UNIVERSITI TENAGA NASIONAL

COLLEGE OF ENGINEERING
Project Proposal

Project Title: Sluggish VCB Mitigation Solution

1 Background

TNBR is conducting a research to investigate and identify root causes of sluggish

switchgear operation. The sluggishness has caused the fault isolating function of
the breaker is being taken over by the back-up protection, thus cause a major
system breakdown. A sluggish gear will aggravate the supposed to be a single
feeder outage to half or full bus interruption which involves 7 to 15 feeders. Such
size of blackout tends to erode TNB’s reputation and will always become news
headlines. The prime objective of the research is to identify the root causes and
to propose remedial actions from the aspect of specification review, material
handling, quality inspection, diagnostic and maintenance procedures.

The main objective of this assignment is to investigate and mitigate the sluggish
operation of switchgears caused by mechanical and electro-mechanical issues.
The study will be carried out on the 11 kV switchgears from TAMCO, EPE and
TOPRANK and 33 kV breakers from EPE.

The scope of the assignment is to identify the appropriate close and trip coil
capacity (VA) that capable of operating the breaker under common stage of
sluggish condition, to explain the phenomena (failure modes), identify the root
causes and their locations as well as to develop or enhance the maintenance
procedure.

2 Objectives

1. To investigate the capacity (VA) of the closing coil and the trip coil that are
capable of overcoming the retarding force from the gears experiencing
sluggishness.

3 Customer Requirement
1. To study the operating mechanism for opening and closing of the vacuum
interrupters for the following gears:-
a. 11kV Tamco
b. 33kV EPE and 11kV EPE
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c. 11kV Toprank

2. UNITEN shall not do destructive tests on the new breakers as these breakers
will be used to replace the old breakers supplied by TNBD to TNBR.

3. UNITEN shall submit Gantt Chart with detail activities under each scope. The
deliverables shall be planned to complete in stages and the status will be
reported in the monthly progress meeting.

4. UNITEN shall state his/ her requirements from TNBR such as testing
equipment etc. TNBR may assist to find the required manpower but their
service charge will be paid by UNITEN.

4 Project Impact to TNB

• Improved switchgear performance and hence improved network reliability.
• The findings of this project will be later used as input to the development of the
switchgear condition-based maintenance (CBM)
• The competency of TNB workers in switchgear maintenance will be enhanced

5 Methodology

1. To check the threshold force value for the initiation of the operating mechanism
to trip or close the (new) breaker. The relationship (either Mathematical or
graphical) between VA (capacity) and the force will be presented and the safety
factor of the coils will be determined.

2. Based on the knowledge or investigation on the dominant sluggish root causes in

the switchgear operating mechanism we are to determine the most probable
retarding force generated by sluggishness. The value will be proven either by
calculation, simulation or other credible method/ sources. The threshold force
value required to initiate the operation of the close and trip mechanism will be
determined. This information will be used to calculate the appropriate coil
capacity for that scenario based on industry design practice. UNITEN will declare
the assumptions used in the calculations. In TNB, breakers are maintained once
in 18 month and a breaker is considered sluggish if the closing or tripping time
takes longer than 100ms. UNITEN shall advise on the practicality of the using the
calculated coil capacity, the methods of implementing the findings as well as to
propose alternative solutions.

6 Scope of Work

Tests will be conducted on each of the following breakers:-

 TAMCO 11 kV
 Toprank 11 kV

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 33kV EPE and 11kV EPE

Task 1 : To calculate the safety factor of the trip and close coil.
The force exerted by the plunger to the hook and the minimum force required to
initiate the movement of the hook will be measured. The electrical parameters will
be recorded. The relationship between force and current will be verified either by
using mathematical calculation, graphical table or other reliable tools.
(Repeat few times each, for statistical analysis)

Task 2: To identify the required coil VA to release the latch successfully

under sluggish scenario.

We will create a scenario where the roller bearing housing at the linkage is
jammed so that the tip of the hook has to experience friction in order to unlatch.
The force required for unlatching the linkages is measured. The test is repeated
few times to comply with intended level of confidence in statistical analysis)

The degree of hardening of the lubricant is not critical for the force to unlatch
because it will only create one scenario i.e. failure of roller bearing housing to
rotate.

The relationship between force and coil capacity (VA) will be estimated. Based
on the industrial design safety factor, the equivalent coil capacity is determined. If
such coil capacity is available in the market and exchangeable with the existing
one in the breaker, we will purchase and proceed with testing the new coil. Force
generated by the new coil will be measured and tested to release the latch under
the sluggish scenario above.

If such coil capacity is not a practical replacement, alternative solutions would be

sought. For example, our focus will be on maintaining the grease to avoid
hardening to such stage whereby the roller bearing housing gets stuck.

7 Deliverables

(a) Report on the compliance of the brand new trip coil and close coil to specifications
and their safety factors as derived from the laboratory experiments.

(b) To report on the required trip and close coil capacity (VA) to overcome the retarding
force from sluggishness, the practicality to replace the existing coils with the new
ones.

(c) To report on other alternative solutions, especially if (b) is found not practical to be
implemented.

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8 Project Implementation Plan

8.1 Please refer to Appendix I for a detailed Gantt chart and milestones.

8.2 Critical Path Work

The critical tasks are:
1. Acquisition of Circuit breaker
2. Acquisition of test and measurement instruments
3. Arranging the contract workers to assemble and dissemble
the circuit breaker
4. Development of procedures to test the solenoid force,
effect of grease hardening.
5. Design and develop jigs and fixtures for force testing
6. Experimentation and Data collection
7. Compilation and Analysis of data and dissemination of
results

8.3 Milestones
Milestone 1: Receiving VCBs
Milestone 2: Understanding Basic Linkages/ Plunger operational
Milestone 3: Hiring contract workers
Milestone 4: Development of jig and fixture for testing
Milestone 5: Conclusion of experimental testing
Milestone 6: Compilation and Analysis of project Report

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9 Resource Plan

9.1 Human Resource

Project members have been identified from UNITEN as follows:

POSITION MAN – TASK

NAME
MONTH
Abdul Talip Zulkarnain Senior Project coodinator
1
Lecture
Dr. Farrukh Nagi Hafiz Asst. Prof. Design,
Dr. Jawaid Asst. Prof fabrication and
1/0.3 testing of
Mechanical Parts
Mohd Hafiz Lecturer Mechanical
0.3/member
Dr. Faris Asst. Prof linkages
John Stevens Senior Design,
Lecturer fabrication and
0.3
testing of
Electrical Parts
Syed Khaleel Senior 0.45 Controls
Lecturer
Uwe Dippel Senior 0.3 Electrical work
Lecturer

Details Costing

days/m memb
mth th leader er
Rate/day 20 400 300
Specialised Services & Consultancy
Abdul Talip Zulkarnain 1 20 8000
Dr. Farrukh Nagi Hafiz 1 20 6000
Dr. Jawaid 0.3 6 1800
Mohd Hafiz 0.3 6 1800
Dr. Faris 0.3 6 1800
John Steven 0.3 6 1800
Syed Khaleel 0.45 9 2700
23900

Instruments/Materials Load Cell 2000

Eye bolts 50
Stainless wire grips 150
Rigging screw 350
Shackles 250
Steel wire 100
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Data Acq. Board 3000
Signal Conditionor 1100
Miscellane
ous 100
7100
Travels 1000

Jig & Fixtures (&Workmanship) 8000

To fabricate the load
measuring device
and attachment for different
VCB make.
External Contractor
(Assemble/Dissemble VCB ) 25000
Charges per visit RM1500
4 (Type VCB)x 4 (dismantle
each unit)=16
Grand 6500
Total 0

9.2 Facilities
• Manufacturing process workshop
• Electrical equipment and accessories

10 Costing
The total Project Contract Cost is RM 65,000

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11 Project Organisation

Project Coordinator

Abdul Talip Zulkarnain

Electrical Section Mechanical Section Control Section

Dr. Farrukh Nagi Syed Khaleel
John Steven
Uwe Dipple Dr. Jawaid

Dr. Faris

Mohd Hafiz

VCB fitters/assemblers

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12 Appendix 1

Gantt chart and milestones

Month 1 2 3 4 5
1 Contract signing
Contract preparation & submission
Proposal approval
Kick-off meeting
Prepare contract
Sign & stamp contact
2 Details works and reports
i Profile measurement of new switchgear
Electrical parameter testing and
ii measurement
Mechanical parameter testing and
iii measurement
iv Compilation and Analysis
v Report a b c

Note:

a. Report on the compliance of the brand new trip coil and close coil to
specifications and their safety factors as derived from the laboratory experiments.

b. To report on the required trip and close coil capacity (VA) to overcome the
retarding force from sluggishness, the practicality to replace the existing coils
with the new ones.

c. To report on other alternative solutions, especially if (b) is found not practical to

be implemented.

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13 Appendix II

Duration
Six (6) months from the date of receiving the of DC power supply unit , profile analyzer,
and new switchgears.

The following cost estimates are provided for review and approval.
Scope of Work Item Estimated Estimated Comments
Man-Days Costs
Task 1 :To calculate the safety 30,000.00
1 factor of the trip and close
coil.

Task 2: To identify the required 35,000.00

coil VA to release the latch
successfully under
sluggish scenario.

Sub Total Man-hours 65,000.00

3 EXPENSES
Flight Fare -
Local -
Travelling
Hotel -
Meal(s) -
Sub Total Disbursements 0

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COST (RM)
Month 1-2 Month 3-4 Month 5 TOTAL
A)Direct Cost

Man Power Cost * 15,000 5,000 5,000 25,000.00

Material/ jig and fixture for testing 1,1 15,

12,000 2,000 00 100.00
Specialised Services & 10, 3,9 23,
Consultancy 10,000 000 00 900.00

Seminar / Training - - - -
Travelling & Miscellaneous 1,
Expenses 500 250 250 000.00

B)Capital Expenditure

Equipment
New VCB with breaker truck - - - -

65,000
GRAND TOTAL .00
Notes

Triggering for 1st invoice cost incurred

(Submission of sec. 7(a) report) 40%

Triggering for 2nd invoice cost incurred

(Submission of sec. 7(b) report) 20%

Triggering for 3rd invoice cost incurred

(Project completion and final report
submission) 40%

* Price subjected to changed according contractor worker rates and requirements

14 Appendix III

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PROFILE OF PROJECT TEAM MEMBERS

Farrukh Nagi Dr. is working as associate professor in Universiti Tenaga Nasional,

department of mechanical engineering. Graduated from NED engineering university,
Karachi (1982). Worked in Pakistan International Airline for seven years as a project
engineer on the development of guidance and control systems and was responsible for
integration and testing of flight by wire system. Completed his MS from university of
Miami USA (1989) and PhD from university of Nottingham UK (1993). During this
period he has gained hand-on experience of working with PLCs, data acquisition and
programming techniques. From 1994-1997 worked in Saudia Arabia – Yanbu Al-
Sinayah in industrial training institute; where engineers and technicians were taught to
use instrumention for control system in petrochemical industries. From 1997-2000
worked in Pakistan Navy engineering college –NUST and had undertaken research
projets pertaining to submarine accoustic detection. Since 2001, is working in UNITEN
and had consulted with company ‘Cognis’ for Automatic waste material disposal system
and is undertaking IRPA and E-science projects from MOSTI. Recently, successfully
developed VCB racking In-Out prototype system for TNBD, which is installed at PPU
Bangi Resort for trails.

Tel: 03-89287226
Email: farrukh@uniten.edu.my

Abdul Talip b. Zulkarnain is currently a lecturer with the Department of Mechanical

Engineering, College of Engineering (COE), University of Tenaga Nasional Berhad. He
holds a Diploma in Mechanical Engineering from Niihama College of Technology,
Japan(1988) and a Bachelor of Mechaninal Engineering from Osaka Institute of
Technology , Japan). He obtained her Master degree from Universiti Tenaga Nasional,
Malaysia, in the area of vibration damper in 2005. Prior to joining Uniten in 1999, he
was a TNB traineer for 5 years, in Institute Latihan Sultan Ahmad Shah, in Electrical and
Instrumentation and working experience with Project Hydro Department, LLN.
Recently, successfully developed VCB racking In-Out prototype system for TNBD,
which is installed at PPU Bangi Resort for trails.

Tel: 03-89212238
Email: abdultalip@uniten.edu.my

Jawaid I. Inayat-Hussain obtained his B.Eng. (Mech.) and M.Eng. (Mech.) from
Universiti Teknologi Malaysia, and Ph.D. (Rotor Dynamics) from Kobe University,
Japan. He spent his entire career in research and development, both in the academia and
in the industry, working mainly in the field of vibration and noise control. He has also
undertaken consulting work in the areas of vibration and noise control, and machinery
condition monitoring for various industries. In recent years his research work has been

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focused on nonlinear response of rotor dynamical system. He is presently an associate
professor at the Department of Mechanical Engineering, Universiti Tenaga Nasional.

Tel : 03 89282263
Email :jawaid@uniten.edu.my

Mr John Steven Navamany is currently a senior lecturer in the Department of Electrical

Power Engineering at the College of Engineering, University Tenaga Nasional
(UNITEN). He received his Diploma (Electrical Power Engineering) from Polytechnic
Ungku Omar in 1980, BSc in Electrical Engineering from Purdue University, USA in
1998, and M.Eng in Electrical Power Engineering University Tenaga Nasional in 2002.
He has more than 10 years experience as a lecturer. Served as a senior
instructor( electrical ) at the utility company’s technical training centre for a period of 15
years. Instructs the technical staff of the utility company and the electrical maintenance
personnel from the electrical industry on the fields of, operation and maintenance of
switchgears and transformers, generator maintenance, power station electrical practice,
motors (AC/DC) and motor controls. Responsibilities include developing and
documenting short term courses. Has undergone industrial training on Power Generation
Equipment for a period of 8 months at Hitachi Power Generation Company of Japan.
Performed overhaul and inspection on switchgears, transformers, generator and exciter
systems and electrical auxiliaries at Port Klang Power Station in 1988 for a period of
about a year. Performed commissioning tests on all electrical equipment in Putrajaya
Power Station, including Gas Insulated Switchgear in switchyard.
Tel: 03-89212235
Email: johnsteven@uniten.edu.my

Syed Khaleel Ahmed is currently a Senior Lecturer in the Department of Electronics and
Communication Engineering of the College of Engineering, Universiti Tenaga Nasional.
He received his B.E. from Anna University, Chennai, India in 1988, and M.S.E.C.E. from
the University of Massachusetts at Amherst, USA in 1994. His interests are in Robust and
Fuzzy Control, Signal Processing, Numerical Techniques, and Neural Networks. He is a
member of IEEE, Inc, USA and ISTE, India.

Tel: 03-89212276
Email: syedkhaleel@uniten.edu.my

Mohd. Hafiz Hasan is a faculty member of the department of mechanical engineering in

UNITEN. He graduated summa cum laude from the University of Michigan, Ann Arbor,
USA with a Bachelor of Science degree in mechanical engineering in 2003. He served as
a tutor in the department of mechanical engineering in UNITEN from 2004 to 2006, after
which he went to Nanyang Technological University, Singapore. He graduated in 2008
with a Master of Science degree in smart product design, and also won the Professional
Engineer’s Board gold medal for graduating with the highest CGPA from his school. He

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currently serves as a lecturer in the department of mechanical engineering in UNITEN,
where he carries out research on optical motion tracking devices and network flow
optimization algorithms. He also teaches an undergraduate course on modeling, designing
and analyzing mechanisms.

Tel: 03-8921 2020 ext. 6048

Email: mhafiz@uniten.edu.my

Uwe Dippel is currently employed as Senior Lecturer in the Department of Computer

Science of the College of Information Technology, Universiti Tenaga Nasional. He holds
a Masters Degree in Electrical Engineering from Technische Universität Berlin,
Germany, and has over the last twenty-five years acquired professional experiences in
various areas of the field; ranging from the German Ministry for Research and
Technology to Broadcasting.

Tel. (03)8921-2374
E-mail: udippel@uniten.edu.my

Ir. Dr. Faris Tarlochan is currently an Assoc. Prof. in the Department of Mechanical
Engineering of the College of Engineering, Universiti Tenaga Nasional. He received his
BSc and MSc from Purdue University, USA in 1998 and 2001 respectively. He
completed his PhD at UPM, Malaysia in 2007. His interests are in applied mechanics,
finite element analysis, failure analysis and composite materials. He is a Chartered and
Professional Engineering registered with the UK Engineering Council and IEM
respectively. He is also a member of IMeche (UK), ASME, IMM, mSET.

Tel: 03-89212224
Email: rameshjit@uniten.edu.my

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