TRAINING

REPORT (JUNE-JULY 2010)

ABB LTD

SUBMITTED BY
ALISHA AGRAWAL
4th YEAR, DELHI COLLGE OF ENGINEERING

CONTENTS
1. OVERVIEW

2. AUXILARY NETWORK
3. AUXILARY SUBSTATIONS
4. EQUIPMENTS USED IN ASS
4.1 AUXILARY TRANSFORMERS
4.2 SWITCHGEAR PANELS
4.3 CIRCUIT BREAKER
4.4 EMERGENCY TRIPPING SYSTEM
4.5 BATTERY AND BATTERY CHARGER
4.6 110V DC DISTRIBUTION BOARD
4.7 AC DISTRIBUTION BOARD

5. PROTECTIONS
6. CABLING
7. TRACTION SYSTEM
8. CONTROL & MONITORING

OVERVIEW
The report describes general description of the broad scope of work, relating to that
covered with respect to DELHI METRO RAIL CORPORATION i.e. Supply,
Installation, Testing and Commissioning of 25kV Flexible OHE, Sectioning Post,
33 kV Cable Network, ASS and SCADA Systems at various levels (elevated, at
grade, underground) which includes:
a) Erection of 25 kV Traction Overhead Equipment for Elevated Lines and ‘At-
grade’, lines (including Depots), and Switching Stations.
b) Erection of Booster Transformers, along the line.
c) Erection of 25 kV cables.
d) Erection of Return Current cables
e) Erection of 33 kV Insulated cables in viaduct, in ground, in Tunnels and at other
places.
f) Erection of 33 kV / 415 V Auxiliary Transformers and associated Switchgear
and Equipment in all ASS’s, including those in Underground Stations.
g) Erection of SCADA System, including Equipments at OCC and at ‘Controlled
Stations’ (RTU).

AUXILIARY NETWORK
The various electrical and electro-mechanical installations in passenger stations are
required to be provided with electrical power at 415 V, 3 phase. For this purpose,
power at 33 kV from the Auxiliary Main Substations (AMS) located in the
premises of the High Voltage Receiving Substations (RSS), is transported to the
Auxiliary Substations (ASS) located in the premises of passenger stations, Through
duplicate feeders made up of 33 kV insulated cables. 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. The Auxiliary power
Network essentially consists of the following:
● 33 kV duplicate feeder from the AMS to a designated ASS in the Corridor,
wherever applicable
● A 33 kV cable Network, comprising of duplicate 33 kV insulated cables of
suitable capacity, laid in cable trenches in the Viaduct, tunnel or at-grade, as
applicable.
● Connection of the 33 kV cables to the 33 kV panels/transformers located in the
ASS
● 33 kV / 415 V Auxiliary Transformers of suitable capacity and associated 33
kV and 415 V Switchgear and other Auxiliary Equipment, installed in the
ASS’s at various passenger stations.

AUXILIARY MAIN SUBSTATIONS (AMS)

The Auxiliary Main Substation (AMS) is located in the RSS premises. The AMS is
provided with the necessary HV System including HV Switchgear, Busbar etc and
also the 66 kV (or 132 kV or 220 kV) / 33 kV, 3 phase transformers. There is an
AMS room and also 33 kV switchgears and other equipments are installed. 33 kV
cables from the outgoing 33 kV Switchgear at the AMS, up to the designated ASS
are also installed. 415V cables of suitable cross section for 100kVA power from
the outgoing 415V Switchgear at the AMS, up to the designated feeder panel in
Electrical panel Room of station for extending station supply to AMS in
emergency are also installed here.

AUXILIARY SUBSTATIONS
Auxiliary Substations (ASS), located in passenger stations, are meant for
transformation of power from 33 kV to 415 V through the 33 kV / 415 V Cast
Resin Dry Type distribution transformer and the 415 V protections, whether on the
elevated portion or in the underground portion. There are 3 ASS in underground
sections and 2 ASS in elevated sections.

The following equipments are installed in the ASS:

● 33 kV / 415 V Cast Resin Dry Type transformers
● 33 kV Panels and Switchgear
● LT Bust Duct (Sandwiched Type)
● 415 V Circuit Breakers (Supply only for Elevated Section)
● 33 kV and 415 V Cables
● All measuring and protective devices
● Emergency Tripping System (For underground Section only)
● Batteries and battery chargers
● ACDBs & DCDBs
● RTU
● Cable paths and earthing
● Safety equipment and all other items (e.g. Chequered Plates) required for
successful and satisfactory working of the ASS,

EQUIPMENTS USED IN ASS

1. 33 KV / 415 V AUXILIARY TRANSFORMERS
The main technical characteristics required for the 33000 / 415-240 V transformers
to be used in Auxiliary Substations (ASS) are given. The transformer is Cast resin
Dry Type, moisture proof, can be installed close to the utilization point which
allows to optimise installation design reducing to the minimum the low voltage
circuits with the corresponding savings in losses and low voltage connections.
The transformer is Self-extinguishing in the event of fire or arcing and no gases
released with danger potential. Step lap core configuration grants lower values of
no load losses, no load current and noise level.
Characteristics
Windings: Copper
Primary Line voltage(phase) 33 kV
Secondary Voltage (off load) 415 V
Secondary Voltage(full load, pf- 0.8) 400 V
Frequency 50Hz
Voltage surge withstand 170 kV
Coupling Dyn11
Cooling Natural
Off load tap changer 0, ± 2.5% and ± 5%

2. SWITCHGEAR PANELS
Switchgear, in electric power systems, or grid, is a combination of electrical
disconnects, fuses and/or circuit breakers, used to isolate electrical equipments.
Switchgear is used both to de-energize equipment to allow work to be done and to
clear faults downstream.
The SWITCHGEAR used in ASS in DMRC is 36kV rated. The cubicle consists of
following compartments:
● Circuit Breaker Compartment: The circuit breaker is withdrawable for
testing and maintenance. Emergency tripping push button is provided for
manual operation of circuit breaker.
 ● Busbar compartment: Busbars are laid in sections from panel to panel and
are fixed. They are made of tubular conductors with either copper or
aluminium material, covered with specially shaped plastic shroud.
● Cable compartment: current transformers and withdrawable voltage
transformers are housed in this compartment. An earthing switch can also
be provided in this cable compartment for temporary earthing when voltage
transformer is not required. Incoming and outgoing cables are connected
here. It is possible to connect 6 single core cables and the rated current
● Low voltage compartment: Accommodates secondary equipment of the
switchgear panel required for particular application. The control cables are
also terminated here.

3. CIRCUIT BREAKER
A circuit breaker is an automatically-operated electrical switch designed to protect
an electrical circuit from damage caused by overload or short circuit. Its basic
function is to detect a fault condition and, by interrupting continuity, to
immediately discontinue electrical flow. Unlike a fuse, which operates once and
then has to be replaced, a circuit breaker can be reset (either manually or
automatically) to resume normal operation. Circuit breakers are made in varying
sizes, from small devices that protect an individual household appliance up to
large switchgear designed to protect high voltage circuits.
The circuit breaker installed in Switchgear panel of the ASS is MV SF6 Indoor
type circuit breaker. It operates on the puffer principle.
The breaker pole contains SF6 gas (sulphur hexafluoride). this gas has features
suitable for the circuit breaker operation:
● The gas is neither combustible nor toxic.
● Is chemically stable and does not age with time.
● Breaking capacity of SF6 gas is not forced and thus no overvoltages are
generated. No damping resistor or surge arrestor is needed, not even when
controlling small motors.
● Any leakage is easily detected. To provide an extra margin of safety, the
breaker is capable of interrupting its rated current at rated voltage even at
atmospheric pressure.
The puffer principle involves compressing the gas between a static piston and a
movable cylinder during the interruption action. The compressed gas is then blown
through a nozzle in which the arcing is taking place.

4. EMERGENCY TRIPPING SYSTEM

The main features are:
● Electrical tripping
● Communication through hotline
The emergency tripping system enables electrical tripping of power supply of
traction time in case of emergency. This is achieved by breakage of the glass fitted
on the front cover of the ETS box, opening the front cover using the handle
provided inside and pressing of the Emergency Push Button. This action will trip
the 25kV Traction time through a predetermined operation of circuit breakers and
relevant interrupters to de-energize the corresponding section.
5. BATTERY & BATTERY CHARGER
Two Battery Banks are provided at every ASS. Each battery is of stationary
compact, nickel-cadmium type consisting of 85 cells. They are maintenance free.
Battery complies with IEC 60622/IEC 60623. The minimum capacity of the
Battery is not be less than 180AH.
Battery Charger
The charger comprises of an inlet transformer and silicon diode/thyristor for
thyristor bridge for converting 3 phase supply to DC voltage. Battery charger has
the provision of Alarm in case of battery low and also has the feature of battery
reverse polarity protection.
AC Power Supply:
- Voltage : 415V ± 10%
- Frequency : 50 Hz ± 3%
- Recharge to 80% of the battery capacity : 8 hours
DC Output:
- Power supply voltage : 110 V + 0%, -15%
- Operating period after AC supply failure : 8 hours

6. 110V DC DISTRIBUTION BOARD

Description
Distribution of the 110 V DC sources is gathered inside two specific cabinets, one
for each half station, called DC auxiliary.
These cabinets are equipped with doors, fitted with flexible seals, close via lock-
bars and on which is installed a mimic diagram with signalling lights denoting the
position of the main apparatuses.
Each cabinet includes:
- Isolating switch
- Master power supply circuit breakers
- Non return diodes and set of normal/stand by supply bars
- The current and voltage protection relays
- The isolation monitoring
- The automatic and manual device for change-over from one source to the other,
with selector switches for automatic and manual, with or without break
- The coupling circuit-breaker for the both 110 V DC sources
Bus bar of DCDB is made of Electrolytic copper with heat shrinking sleeves.
Internal cabling/wiring of DCDB is Fire retardant low smoke Zero halogen type
(FRLSOH) for underground section and Fire retardant low smoke type (FRLS) for
elevated section .Wiring of suitable sizing is selected to carry the full load current.
MCB is selected for providing discrimination between incoming and outgoing
feeders.

7. AC DISTRIBUTION BOARD
For providing AC 415 V Supply, AC Distribution Board is provided in the ASS.
Incoming Feeder of ACDB is provided with Earth Leakage Circuit Breakers along
with MCCB/MCB. Bus Bar and MCB for all the feeders are sufficiently rated to
provide the overloading and short circuit protection. Bus bar of ACDB is made of
Electrolytic copper with heat shrinking sleeves. Internal cabling/wiring of ACDB
is Fire retardant low smoke Zero halogen type (FRLSOH) for underground section
and Fire retardant low smoke type (FRLS) for elevated section. Minimum
Clearance between Phases and Phase & Earth/Neutral is 20 mm.

PROTECTIONS
GENERAL DEFINITION
The purpose of the protection equipment is to ensure insulation or de-energising
of equipment whose operating conditions have become abnormal to avoid:
- any major repercussions on the traffic
- any damages or dangerous effects on person and equipment.
The protection system deploys numerical relays and complies with a high
performance standard regarding reliability, maintenance, availability, safety of
operation and electromagnetic compatibility.
PROTECTION DESCRIPTIONS:
Major protections employed in the system are:
Hydraulic or thermal protections
These protections, such as lack of pressure or abnormal temperature, include
measuring elements situated on the protected apparatus, actuating a contact
(mandatory of flip-flop type) which represent the start of the protection line.
Electrical protections
All the protection relays used shall be of numerical Type
Over current protections
This function ensures the tripping of concerned circuit breaker when the current
value reach the highest allowable load on the network in instantaneous or delayed
time conditions.
Following the network configuration, pre-set tripping thresholds could be
commuted via automatic interlocking or voluntary action.
SF6 pressure protection device
The protection devices for this equipment ensure permanent monitoring of gas
pressure inside each compartment by mean of temperature compensated
monitoring devices triggering a dual alarm threshold annunciation system in the
event of gas pressure drops.
33 KV CABLE PROTECTION
A fault on the 33 kV cables in the 33 kV Distribution Loop, is cleared by the
Circuit Breaker (RCCB) located in the AMS, wherefrom the Loop is deriving 33
kV power supply. The identification of the section of the Loop where the fault has
occurred, is facilitated by the Fault detection relays installed on each outgoing 33
kV board, of each ASS. This relay sends to the ECC an indication that it detects a
fault. This is seen on the screen of the ECC equipment and the fault could be
located between the last relay detecting the fault and the first relay not detecting
the fault. With these indications the operator is able to take the necessary measure
to isolate the faulty section and to reenergize the healthy part of the network.
The equipment for location of the fault is made of one torroidal transformer on
which a current relay is connected.
ASS EQUIPMENT PROTECTION
Medium voltage network protection
The medium voltage network is protected by RCCB’s located at AMS.
Nevertheless in each ASS, at the incoming interrupter of each cable, a zero
sequence detection relay is installed. This relay monitors the detection functioning
to the ECC, as well as in the ASS.
Transformer protection
The transformer is protected against fault by the followings
- F 50: Instantaneous over current protection
- F 51: Time delayed over current protection
- F50 N: Instantaneous earth fault protection (zero sequence)
- F51 N: Time delayed earth fault protection (zero sequence)
- Differential and restricted earth fault protection
More over, it is protected against heating by a two threshold temperature
protection. The first threshold transmits an alarm to the ECC as well as in the ASS.
The second threshold trips the respective MVCB and corresponding downstream
LVCB and transmit an alarm to the ECC.
Low voltage protection
The low voltage circuit breaker is equipped with magneto-thermal protection to
protect the main circuit against short-circuit, over-current and earth fault. This
protection is thermally compensated to take into account the ambient temperature.
It is equipped on the LVCB and LVCCB.The selectivity takes into account the
time delay and the current level of the downstream protections.

CABLING
The cables in the underground section are 19/33 kV (E), grade, Single Core, 400
sq.mm annealed Circular stranded copper conductor, XLPE insulated.

· CONDUCTOR SCREEN
The conductor screen is provided over the conductor by extrusion of
semiconducting compound. Conductor screen is of Non-metallic material and
consist of a layer of extruded thermoses semi conductive compound of suitable
thickness and volume resistivity.

· INSULATION
The XLPE insulation is used on power cable in wet and dry locations. The
conductor with screening is provided with cross-linked polyethylene (XLPE)
insulation applied by extrusion. The nominal thickness of insulation is not less than
9mm

· INSULATION SCREEN
The Insulation screening is applied direct upon the insulation and is of a layer of
extruded semi conducting thermosetting compound firmly and totally bonded to
the Insulation.
· The other layers include water barrier, metallic screen, inner sheath,
armouring, outer sheath on the cable.

TRACTION NETWORK
DESCRIPTION
The Traction Power Supply Network transforms the High voltage
(220kV/132kV/66kV) into 25 kV by means of transformers and distributes the 25
kV through adequate protecting and sectioning equipment to the Over Head
Catenary system (OHE) which feeds the Electric Multiple Units. It is mainly
composed of Feeding Posts (FP), Sectioning Post (SP), Sub- Sectioning Post (SS)
and Sub-Sectioning & Paralleling Post (SSP), collectively referred to as ‘Switching
Stations’.
Traction power at 25 kV is fed to the various Corridors from the
TractionSubstations (TSS) located in the premises of Receiving Substations
(RSS),as explained below. The feed fro every Corridor is further divided into
several Subsections,with the help of switching stations. For eg. On the corridor S1
- Shahdara-Dilshad Garden, a switching station is located at Dilshad Garden.
TRACTION SUBSTATIONS
DESCRIPTION
Traction Substation (TSS) located by the side of the Receiving Substation,
performs the task of converting the 220kV, 132 kV or 66kV incoming power to
27.5 kV single phase power and of supplying this power to the traction overhead
equipment through appropriate switchgear and protection arrangements.
SWITCHING POSTS
FUNCTION
For purposes of operation and maintenance, the Traction Overhead Equipment
between 2 Traction Substations is subdivided into several smaller sections by
introducing switching stations. Switching stations fall mainly under 3 Categories:
Sectioning Post (SP)
The function of Sectioning Post is to segregate the power supply feeds from
adjacent substations, since the 2 feeds will have a phase difference between them
and cannot be coupled together. The Sectioning Post will have a Neutral Section in
front of it and the OHE on either side of the Neutral Section will not be bridged.
Sub Sectioning and Paralleling Posts (SSP)
At strategic intervals the OHE is Sub Sectioned by means of an insulated overlap,
which is normally bridged by an interrupter. In addition, the Up and Down track
OHE’s are paralleled at these SSP’s by means of Interrupter. The SSP provides a
Sectioning facility and also helps to improve the voltage regulation because of
paralleling.
Sub Sectioning Station (SS)
With a view to limiting the length of any section of OHE, which can be affected by
a fault or an electrical isolation for maintenance, the OHE is further Sub Sectioned,
so that generally not more than 3 or 4 Metro Stations fall in one Subsection.No
paralleling facility is provided at these Sub-Sectioning Stations.
Traction Overhead Equipment
Flexible OHE
In elevated sections and ‘at-grade’ section, flexible 25 kV Overhead Equipment
(OHE) comprising a messenger wire, contact wire and droppers is used.
Rigid OCS
In underground sections, 25 kV Rigid Overhead Catenary System (OCS) is used.

MAJOR EQUIPMENTS USED IN TRACTION SYSTEM:

1. BOOSTER TRANSFORMERS
GENERAL
Booster transformers are basically two-winding transformers (1:1 ratio), with the
primary winding connected in series with the OHE and the secondary in series with
a return conductor. Since the primary winding is connected in series with the
overhead equipment, the Booster transformers are subjected to frequent and heavy
short circuits due to transient faults.
RATING
The Booster transformers shall have a rating of 150KVA or 280 kVA, as required.
The salient technical requirements are as follows:-

Nominal Rating 150KVA 280 kVA

Rated Current and voltage 366A at 409V 500 A at 560 V
Overload rating (15 mts) 550A 750 A
Impedance at full load at 75oc 0.15 ohm (Max) 0.15 ohm (Max)
Guaranteed max no load losses 225W 350 W
Guaranteed max load losses 4000W 6500 W

The Booster transformers may be oil filled type or dry cast resin type.

2. 25 KV SWITCHGEAR
Operating Conditions:
Equipment are designed to operate under:
- Outdoors tropical conditions (55° C with 95% relative humidity)
- Electromagnetic specific environment (complying with EN 50121-5)
- Plus 10% minus 15% supply voltage variations
Also protections against corrosion through paint work are taken and earthing is
done.
3. Circuit Breakers, Interrupters and Isolators
General
These apparatuses are pole mounted with the switching part at pole top level,
separated from the control equipment located at hand level and base pole mounted,
both connected together with a transmitting mechanism.
a) Circuit Breakers / Interrupters
Each Circuit Breaker is SF6 or Vacuum type and includes:
- Up & down stream connectors
- Life sealed unit pole
- Energy accumulation type actuation system (electromechanical springs or
magnetic actuated mechanism)
- Electric and manual arming capability (Tripping and closing coils motor...)
- Under-voltage tripping coil (Auxiliary voltage off)
- Locking and interlocking devices
- Open / Closed auxiliary contacts
- Low voltage multi-pin connector and flexible cable
b)Isolators
The Isolator is air insulated type and includes:
- Up & down stream connectors
- Vertical break
- Motor operated where required and manually operated capability
- Locking and interlocking devices
- Open / Closed auxiliary contacts
- Low voltage multi-pin connector and flexible cable
All interrupters and isolators have provision for pre-drilled copper plates
in order to receive 2 x 240 mm² cable.
4. Voltage Transformers
The voltage transformers are masts mounted. As the primary is connected directly
to the catenary, which is designed for 14 kA short-circuit current, voltage
transformers are able to guarantee electrodynamics and thermal stresses resulting
from this level of short circuit current.
Voltage transformers have a ratio of 25000/110V and are dry resin type. It is
ensured that self-heating is less than 1°C per hour.

5. Current transformers
Current transformers are dry resin, and ensure that self-heating is less than 1°C per
hour.The self heating complies with the climatic conditions.The primary
connectors are able to handle at least 2500A for 5min without overheating.
SPECIFICATION OF 25 KV TRACTION POWER CABLE.
The cable is capable of 25/45/52 kV, grade, single core, 240 sq.mm stranded
Copper conductor, XLPE insulated, copper wire screened , tape armouring, PVC
sheathed cables. It confirms to IEC 60502 Part 2 latest for construction and IEC
60840 for testing.
25 kV cable is dry-insulated, radial-field cable, based on proven technology.

Control & Monitoring

The Control and Monitoring System is required to supervise, control and acquire
the various specified data from the ‘Controlled Stations’ along the Line, such as
Receiving Substations, Auxiliary Substations, Traction and Auxiliary Networks,
Metro Stations, Switching Stations (SP, SSP etc) along the Line, Depot etc.For this
purpose, a central control station, referred to as Operation Control Centre (OCC) is
provided at a particular station and a Remote Terminal Unit (RTU) or equivalent is
provided at the ‘Controlled Stations’. The OCC and RTU can dialogue with each
other. The complete system consisting of OCC equipments and RTU, is
collectively referred to as SCADA (Supervisory Control And Data Acquisition).
For this purpose, the central control station referred to as Energy Control Centre
(ECC/OCC) is located at Shastri Park for Line-1 &2 located and at Metro Bhawan
Barakhamba Road for Line-3. The necessary communication channels are in the
form of Optic Fire Cable (OFC).
Integrated Operation
The OCC at Shastri Park and the OCC at Metro Bhavan are required to be able to
dialogue with each other. In the final integrated operation, it is anticipated that the
Power Controller sitting in Metro Bhavan will be able to control the entire network
of Metro lines covered under Phase I and Phase II Projects.