sunil kumar

Scope: End-to-end T&C, diagnostic testing, and capital project execution for 33 kV / 6.6 kV / 415 V systems at 200
MVA SAF ferro alloy operations; multi-crore CAPEX project management from conceptualisation through
commissioning and handover.
Protection Relay Testing & Commissioning
▶ Commissioned differential protection (low-impedance) and REF scheme for 5 × 33/6.6 kV, 10/12 MVA
distribution transformers using Siemens 7SR5421 relay: CT polarity verification, VKSAT/VKACT calculation,
stability test, sensitivity check; secondary injection via Omicron CMC and ISA; full scheme documentation
signed off
▶ Commissioned ABB VD4 VCB panels with arc flash protection relay for all 5 SAF furnace bays: arc flash

O&M and protection T&C across 2, 500 MW aluminium smelter distribution system, 380 V - 132 kV (1.1 MTPA
capacity). Multi-vendor environment: ABB, Areva, Toshiba, GE, ArcTeq, Argus Reyrolle.
▶ End-to-end protection relay T&C across entire smelter distribution system using Omicron, Manta, ISA: trip
logic, DC scheme, interlock scheme, TCS, REF stability/sensitivity, transformer differential stability/sensitivity,
distance protection zone setting verification across bus sections, transformer feeders, motor feeders
▶ CB testing (timing, contact resistance, VCB bottle integrity); AIS and GIS switchgear maintenance up to 132
kV; power transformer diagnostics (Alstom, ABB); 250 MVA reactor maintenance; RMU maintenance (Brush
make)
▶ Energy meter and transducer calibration; SCADA signal verification; protection event analysis; zero
protection-related outages over 3-year tenure
▶ Rigorous PTW/LOTO, barricading, risk assessment, method statement preparation, hazard identification on
live 132 kV systems; zero safety incidents

ABB SACE EMAX ACB
testing; auto bus transfer scheme
verification; CT/PT, relay testing (ABB
REM-604 motor protection, ABB REF
615 feeder); 2×2.5 MVA transformer
Tan-Delta and Hi-Pot
ABB SACE EMAX;
ABB REF-615 / REM
604; Tan-Delta Full pre
commissioni
ng suite
signed off;
auto bus
transfer
proven Low-impedance
differential and REF scheme
commissioning (Siemens 7SR5421);
secondary injection; CT polarity
verification; VKSAT/VKACT checks;
scheme stability tested
Siemens 7SR5421,
ISA, Omicron CMC Zero
protection
mal
operations;
transformer
s energised
on schedule
ABB VD4 VCB Arc flash relay
setting, pick-up level verification, light
sensor calibration; VCB timing, contact
resistance, anti-pumping, TCS, breaker
close/trip scheme; bus protection
integration
ABB VD4; arc flash
relay; Omicron CMC Arc flash
clearance <
50 ms
verified;
breaker
close time ≤
60 ms AFE VFD pre
commissioning checks; MV switchgear
isolation; drive parameter
configuration; full-load acceptance test;
harmonic current verification (IEEE
519)
IEC 61800; ABB AFE
VFD; Power analyser Power 8 MW
→ 6.5 MW
(saving
~₹9-10
Cr/year);
accepted on
first run Online PD via HFCT, Techimp PDCheck; Predictive

▶ NTPC Jaminipali: commissioning and retrofitting of 6.6 kV VCB/VCU (Schneider HWX); CT/PT testing; relay
testing (Vamp 255); Bus CRM; Hi-Pot on 6.6 kV panels; all pre-commissioning tests executed and
documented
▶ Maithon Power: commissioning of 415 V ACB panels (ABB SACE EMAX) with Auto Bus Transfer scheme; relay
testing (ABB REF-615 feeder, ABB REM-604 motor); 2×2.5 MVA transformer Tan-Delta and Hi-Pot (AC) on
3C×630 mm² cable; all scheme checks signed off

Electrical engineering for 75 MVA SAF (145K MTPA) and greenfield 132/11 kV switchyard commissioning.
▶ 132/11 kV Switchyard Commissioning — 6 Bays (Greenfield): SF6 CB timing/resistance, CT/PT/CVT winding
checks, ratio/polarity; ABB protection relay commissioning (differential, REF, distance, OC/EF); 2×50 MVA
transformer (IR/PI, turns ratio, vector group, OLTC); earthing grid; SCADA signal mapping; formal OPTCL grid
connection approval — delivered in 3 months, zero protection trips
▶ OLTC retrofitting project: replaced old units with new units including full acceptance testing; transformer
repairing, rewinding, and complete overhauling (CGL make 132/11 kV and furnace transformers)
▶ HV cable laying, routing, trench supervision, MV termination; earth pit installation; battery/DC panel testing

▶ O&M of 7.5 MVA, 9 MVA, 11 MVA electric arc furnaces; furnace transformer OLTC maintenance; control relay
panel upkeep; HV switchgear testing and maintenance; protection relay commissioning support