Report:
Date: 9th September 2007
Program

1. Traveling by Thai Airways from KLIA to Suvarnabh Airport Bangkok, Thailand for transit.
2. Suvarnabh Airport to Frankfurt Airport by Lufthansa Airways.
3. Frankfurt Airport to Tegel Airport, Berlin by Lufthansa Airways.

Date: 10th September 2007
Program:

1. Arrived at Tegel Airport, Berlin at Tuesday 08.45am Berlin Time. Pick up by Siemens Training Instructor Mr. Joerg Hellhammer.
2. Check in at Econtel Hotel.
3. Free activity on 10th September 2007

Date: 11th September 2007
Program:
1. Siemens Factory Visit at 9.00am
2. Explanation about Siemens AG Circuit Breaker Product by Mr. Joerg Hellhammer.
3. Explanation of Live Tank and Dead Tank Circuit Breaker.
4. Slide Show and Video presentation.
5. Hand out documentation of 3AP1 FG for rated voltage 72.5kV and 145kV
6. Program ended at 4.30pm Berlin Time.

Instructor: Mr. Joerg Hellhammer
Department: PTD H3 (Power Transmission and Distribution) Circuit Breaker and Disconnector.

Introduction:

PTD H3
P : Power
T : Transmission
D : Distribution
H : High Voltage
3 : Siemens Internal code for Circuit Breaker and Disconnector.

Circuit Breaker Ordered by SPM for SESB
- 5 units 6.6kV (72.5kV) Type 3AP1FG
- 5 units 132kV (145kV) Type 3AP1FG
Note : Circuit Breaker Type same but the CB rating is different.

3AP1FG
a. 3 : Stand for Circuit Breaker
b. A : Stand for Air Insulated (AIS)
c. P : Version P see explanations below
d. 1 : Single Interrupter Unit.
e. F : Feda (Germany Language) means Spring
f. G : Gang ( Three Pole Gang)

Version:
O , P , Q , R , S , T
Q,R,S,T : Hydraulic system (Old Version) Eg: 3AT2/3
P : Latest Version (Spring Charge)
O : Future Version.




Live Tank Circuit Breaker
Type 3AP
Minimum operating energy needed for maximum operating requirement
They are used for voltage range up to 420kV.

Dead Tank Circuit Breaker
Voltage Rated: 3AP(Spring Charge) up to 245kV only.
: 3AT (Hydraulic) up to 550kV.


Day 2 :
Date : 12th September 2007
Program:
1. Program started at 8.30 am Berlin Time.
2. Explanations about FAT routine test to be carry out during FAT on 13th September 2007.
3. Presentation and inspection of mechanism at Operation Presentation room.
4. Factory Site Visit, Production Line, assemble, Testing and Packaging.
5. Circuit Breaker movement mechanism explanations and installation video.
6. Circuit Breaker Scheme explanations.
7. Program ended at 17.30pm Berlin Time.

FAT routine test review for 3AP1 FG

Travel test.
The test included spring charging time, SF6 gas pressure and movement of interrupter unit and the main contact of circuit breaker.

1. Timing test of Interrupter unit during CB closing operation.
2. Timing test of main contact of CB during Opening operation.
3. Closing and Tripping coil power consumption measurement. ( we usually use to get the resistance of the coil).
4. Trip-Close-Trip Operation ( Graph measurement)
5. Close – Trip – Close Operation ( Graph measurement)
6. Pressure Test of circuit breaker IEC standard and ANSI Standard. 145kV rated at 310kV and 72.5kV rated at 160kV.
7. SF6 density monitoring test. ( Stage 1 alarm and Stage 2 lock-in.

-Presentation and inspection of mechanism
-Transport Lever (Free-Wheel): Is not for transportation locking device, its just claim as the limit switch during charging the spring. This liver act as a protection device to the motor charging, overcharging spring may damage the charging and damping mechanism.

-Operating Lever of circuit breaker mechanism for Close and Open Operation.
-Auxiliary contact of circuit breaker
At schematic drawing ( 458 00123 372 sheet: 8/19) only shown 10 no’s normally open contact and 9 no’s normally close contact has been wired to terminal block.
- If any faulty contact refer to ( 458 00123 372 sheet: 14/19) there shown a few contact not wired to terminal block ( which not shown the address)

Spring Charging Mechanism
2 Type of spring - Closing Spring ( Big Size Spring)
- Opening Spring ( Small size)



Installation of 3AP1 FG (145kV)

Step 1:
a. Moving the breaker base and operating mechanism unit with a crane.
b. Hang the crane hooks in the lifting eye bolt of the breaker base.
Step 2:
a. Installation of pole columns and coupling of the operating mechanism
b. Installation of pole B (centre)
c. Remove red marking screw (transportation screw) replace with new screw provided (M16X60) from accessories pack.
d. To couple the mechanism, make the pole column in open position and lock the mechanism with M6 screw provided at center movement mechanism.
Step 3:
a. Install Pole A and Pole C
b. Release M6 Screw for free movement of center rod.

Step 4:
a. Connect the gas pipe
b. Test the gas valve by press it slowly.
c. Connect 3 pole pipe at the same time ( the gas will flow to another open pipe which open)
d. After complete connect the piping, fill the SF6 gas directly ( slow pressure) until 6.5bar at 38 degree Celsius.( 6 bar at 20 degree Celsius)
Step 5:
a. Erect the electrical circuit.
b. Charge the spring with motor operation.
c. Close open operation

Installation of 3AP1 FG (72.5kV)
Just check the M6 Screw (locking device) already release.
Erect the electrical circuit
Fill the SF6 gas
Charge the spring by motor operation
Close open operation
**Refer to installation manual for detail


Circuit Breaker Scheme

1. Circuit Breaker 3AP1 FG 145kV and 66kV already design as Lock In Circuit Breaker, SESB already agree the scheme as per previous circuit breaker install by them.
2. Circuit Breaker current rating which state at the order is 1250A, as per discuss Siemens AG agree to change it to 3150A for 145kV and 2000A for 66kV. ( due to misunderstanding between Siemens (M) and Siemens AG.
3. Installation of 1kV resistor between closing and tripping coil will interrupt Trip circuit supervision, but SESB confirm it not interrupt the Trip circuit supervision scheme. (No changing of schematic drawing during their 1st installation of Siemens circuit breaker) Drawing ref: 458 00123 372 sheets: 7/19.
4. SF6 stage 1 only give the signal to enunciator as per agree by SESB. ( it will not involved in tripping circuit)
5. SF6 Stage 2 will lock-in the CB, but it may trip 1sec before K10 operated if the circuit wired, this scheme not recommended by Siemens AG. Drawing ref: 458 00123 372 sheets: 6/19.
6. Spring uncharged signal always appear at annunciator, due no timer relay install to delay the signal. ( in this case SESB agree to proceed on this scheme)
7. Heater recommended using three phase supply since the circuit breaker use 3 separated MCBs. Setting of the heater recommended by Siemens AG is 3degree more then ambient temperature.(Celsius)
8. Plug socket outlet already install by using European standard plug, SESB want us to provide the adaptor for it . ( Siemens AG will avoid the guarantee if have any touching on their scheme)
9. Installation of Variastor at K9, K10 and K69 to prevent over voltage from damage the coil of the relay, but if over Voltage happen the variastor will short the circuit ( if over voltage happen more then 1 minute and will not return to previously it was). The conclusion is it will trip the MCB of the supply, this will cause of interruption for the system. ( SESB agree to used this scheme cause of probability its happen is too small) Drawing ref: 458 00123 372 sheet: 6/19


Day 3 :
Date : 13th September 2007
Program:
1. Program started at 8.30 am Berlin time.
2. FAT test begin on 3AP1 FG 145kV
3. Factory Site visit Production line and final packaging of CB to deliver .
4. FAT test on 3AP1 FG 72.5kV
5. Test result compiling (by Siemens AG)
6. Closing meeting on Circuit Breaker session.
7. Program ended at 17.30pm Berlin time.

FAT on 3AP1 FG Circuit Breaker

Test Conduct by Siemens AG Rep. : Mr. Ralf Tschiesche
Contact Resistance Test
a. Injection Current apply 100A dc
b. Measurement of contact reading in mV dc
c. Acceptance contact resistance is around 25 micro ohms for 145kV circuit breaker.
d. Acceptance contact resistance is around 33 micro ohms for 72.5kV circuit breaker.
e. The reading of 145kV and 72.5kV different due to size of the contact.

Operation test ( 5 times each operation)
a. Close Operation and travel test.
b. Open Operation and travel test
c. Close Open operation and travel test
d. Open Close Open Operation and travel test

SF6 density monitoring.
a. Alarm stage ( Stage 1)
b. Lock In stage ( Stage 2)

Local test
a. SF6 Lock In operation
b. Local Close Operation
c. Local Trip Operation

Insulation resistance test
a. All internal wire already tested by using 2kV insulation tester.

Pressure Test.
a. Voltage applied 310kV for 145kV voltage rated circuit breaker.
b. Voltage applied 160kV for 72.5kV voltage rated circuit breaker.
c. All tests have been done during CB open position.
d. Pressure test for CB close not done.
e. Partial discharge also not conducted.

Day 4 :
Date : 14th September 2007
Program:
Closing program with Mr. Joerg Hellhammer at Siemens PTD department.
a. Check Out from Econtel Hotel at 6.00pm Berlin Time
b. Travel to Tegel Airport, Berlin by Taxi.
c. Travel from Tegel Airport to Frankfurt by Lufthansa Airways
d. Travel from Frankfurt Airport to Suvarnabh Airport, Bangkok.by Lufthansa Airways.
e. Travel from Suvarnabh Airport to KLIA by Lufthansa Airways.

Arrived at KLIA at 15 September 2007 time 18.15 pm.

Berlin - the Exploration

It's always my dream to go for an overseas trip. Alhamdulliah, it happened. Thanks to SPM who have faith in me. Thanks to enal who never fail in trusting me. And not fogetting to other SPM testing members who willing to cover my testing job here, especially, team members and anak2 didik in Permas jaya substaion. dun worry, pergi ku bukan jauh, Germany sajer..dan pergi ku bukan lama, seminggu sajer. :)

This exciting journey started at this award winner airport - KLIA. Selected Airline - Thai AirLines...So long , farewell Malaysia, till we meet again in 7 days time ! Insyaallah ..
our fisrt transit, Bangkok. Me and Azam waited for 1 and a half hour before cathing up our next flight to another transit-Franfurt.

But as we get into the Lufthansa airline in Bangkok, some problem arose. We have been terrigated as we are the murderer by the germany immigration. All sort of stupid, dummy and non-logical questions need to be answered. What a mess ! We do understand, some immigration need to question "our wealthy" but if they really need to know on how much money we have in our bank, they should do it at front-end, before they print out our ticket may be, not in the middle of the no-where. It dosn't matter if they ask in a polite manner but the way they asking question, lile %$#*. I didn't plan to do" shop till you drop" that why I only have 300 euros in my pocket. But as they saying " you can't survive with 300 euros in Berlin". What the hack, i didn't go to Berlin to find my soul mate and started my own famly there. I went there for training for God sake!Lucky I have my 2 frens who save the day, Mr Visa and Mr Mastercard. As I introduce my 2 frens to mr "rude" germany immigration, he's agree to swallow all his stupid words that coming from his mouth and let me go freely.

I was welcomed by rain drop in Berlin. This shot was taken from the taxi. Fares from Tegel airport Berlin to Econtel hotel worth 10 euro.
After a very long 16 hours journey, kehausan melanda. Bought drinks from a nearby shop, 2 cans of ice lemon tean and a can of Fanta cost me 5 euro. kalau kat mesia, duit sebanyak tuh dah boleh beli satu catoon ice lemon tea dah
This is one of the beautiful building in berlin. A very unique and antique structured and well maintain too.

For more beautiful snap shots in Berlin, view more pictures from here.http://mcta1975.fotopages.com/

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