INDOOR HV SWITCHGEAR

CONTENTS
Theory and Application
Design Features
Constructional Features
Installation Requirements
Tests
Appendix – I

THEORY AND APPLICATION

Voltage classification as per Indian Electricity Rules 1956:-
Low Voltage (LV) Up to 250 Volts
Medium Voltage (MV) from 251 to 650 volts
High Voltage (HV) from 651 to 33000 volts
Extra High Voltage (EHV) above 33000 Volts

HIGH VOLTAGE INDOOR SWITCHGEAR:

Switchgear located indoor for system voltages of 3.3 kV to 33kV.

SWITCHGEAR (SG)
Line up of switching devices for a load centre.

SWITCHGEAR CUBICLE
Enclosure for switching device of a circuit.
Switchgear will comprise a number of cubicles depending on the number of Incoming and Outgoing
circuits in the load centre.

METAL ENCLOSED SWITCHGEAR (REFER IS 1885)

Switchgear assemblies with external enclosures intended to be earthed.

METAL CLAD SG (REFER IS 1885)

Switchgear Cubicle components arranged in separate metal compartments intended to be earthed.

Page 1 of 15
 INDOOR HV SWITCHGEAR

APPLICATION OF SWITCHING DEVICES IN LOAD CENTRE

Make, break and continuously carry the maximum load current of the circuit.
Withstand starting currents and switching over voltages during switching on and off the load particularly
squirrel cage induction motors.
Trip the circuit under overload, short circuit and other abnormal operating conditions of the load.

CURRENT IN RUSH DURING SWITCHING ON:-

Magnetising current inrush for switching on transformer
Starting current of induction motor with direct-on line ( DOL ) starting can be 6 times full load current
plus 20% tolerance.
Current inrush for switching on capacitor banks can be 5 to 6 times full load current.

SWITCHING OVER VOLTAGES DURING SWITCHING OFF:-

Over voltages inherent in breaker design due to current chopping.
Over voltages on switching off induction motors particularly of smaller rating where surge impedance is
high.
Switching over voltages is detrimental to motor winding insulation.

SWITCHING DEVICE ALTERNATIVES

CIRCUIT BREAKER
Performs all basic duties mentioned.

CONTACTOR WITH LOAD BREAK ISOLATOR AND HRC FUSES:

Short circuits cleared by HRC fuses, other duties done by Contactor.

LOAD BREAK SWITCH AND HRC FUSES:

Short circuits and overloads cleared by HRC Fuses. Make and break of load current by switch.

OFF LOAD ISOLATOR:

These are used along with circuit breaker in double bus bar systems. Isolator to be operated only when
breaker is open.

Page 2 of 15
 INDOOR HV SWITCHGEAR

CIRCUIT BREAKER ALTERNATIVES:

Air breaker (mostly phased out)
Air blast (mostly phased out)
Minimum oil
Vacuum
Sulphur hexafluoride (SF 6)

MINIMUM OIL CIRCUIT BREAKER (MOCB)

Old technology, being phased out. Presently available for smaller interrupting capacities.
Has fire hazard.
Prone to switching over voltages when switching off induction motors of smaller rating.

VACUUM CIRCUIT BREAKER (VCB):

Contact separation takes place in Vacuum
Contact zone rapidly de-energized. Dielectric recovery time is around one microsecond.
Current is chopped to zero. Hence, switching over voltages is high, around 5 to 8 P.U.
Very little maintenance required.
Long life of Vacuum bottle. 10000 normal operation or 50 -100 short circuit breakings.
Not possible to monitor loss of Vacuum at site.

SF6 CIRCUIT BREAKER:

Arc current following opening of breaker interrupted by SF6 gas.
Two basic designs available

PUFFER TYPE
Arc is cooled by a continuous flow of SF6 gas.

ROTATING ARC OR SELF EXTINGUISHING TYPE –

Arc is rotated in SF6 gas environment through a magnetic field created by the current to be broken.
Current is broken at zero current. Hence, switching over voltages are less around 2.5P.U.
Very little maintenance
Long breaker pole life: 5000 operation at rated current or 20 – 30 short circuit interruptions.

Page 3 of 15
 INDOOR HV SWITCHGEAR

Both sealed and unsealed type breaker chambers available.

Pressure monitoring is possible in unsealed chambers. Fall in pressure restored by topping up at site.

SYSTEM EARTHING:
EFFECTIVELY EARTHED
The neutral of power supply system solidly connected to earth.

NON EFFECTIVELY EARTHED

The neutral of power supply system connected to earth through low or high resistance to restrict earth
fault current. Generally applicable up to 11 kV System.
Non effectively earthed system requires higher insulation level of the SG.

CONTROL OF SWITCHING OVER VOLTAGES:

MOCB and VCB are prone to switching over voltages.
Switching over voltages are detrimental to motor winding insulation.
Provide Zinc-Oxide surge arresters at breaker outgoing terminals of each motor circuit.

DESIGN FEATURES
MAJOR COMPONENTS IN SWITCHGEAR CUBICLE
Bus bars
Main Switching device
Current and Voltage Transformers (CTs & VTs)
Cable boxes for terminating power cables or bus duct termination
Instruments, meters, protection relays, lockout relays, auxiliary relays, time delay relays etc.,
Control Switches, selector switches, push buttons, indicating lamps, mechanical position indicator etc.,
Cubicle wiring, terminal blocks, space heater etc.,

SWITCHING DEVICE OPTIONS

SELECT BASED ON CIRCUIT REQUIREMENTS:
Circuit breaker
Contactor with load break isolator and HRC fuses.
Load break switch and HRC fuses

Page 4 of 15
 INDOOR HV SWITCHGEAR

Circuit breaker with off load isolators in double Bus bar system.

BUS BAR CONFIGURATION:

Single Bus bar system- for general application.
Double Bus bar system- for special application where loads are to be selectively supplied from two
sources.

SWITCHGEAR CUBICLES
kV
a) Nominal System Voltage 3.3 6.6 11 22 33
b) Maximum System Voltage 3.6 7.2 12 24 36
c) Phases & Frequency 3 Phases, 50 Hz
d) System Neutral Earthing Effectively Earthed (EE) or
Non Effectively Earthed (NEE)
e) One minute power frequency kV ( rms )
withstand:
For EE System 10 20 28 50 70
For NEE System ( upto 11kV ) 20 28 50 - -

System Voltage kV 3.3 6.6 11 22 33

1.2/50 µ sec Impulse withstands voltage:
For EE System-kV (peak) 40 60 75 125 170
For NEE System –kV (peak) 60 75 125 - -
Short Circuit Withstand
1 Sec at rated Voltage KA (rms)- Specify same as breaker rating.
Dynamic rating – Specify same as breaker making current.
Minimum clearances in air of live parts (BS 162)
Phase to Phase - mm 51 90 127 242 357
Phase to Earth - mm 51 64 76 140 223
For NEE System one step higher clearances to be adopted.
* Ambient temperature - generally 40oC. Higher temperature as per project requirements.

Page 5 of 15
 INDOOR HV SWITCHGEAR

BUS BARS
Bus bar insulation options-
Air insulated with insulated phase barriers.
Fully insulated.
Bus support insulators-
Type- Epoxy resin cast / ceramics
Voltages – kV 3.6 7.2 12 24 36
Creepage Distances– mm 75 130 230 380 580

Material
Electrical grade aluminium E91E as per IS – 5082 (copper optional)
Maximum temperature at continuous current rating-
90oC for non silver plated joints.
105oC for silver plated joints.

CIRCUIT BREAKER
a) Type SF6/VCB/MOCB
b) Rated Voltage As per system voltage
c) Rated operating duty 0 – 0.3 sec – CO – 3 min – CO
d) Rated Current Select next higher standard size over
maximum load current.

e) Rated breaking capacity - MVA Select next higher standard size over
kA ( rms ) system fault level.
f) Rated making current- kA ( peak ) 2.5 x kA ( rms )

g) Short Time Current withstand for 1 Specify same as above kA ( rms)

second ( or 3 sec, if required) duration

h) Total opening time 3 cycles ( 60 ms)

i) Total closing time 4 cycles ( 80 ms)
j) Operating mechanism Motor wound, spring changed, trip
free, anti pumping.

Page 6 of 15
 INDOOR HV SWITCHGEAR

k) Minimum No. of Auxiliary contacts 6 No. + 6 NC on fixed part of cubicle.

for purchaser’s use.

l) Control voltage for closing/tripping Select from 24/48/110/220 Volts DC

coil
m) Limits of operation:
Closing coil 85 – 110% of rated voltage
Shunt trip coil 50 – 110% of rated voltage

n) Applicable standards IS 2516

DRAW OUT TYPE BREAKERS:

Distinct drawn out test position to check breaker operation without energizing power circuit.
Withdrawal of breaker from service to test position and re-engagement should be possible only when
same is open.
Operation of breaker shall be possible only when same is in service or test or fully drawn out position.
Breaker of given rating should be prevented from engaging with a stationery element of higher rating.
Safety shutters – operated automatically when breaker is withdraw to cover live stationery contacts.

BREAKER ACCESSORIES:
Emergency manual trip push button.
Mechanical position indicators for ON/OFF and test and service positions.
Mechanical position indicator for closing spring charged.
Operation counter.
Manual spring charging facility.

CONTACTOR:
a Make JYOTHI ABB ALSTOM
b Type Vacuum
c Voltage Upto 7.2kV Upto 12kV Upto 7.2kV
d Rated Current 400 A 600 A 400 A
e A C 3 duty Yes Yes Yes
f A C 4 duty Yes Yes upto 420A Yes

Page 7 of 15
 INDOOR HV SWITCHGEAR

LOAD BREAK SWITCH / ISOLATOR:

a Type Air Break

b Operating Mechanism Manual spring assisted quick make and

break
c Rated Current As per circuit requirement

d Short time withstand current As per SG data

e Interlocks Mechanical (castle lock & key ) or

Electrical ( solenoid)

CURRENT TRANSFORMERS (CTS)

a Type Cast resin, bar primary,multicore as
required.
b Insulation Class E or better
c Rated primary Current ( Load current rounded off ) Amps
d Rated secondary current 1 Amp

e Ratio Primary current / 1

f Metering CT -
Accuracy Class 1.0
Burden Based on burdens of connected
instruments & meters.
g Protection CT -
Accuracy 5 P 10 for over current & earth fault
relays class PS for special relays such as
differential.
Burden Based on burdens of connected relays.
h Applicable Standard IS 2705

Page 8 of 15
 INDOOR HV SWITCHGEAR

VOLTAGE TRANSFORMERS:
a) Type Cast resin, Single phase, Draw out, dual
secondary if required.
b) Insulation Clans E or better
c) Rated Primary Voltage System Voltage / Ö 3
d) Rated Secondary Voltage 110 / Ö 3 volts
e) Method of connection Primary / Star / Star
Secondary
f) Accuracy class 1.0 for Metering
3 P for Protection (wherever applicable)
g) Burden Based on connected meters and relays.
h) Over Voltage Factors:
Continuous 1.2
Short time for effectively earthed 1.5 for 30 seconds
system
Short time for non effectively 1.9 for 8 hours
earthed system
i) Applicable Standards IS 3156

METERING:
a) Metering Schemes:
Incoming from Transformer Ammeter ( AM ) with Ammeter switch
(AS ) KW, Power Factor, KWH.

Outgoing Transformer Circuit AM with AS,KW, KWH.

Outgoing Motor Circuit AM with AS

Bus bars Voltmeter with Voltmeter Switch
Capacitors banks AM with AS, kVAR
b) Technical particulars:
i. Indicating Instruments
(AM, VM,PF,KW, kVAR)
• Accuracy class 1.5
• Case size 110 sq. mm
• Angle of deflection 240O
• Current / Voltage Coil 3 to 4 VA
burden
• Type of mounting Flush / Semi flush
ii. Energy Meter (KWH)
Accuracy Class 1.0

Page 9 of 15
 INDOOR HV SWITCHGEAR

iii Digital instruments / meters These could be provided in lieu of

conventional ones mentioned above.

DESIGN FEATURES - Control Wiring:

WIRES
660 V grade, single core, stranded and tinned copper conductor, PVC insulated, colour coded as per
standard.
Size of conductor – minimum 1.5 Sq.mm for general wiring and 2.5 Sq.mm for CT circuits.

TERMINAL BLOCKS:
Type and Rating - 10 Amps, 660V grade, and one piece moulded with insulated
Barriers.
Preferred clearances:
Between two rows - 150mm
Between gland Plate and First row - 250mm
Wire Termination:
Tinned Copper Lugs
Solder less crimping type
Accessories:
240V, Single phase cubicle heater with thermostat, switch and fuse to prevent moisture
condensation.
PROTECTION:
Protection schemes and relay particulars are discussed in a separate lecture.

CONTROL AND INDICATION:

Provision to be kept for the following as per process requirement.
Local and remote control through local/remote selector switch.
Local and remote indication for breakers/contactor ‘ON’, ‘ OFF', 'auto trip and ‘breaker trip
circuit healthy’.
Receive trip impulse from external fault contacts such as Buchholz Relay, high oil/winding
temperature of transformers, high bearing temperature of motor etc.
Interlock with other breakers
Receive signals for automatic starting and stopping of motors as per process requirements.

Page 10 of 15
 INDOOR HV SWITCHGEAR

Remote annunciation for auto trip on fault.

Mechanical/Electrical/Interlock between breaker and corresponding off load isolators such that
these can be operated only when breaker is open.

CONSTRUCTIONAL FEATURES
METAL CLAD CONSTRUCTION:
a) Separate metal enclosed and earthed compartments in each cubicle for:
Main Switching Equipment
Bus bars
Instruments and relays
Instrument Transformers i.e. CTs and VTs. However, CTs and VTs located in cable compartment
are acceptable.
Power Cables.
b) Full side sheet in between adjacent SG cubicles.
c) Bottom of SG Cubicle fully covered by sheet steel.

SHEET STEEL:
Sheet steel for metal clad compartments and overall enclosure shall be 2.0 mm thick cold rolled / 2.5mm
thick hot rolled.

DEGREE OF PROTECTION:
IP 4 X as per IS 3427

SWITCH COMPARTMENT:
Compartment to house all switching equipment.
Switching equipment shall be preferably draw out type.
Separate door to be provided for the compartment.
Compartment to fully house breaker in both service and test positions.

BUS BAR COMPARTMENT:

Location of bus bars – rear top portion is preferred. However, in some design these are located at the
bottom of the cubicle.
Bus bars shall be colour coded for phase indication.

Page 11 of 15
 INDOOR HV SWITCHGEAR

INSTRUMENT AND RELAY COMPARTMENT:

Separate compartment located on the front above switch compartment with its own access door.
Shall house all instruments, relays, control switch, local/remote selector switch, push buttons, indicating
lamps etc., as required.
Instruments and relays are to be mounted flush or semi flesh on the hinged door.

CABLE COMPARTMENT:
Shall house power cable connections, associated cable box/pot head and also zero sequence CT, wherever
provided.
Cable entry – from bottom is preferred:
Top entry is also possible.

SAFETY EARTHING
Earth bus:
Run throughout the length of SG and connected to frame work of each cubicle and each switching device
earth bar.
Bus material – galvanized steel (GS). (Optional Copper)
Earthing Switch / Truck:
For earthing incoming and outgoing feeders (cables/ bus ducts) during maintenance, alternative
arrangements possible are:
i Earthing switch in each cubicle interlocked with main switch to prevent earthing of live circuit.
or
ii Earthing truck to be inserted after withdrawing main switch truck. One earthing truck may serve
all the cubicles in a SG.
Option (ii) is generally provided.
Hinged doors bonded to compartment by flexible braid.

INSTALLATION REQUIREMENTS
PREFERRED DIMENSIONS FOR LOCATING SG
SG front space:
Front to front distance between two rows of SG – 3000mm
Front of SG to nearest obstruction (wall, column etc.) in single row arrangement - 2000mm
SG back space from deepest part of SG to nearest obstruction – 1000mm (min. 800mm as per code)

Page 12 of 15
 INDOOR HV SWITCHGEAR

Preferred dimensions for locating SG

Sides & top of SG - 1000mm

Switchgear room requirements:

Good ventilation
At least two exit doors. Doors should open outwards. Wooden doors and sliding doors not acceptable.
Doors and windows are to be fire proof.
Pipes carrying steam, water, oil or other fluids not to be routed through the room.
All floor and wall opening for cable entries to be sealed with fire proof material after cable laying.
Adequate fire detection and protection to be provided.

TYPE TEST:
Tests carried out at factory on a proto type of the switchgear cubicle.
List of Type Tests:
Dielectric tests:
Impulse Voltage test
Power frequency voltage withstand test on power circuits.
Power frequency voltage withstand test on auxiliary and control circuits.
Temperature rise test on power and auxiliary circuits
Measurement of resistance of the main circuit.
Short-time withstand current and peak withstand current tests.

Routine Tests:
Tests carried out at factory on every switchgear cubicle to reveal faults in material or construction.
List of Routine Tests:
High Voltage test on power circuits.
High Voltage test on control and auxiliary circuits..
Insulation resistance test on power, control and auxiliary circuits.
Functional checks of switching device operation, motor wound spring charged mechanism, mechanical
position indicators, selector switch, control switch, push buttons, indicating lamps etc., safety interlocks,
safety shutters auxiliary relays etc.,

Page 13 of 15
 INDOOR HV SWITCHGEAR

Functional check of breaker truck – smooth movement, test and service positions, inter-changeability of
breaker trucks of similar rating and non interchangeability with a truck of higher rating.

APPENDIX - 1
Availability of indoor breakers from some leading manufacturers:
Product Availability
SL. # Make
Type of Voltage Current ( Amps ) Breaking
Brk. (kV ) Capacity
(KA)
1 ABB SF6 12 1200,1600,2000, 40
2500,3000
VCB 12 630,1250,1600 18.4,26.3

SF6 24 1250,2000,2500 26.3

SF6 36 1250,2000,2500 26.3
2 Crompton SF6 7.2 1250,2000,3150 40
Greaves SF6 12 1250,2000,3150 40
VCB 12 800 13.1
VCB 12 800,1250,1600 20
VCB 12 800,1200,1600 26.3
VCB 12 800,1250,1600, 40
2500,3150
MOCB 3.6 800 26.3
MOCB 7.2 800 21.9
MOCB 12 800,1250 18.4
3 Siemens VCB 7.2 1250 25
VCB 12 1250 25

VCB 36 2500 31.5

4 MEI VCB 12 Upto 1600A 31.5
5 Jyothi VCB 3.6 630 25
VCB 7.2 630 22
VCB 12 1250,2000,2500, 44 ( 7.2 kV )
3150 40 ( 12kV )
VCB 12 1250,2000 25, 31.5
VCB 12 630,1250 13.1
VCB 36 1250,2000 25

Page 14 of 15
 INDOOR HV SWITCHGEAR

NOTES:
The above table is for general information. Various product ranges are available with other
manufacturers.
Manufacturers generally offer 12 kV breakers for 3.6 and 7.2 kV systems also.

Page 15 of 15