11kV VCB Panel Replacement for Chemical Processing Plant — Maharashtra
A chemical processing plant in Maharashtra was experiencing frequent and costly nuisance HT trips — averaging 8 per month — from an ageing electromechanical relay protection system in their 11kV switchgear. Each trip halted a batch process that could not be restarted without a 4-hour clean-down cycle.
The Challenge
The existing 11kV switchgear used overcurrent relays from the 1990s with drifted settings and worn contacts. Relay coordination between incoming and outgoing feeders had broken down — any fault, however small, was cascading to trip the entire HT incomer. The protection system had never been professionally re-coordinated. A complete panel replacement was required, but had to be executed during a 72-hour planned shutdown window.
The Actaan Solution
Actaan Electric designed, manufactured, and installed a new 11kV VCB panel lineup — incomer, bus coupler, and four outgoing feeders — with numerical relay protection (SEL/MiCOM) properly coordinated to the site's fault level and transformer impedance. Relay grading was calculated and documented. The complete replacement, cable termination, protection testing, and energisation was completed in 68 hours.
Scope of Supply & Work
- ·11kV VCB lineup: incomer, bus coupler, 4 outgoing feeders
- ·Numerical relay protection (SEL/MiCOM) — O/C, E/F, D/T
- ·Relay grading study and full coordination documentation
- ·Metering cubicle with CT/PT accuracy testing
- ·Complete HT cable termination and testing
- ·Protection panel testing and commissioning
- ·Energised within 68-hour planned shutdown window
Results
Other projects by Actaan Electric.
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