Siemens 3AP2-FI Manual

OPERATION & MAINTENANCE
MANUAL FOR
400kV CIRCUIT BREAKER
JINDAL INDIA THERMAL POWER LIMITED
(2 x 600MW THERMAL POWER PROJECT)
DOC. No. - SIEM-JITPL.5404A-EL-3-2112 400kV Circuit Breaker Date 23.06.2011 Page 1 of 109
Project JINDAL INDIA THERMAL POWER LIMITED
(2 x 600 MW THERMAL POWER PROJECT) O&M Consultant TATA CONSULTING ENGINEERS
OPERATION & MAINTENANCE MANUAL FOR 400kV CIRCUIT BREAKER
Owner JINDAL INDIATHERMAL POWER LIMITED
Project 2 x 600 MW THERMAL POWER PROJECT
Consultant TATA CONSULTING ENGINEERS
Document
Type O & M Manual (Information Only) Document Number
Document
Name 400kV Circuit Breaker - Manual SIEM-JITPL.5404A-EL-3-2112
Siemens Limited,
Aurangabad.
Copyright© Siemens Ltd 2007.
The reproduction, transmission or use of this document or its contents is not permitted without express written au-
thority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a
utility model or design, are reserved.

1
s
Operating Instructions
Circuit-Breaker 3AP2 Fl
for rated voltage 420 kV
1003006a
Siemens Ltd.
© Siemens Ltd 2007

2
The Siemens Ltd, Power Transmission and Distribution Group, High Voltage Division has introduced and
appiies a quality system in accordance with EN ISO 9001.
If you require further copies of the operating instructions, please order them from the appropriate Siemens office,
indicating the title and order number:
Published by:
Siemens Ltd.
Power Transmission and Distribution
High Voltage
E-76. Waluj MIDC
Aurangabad 431136
Tel.: [phone]
Fax: [phone]
Subject to change.
All rights, including rights of translation, reproduction by
printing, copying or similar methods, even of parts are
reserved.
Offenders will be liable for damages.

3
1 Contents
1 Contents
2 General 7
2.1 Introduction 7
2.1.1 Arrangement of the Operating Instructions 7
2.1.2 Communication by Means of the Operating Instructions 7
2.2 Safety Instructions 8
3 Description 11
3.1 Technical Data 11
3.1.1 Standards, Regulations 11
3.1.2 Operating Temperatures 11
3.1.3 Insulation Rating 12
3.1.4 Electrical Data 12
3.1.5 Operating Times 13
3.1.6 Arc Quenching Medium SF614
3.1.7 Auxiliary Switch 14
3.1.8 Anti-Condensation Heaters 15
3.1.9 Reference Contact IK-3 15
3.1.10 Further Technical Data 15
3.2 Circuit-Breaker 16
3.3 Pole Column 18
3.4 Interrupter Unit 20
3.5 Arc Quenching 22
3.6 Spring Drive Mechanism of the Circuit- Breaker 24
3.6.1 Charging the Closing Spring 24
3.6.2 Closing 24
3.6.3 Opening 25
3.6.4 Operating Sequence 25
3.7 Function of the Spring Drive Mechanism 26
3.7.1 Charging the Closing Spring 26
3.7.2 Closing 29
3.7.3 Tripping 34
3.8 Control 35
3.8.1 Spring Winding Mechanism 36
3.8.2 Gas Monitoring 36
3.8.3 Lockouts 39
3.8.4 Motor Control 39
3.8.5 Anti-Condensation Heaters 39
3.8.6 Signals 39
3.8.7 Free Auxiliary Switch Contacts 40
3.8.8 Operating Cycle Counter 40
3.9 Reference Contact IK-3 41
3.9.1 Introduction 41

4
1 Contents
4 Installation 43
4.1 Safety Rules for Installation 43
4.2 Delivery and Storage 46
4.2.1 Packing 46
4.2.2 Checking on Arrival 46
4.2.3 Storage 46
4.3 Cleaning Liquids, Lubricants and Corrosion Protection Agents 48
4.3.1 Cleaning Liquids 48
4.3.2 Lubricants and Corrosion Protection Agents 49
4.4 General Instructions for Installation 50
4.5 Installation of the Circuit-Breaker 51
4.5.1 Requirements for Assembly 51
4.5.2 Assembly on Supporting Pillars at the Place of Installation 51
4.5.3 Assembly Overview 52
4.5.4 Disassembling the Insulator Column Kit 52
4.5.5 Assembly of the Control Cubicle 55
4.5.6 Assembly of the Operating Mechanism Cubicles 56
4.5.7 Assembling the Insulator Column 57
4.5.8 Erecting the Double-Break Assembly 62
4.5.9 Lifting Plate 68
4.5.10 Coupling the Operating Mechanism 69
4.5.11 Connecting the Gas Pipes 70
4.6 Earthing and Connecting the Leads 72
4.6.1 Earthing 72
4.6.2 Work on High-Voltage Terminals 72
4.6.3 Connecting the Leads 73
4.7 Filling the Circuit-Breaker with Gas 74
4.7.1 Evacuating 74
4.7.2 Filling the Breaker from the Gas Cylinder 74
4.7.3 Leakage Test after Installation 76
4.8 Carrying Out Test Operations 77
4.9 Checks before Commissioning 79
4.9.1
A
nti-Condensation Heaters 79
4.9.2 Test of Wiring between Substation and Circuit-Breaker 79
4.9.3 Commissioning Report 79
5 Operation 81
5.1 Instructions for Operation 81
5.1.1 Closing and Opening 81
5.1.2 SF6Pressure 81
5.1.3 General Lockout 82

5
1211
1 Contents
5.1.4 Mechanical Reclosing Lockout 82
5.1.5 Max. Permissible Number of Interruptions 82
5.1.6 Recommended Procedure in the Event of Irregularities on the Circuit-Breaker
3AP2 Fl
85
5.2 Disposing of High-Voltage Switching Devices and Systems 87
6 Maintenance 89
6.1 Inspection and Maintenance - General 89
6.1.1 Maintenance Services (Schedule) 89
6.1.2 Assignment of Personnel 90
6.1.3 Maintenance Kits 90
6.1.4 Initial Date for Inspection and Maintenance Service 90
6.1.5 Disturbances 91
6.1.6 Points to be Noted 91
6.2 Safety Rules for Inspection and Maintenance Service - General 92
6.3 Maintenance Schedule 96
6.4 Work to be Carried Out in Accordance with the Maintenance Schedule 98
6.4.1 General Inspection 98
6.4.2 Drawing Off the SF6Gas 98
6.4.3 Check of Contact System 99
6.4.4 Evacuating and Filling the Circuit-Breaker with Gas 100
6.4.5 Check Gas Pressure Gauge 103
6.4.6 Testing the Density Monitor 103
6.4.7 Check for Leaks on Operational Circuit- Breaker 104
6.4.8 Checks at Drive Mechanism 105
6.4.9 Terminal Strip 107
6.4.10 Anti-Condensation Heaters 107
6.4.11 Function Checks 107
6.4.12 Check of Motor Control 108
6.4.13 Measuring the SF6Gas Humidity Content 108
6.4.14 Measuring the SF6Air Content 108
6.4.15 Anti-Corrosion Protection 109
6.4.16 Special Occurrences 109
Commissioning Report for the Circuit-Breaker 3AP 111
Function Diagram of Spring Drive Mechanism 119
1 Contents

6
2 General
2 General
2.1 Introduction
These operating instructions apply to high-voltage circuit-breakers with the serial numbers given on the title
page. They are intended to familiarize operating personnel with the design and functioning of the circuit-
breaker. They also supply details of operation and provide information on installation and maintenance.
All values of pressure given are gauge values unless absolute pressure is expressly stated.
It is advisable for the operating personnel to familiarize themselves as early as possible with the instructions,
and with the aid of other documents supplied to gather any relevant further information on the circuit-breaker
and its features.
)Note
The operating instructions contain information on proper operation and maintenance of the
circuit-breaker, together with certain supplementary warning notices. They are intended to
point out impermissible actions and to show the potential danger associated with operation
of the circuit-breaker.
Should further information be desired or should particular problems arise which are not covered
sufficiently in the operating instructions, the matter should be referred to the local Siemens sales
office.
2.1.1 Arrangement of the Operating Instructions
These operating instructions are divided into chapters
1- Contents, 2- General, 3- Description, 4- Installation, 5- Operation and 6- Maintenance.
2.1.2 Communication by Means of the Operating Instructions
In verbal or written communication, as well as when ordering any spare parts required, please use the des-
ignations and part numbers used in the operating instructions, giving details of the order number of the
operating instructions 927 00966 174 A, the page number and specifying the number of the illustration (Fig.).
In this way, misunderstandings can be prevented.

7
2 General
2.2 Safety Instructions
During operation, certain parts of the circuit-breaker are live and hazardous voltages therefore present.
Certain parts are also under gas pressure (SF6).
In its pure state, sulphur hexafluoride (SF6) is a colourless, odourless, tasteless, non-toxic and non-flammable
gas, inactive like nitrogen. SF6is safe if there is adequate oxygen present in inhaled air. SF6constitutes no
danger to the ecosystem.
Personnel must be thoroughly familiar with all warnings and procedures for installation, operation,
maintenance and repair contained in these operating instructions.
WARNING
Non-observance of warnings can result in death, severe personal injury and substantial
property and environmental damage.
The user of the circuit-breaker must ensure that the installation, maintenance and relevant operating direc-
tives to the appropriate activity, local safety regulations and information on what to do in the event of an acci-
dent are available or displayed, e.g. on a notice board so that they can be referred to at any time.
Additionally to the safety rules valid in the country in question a few precautionary measures and points to be
noted are listed below:
- The accessory items required for installation, operation and maintenance of the circuit-breaker and for
reasons of safety (protecting clothes, devices for manual operation, warning signs, hand lamps, fire
extinguishers etc.) must be stored neatly at a certain point and be checked regularly for completeness
and proper functioning. This also includes the complete operating instructions.
-The specified maintenance intervals and the instructions for repair and replacement must be adhered to.
-Detailed warning references describing the secure execution of dangerous work are included in the
particular sections of the operating instructions. They are highlighted by frames, bold lettering and/or
other means.
WARNING
in the sense of these operating instructions means that death, severe personal injury or
substantial property and environmental damage may occur if appropriate safety measures
are not taken.
Attention
in the sense of these operating instructions means that light personal injury or
property/environmental damage may occur if appropriate safety measures are not taken.
)Note
Note in the sense of these operating instructions means information to simplify and improve the
handling of the circuit-breaker. They are based on the experiences of Siemens staff.

8
3 Description
3 Description
3.1 Technical Data
The 3AP2 Fl circuit-breaker is of the self-compression type and uses SF6-gas for insulation and arc-quench-
ing purposes. It is of triple-pole outdoor design.
The circuit-breaker is equipped with one operating mechanism per pole and therefore suitable for single and
triple pole auto reclosing.
3.1.1 Standards, Regulations
The circuit-breaker, together with the equipment and special tools supplied, is in conformity with the statutory
laws, rules and standards applying at the time of delivery.
- The specifications in IEC Publications 62271-100.
- The specifications in lEC-Publications 60694.
3.1.2 Operating Temperatures
The circuit-breakers are designed for operation in an ambient temperature range from -25°C to 45°C.

9
3 Description
3.1.3 Insulation Rating
Rated voltage 420 kV
Rated short-duration power-frequency
withstand voltage
to earth 520 kV
across the open circuit-breaker 610 kV
between phases 520 kV
Rated lightning impulse withstand
voltage
to earth 1425 kV
across the open circuit-breaker 1425 kV
between phases 1425 kV
Impulse against power frequency
voltage 1425 kV +240 kV
Rated switching impulse withstand
voltage
to earth 1050 kV
across the open circuit-breaker 1050 kV
between phases 1575 kV
Impulse against power frequency
voltage 900 kV + 345 kV
Flashover distance in air
to earth 3180 mm
across the open circuit-breaker 3200 mm
between phases see dimension drawing
Minimum creepage distance over the
insulators' surfaces
to earth 10050 mm
across the open circuit-breaker 10500 mm
Table 1 Insulation rating
3.1.4 Electrical Data
Rated voltage 420 kV
Rated frequency 50 Hz
Rated normal current 3150 A
Rated short-circuit breaking current 50 kA
Rated line-charging breaking current
(1.4 p.u.) 600 A
Rated cable-charging breaking
current (1.4 p.u.) 400 A
Transient recovery voltage under
terminal fault conditions ace. to IEC
Rated short-circuit making current 135kA
Rated short-circuit duration 3s
Rated operating sequence O-0,3s-CO-3min-CO
Table 2 Electrical data

10
3 Description
3.1.5 Operating Times
Minimum command duration (Closing com-
mand) 80 ms
Minimum command duration (Opening
command) 80 ms
Closing time 65 ms + 6 ms
Opening time 23 ms + 3 ms
Rated break time <40 ms
Close-open-time 60 ms + 10 ms
Dead time 300 ms
Table 3 Operating times

3 Description
3.1.6 Arc Quenching Medium SF6
a SF6-filling gauge pressure (nominal density line)
b Signal Loss of SF6
c General lockout SF6
e Liquefaction curve
Fig. 1 SF6-filling and operating values of density
monitor (gauge pressure)
Filling weight (complete circuit-breaker) 44.6 kg
Volume (complete circuit-breaker) 966 dm3
SF6nominal filling gauge pressure at +20°C 6.0 bar
Monitoring of the SF6
Signal Loss ofSF6at 20°C
General lockout SF6at 20°C
5.2 bar 5.0 bar
Filter material (complete circuit-breaker) 7.5 kg
Table 4 Arc quenching medium SF6
3.1.7. Auxiliary Switch
Rated voltage 250 VDC 220 VDC 125VDC 110VDC 60VDC 48VDC
Rated normal current 10A 10A 10A 10A 10A 10A
Switching capacity
Resistive load 2.5 A 2.5 A 4A 5A 9A 10A
Resistive-inductive load
(time constant x = 20 ms) 1,2 A 2A 2.5 A 4A 7A 9A
Table 5 Auxiliary switch
Auxiliary switch contact class 1
11

12
3 Description
3.1.8 Anti-Condensation Heaters
Control cubicle 90 W
Operating mechanism 210 W
Table 6 Anti-condensation heaters
The anti-condensation heaters must always be
switched on.
3.1.9 Reference Contact IK-3
Principle Fixed Hall sensor and moving magnet
Hall sensor HE-6103
Magnet HE-6104
Supply voltage 24VDC
Operating tempera-
ture -40°C ... +85°C
Output 4...20 mA, CLOSE: >18 mA, OPEN: <6 mA
Resolution <0,2 ms
Transmission Current loop, max. 500 m
Table 7 Technical Data IK-3
3.1.10 Further Technical Data
)Note
Technical Data for
- Trip voltage
- Control voltage
- Heater voltage
- Pressure monitoring for SF6
- Charging motor of the spring drive mecha-
nism
are indicated in the circuit diagram.
)Note
Technical Data for
- Circuit-breaker weights
- the permitted cable pull F
are indicated in the dimension drawing.

3 Description
3.2 Circuit-Breaker
The pole columns of the circuit-breaker are each mounted on a base 11, to the side of each of which an operating
mechanism cubicle 15.1 is fitted.
The insulator columns are assembled from several multished insulators and each of them supports an double
break interrupter assembly consisting of two interrupter units 22 with grading capacitors 23 connected in parallel
and a bell-crank mechanism 21.
Control cabinet 12 is also located at pole B.
15.1 12
21
11 Base
12 Control cubicle
15.1 Operating mechanism cubicle
16 Post insulator
21 Bell-crank mechanism
22 Interrupter unit
Fig. 2 Design of the circuit-breaker 3AP2 Fl 1003000a
13

14
3 Description
The two interrupter units provide a double-break feature per pole, the grading capacitors ensuring uniform voltage
distribution.
The double break assembly and the insulator column are filled with SF6for arc-quenching and insulating
purposes.
The density of the SF6gas for each circuit-breaker pole is monitored by a density monitor and the gas pressure
indicated by a manometer.
The energy required for switching is stored in one closing spring and one opening spring. The closing and
opening springs are located in the operating mechanism unit.
Control cabinet 12, which is attached to circuit-breaker pole B, contains the equipment for controlling and mon-
itoring the circuit-breaker and the terminal blocks required for the electrical connection. SF6gas is monitored
single-poled in the operating mechanism cabinet.
There are cables for electrical coupling of the control with the three operating mechanism.

3 Description
3.3 Pole Column
The circuit-breaker's three pole columns are of identical design. Fig. 3 shows a cross-section of a pole column.
The double break assembly unit is mounted on post insulators which provide insulation against earth.
22.22
15.16.3
15.11
15.9 15
15.8.3
15 Corner gear
15.11 Filter cowl
15.16.3 Filter bag
15.8.3 Shaft
15.9 Lever
16 Post insulator
16.9 Operating rod
18.27.1 Driving rod
21 Bell-crank mechanism
22 Interrupter unit
22.1 Jacket
22.22 High-voltage terminal
Fig. 3 Sectional view of pole column
15

16
3 Description
The switching operation is transmitted to the interrupter units 22 (high-voltage potential) by the spring drive
mechanism (ground potential) via an operating mechanism rod 18.27.1, the shaft 15.8.3, the operating rod 16.9
and the bell-crenk mechanism 21.
The filter cowls 15.11 contains the filter material 15.16.3 which collects SF6decompositon products and moisture
residue.
22
23.2
23.1
1001360a
22 Interrupter unit
23 Grading capacitor
23.1 Inner bracket
23.2 Outer bracket
Fig. 4 Arrangement of grading capacitor

3 Description
3.4 Interrupter Unit
Fig. 5 shows a sectional view of an interrupter unit. The breaker contacts are accommodated in the gas-tight
porcelain jacket 22.1.
15.11 Filter cowl
16.9 Operating rod
21.1 Gear unit housing
22.1 Jacket
22.11 Tube contact
22.11.1 Nozzle
22.11.17 Piston
22.11.18 Valve plate
22.11.19 Valve group
22.11.2 Auxiliary nozzle
22.17.1 Pull rod
22.17.2 Coupling rod
22.22 High-voltage terminal
22.23 Inner socket
22.29 Sealing ring
22.3 Contact laminations
22.31 Contact carrier
22.32 Base
22.35 Cover
22.4 Tandem gear
22.41 Heat cylinder
22.45 Electrode
22.5 Guide rail
22.52 Pin
22.9 Pin
Fig. 5 Interrupter unit
The main circuit of an interrupter unit consists of the high-voltage terminal 22.22, the socket 22.32, the contact
carrier 22.31, the contact laminations 22.3 arranged in rings in the contact carrier, the heat cylinder 22.41, the
inner socket 22.23 and the gearbox 21.1.
The contact laminations 22.3 support themselves centrically from the contact carrier 22.31 inwards to the heating
cylinder 22.41. The internal stress of the contact laminations 22.3 generates the necessary contact pressure from
the contact carrier 22.31 onto the heating cylinder 22.41.
17

18
3 Description
Parallel to the main circuit is the arcing circuit, which is made up of the movable pin 22.9 in the contact carrier
22.31 and the moving tube contact 22.11 situated in the heating cylinder 22.41.
The pin 22.9 and the tube contact 22.11 are made of materials which produce only minimal contact erosion.
The tube contact 22.11, the piston 22.11.17 and the heat cylinder 22.41 are mechanically interconnected and
coupled with the pull rod 22.17.1. They form the moving part of the interrupter unit.
A guide rail 22.5 is mounted at the nozzle 22.11.1. This engages with the control lever 22.46 via the pin 22.52. As
a result, the control lever is subjected to rotary movement, causing linear movement of the pin against the
direction of movement of the nozzle. The electrode 22.45 is connected to the nozzle via the gears using two
connecting rods and provides the pin with dielectric shielding.
The rear side of the piston 22.11.17 is equipped with a valve plate 22.11.18 which together with the valve group
22.11.19 makes up the compression unit for arc quenching.
The breaking process in the interrupter unit is described in a schematic diagram in the section 3.5 Arc Quenching.

3 Description
3.5 Arc Quenching
In an opening operation, the main contact that exists between the contact laminations 22.3 and the heat cylinder
22.41 is opened (Fig. 6, position b). The arcing contact, consisting of the pin 22.9 and the tube contact 22.11
remains closed, with the result that the current commutates onto the arcing contact.
22.11.19 KV 22.11.18 22.41 22.11 22.5 22.52
19
a)
22.11.17 HV 22.11.2 22.3 22.11.1 22.9 22.51 22.46 22.56
b)
C)
d)
a) CLOSED position
b) Opening: main contact in OPEN position
c) Opening: arcing contact in OPEN position
d) OPEN position
HV Heating volume
KV Compression volume
22.11 Tube contact
22.11.1 Nozzle
22.11.17 Piston
22.11.18 Valve plate
22.11.19 Valve group
22.11.2 Auxiliary nozzle
22.3 Contact lamination
22.41 Heat cylinder
22.46 Cam lever
22.5 Guide rail
22.51 Coupler
22.52 Pin
22.56 Lever
22.9 Pin (moving)
Fig. 6 Schematics of opening operation