making opening on casted walls.
• There should be adequate space for pulling cable in pipe . After completion of installation ends of pipe be properly sealed to
prevent ingress of water however maintainability is also to be ensured.
• Cable tag shall be tied and placed as per defined interval as per specification to facilitate maintenance during life span.
• The above are few common precaution however specific instruction for power cables of HT, EHT cables are to be ensured.
These are to be laid under supervision of expert from manufacturer/supplier’s works.
• Armored cables armer is grounded at end points .
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 Lightening arrester

• The units of a multi – unit

Lightning Arrester should be
assembled in the sequence shown
on the rating plate of the LA or in
the catalogue of the manufacturer
• The insulated base unit should be
erected in case of Lightning
Arresters provided with surge
monitors.
• The direction of the open end of
the explosion release vent (at top
& bottom) is away from adjacent
expensive equipment such as
transformers.
• Fit the corona / grading ring on
the top of the Lightning Arrester, if
provided.

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 • For LT control cables and power cables up to 35 mm square.
• Check continuity and IR value of each core and also check if any short circuit between any two
cores.
• Check cable schedule i.e. termination details between different equipment control box, MK or
control panels for correctness. This is most vital as error at this stage cost more by increasing

Cable •
testing time. A uniform ferruling scheme be followed for entire plant.
It is good practice to keep a record of checking of cable schedule by authorized person duly
entered.

Termination •
•
Ensure that not more than two core be terminated at one terminal.
Ferrule details shall be checked before release for ferrule printing as this will reduce rework
• Correctness of ferrules, best quality of ferrules be ensured . Each cable core be checked with
ferrule before releasing for termination if feasible, however even before testing it is advisable to
check termination for correctness to avoid time loss in trouble shooting and rectification.
• Proper dressing of control and power cables is not only for aesthetics but a good workmanship
too.
• Proper glanding of cables with tag number on gland plate and cable be ensured. Spare holes for
each type minimum 1 be put on gland plate which shall be plugged for vermin proofing. Holes for
gland shall be made by hole saw cutter.
• Use of insulated lugs is recommended . The type of lugs be defined upon nature of application. All
lugs to be properly crimped with crimping tool.

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Control relay panels. Marshalling kiosk, Distribution boards ,
control desk , LT switchgear

• If packing found damage report for insurance claim. Follow the procedure.
• Transport the panels preferably in packed condition to site location from
store.
• Keep ready mounting frame. Check matching of civil and panel mounting
drawing for foundation bolt for correct matching of holes as per layout.
• Unpack the box and place the panels carefully as per drawing.
• Visual inspection of panel and record the facts after mounting the panels.
• Check for correctness and tightness of termination of internal wiring.

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• 87T Transformer differential
protection, two winding
Protective • 87T Transformer differential
relaying protection, three winding
• 87N Restricted earth fault
protection, low impedance
• 87 1Ph High impedance
differential protection
• 87G Generator differential
protection
• Impedance protection
• 21 Five-zone distance
protection, quadrilateral
characteristic
• 68 Power swing detection
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• 21G Under impedance protection for
generators and transformers
• 40 Loss of excitation
• 13 Out-of-step protection
• 50 Instantaneous phase overcurrent
protection
• 51/67 Four-step phase overcurrent
protection
• 50N Instantaneous residual
overcurrent protection
• 51N/67N Four-step directional residual
overcurrent protection
• 67N Sensitive directional residual
overcurrent and power protection
• 37 Time-delayed two-step
undercurrent protection
• 26 Thermal overload protection, one
time constant
• 49 Thermal overload protection, two
time constants
 • 50BF Breaker failure protection
• 52PD Pole discordance
protection
• 46 Broken conductor check
Protective relay • 37 Directional underpower
protection
continued • 32 Directional overpower
protection
• 46 Negative sequence-based
overcurrent function
• 50AE Accidental energizing
protection for synchronous
generator
• 46I2 Negative-sequence time
overcurrent protection for
machines
• 51V Voltage-restrained time
overcurrent protection
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• Voltage protection
• 27 Two-step undervoltage
protection
• 59 Two-step overvoltage
protection
• 59N Two-step residual
overvoltage protection
• 24 Overexcitation protection
• 27 Loss-of-voltage check
• 64 100% Stator earth fault
protection, 3rd harmonic based
• 81 Underfrequency function
• 81 Over frequency function
• 81 Rate-of-change frequency
protection