Vocational Training Report

Report on Summer Training done at

NTPC Dadri(NCPS)

Submitted By:
 CERTIFICATE
This is to certify that type name has completed his summer
training at the department of Electrical maintenance
department N.T.P.C Dadri. The project entitled “Electrical
Maintenance “under the guidance and supervision of Mr.
name of the Executive Officer Electrical Main Plant gas,
NTPC Dadri.

Mr. __________________
Electrical Main Plant Gas
NTPC Dadri
Overview of NTPC
NTPC was set up in the central sector in the 1975 in response to widening demand
& supply gap with the main objective of planning, promoting & organizing an
integrated development to thermal power in India. Ever since its inception, NTPC
has never looked back and the corporation is treading steps of success one after the
other. The only PSU to have achieved excellent rating in respect of MOU targets
signed with Govt. of India each year. NTPC is poised to become a 40,000 MW gint
corporation by the end of XI plan i.e. 2012 AD. Lighting up one fourth of the nation,
NTPC has an installed capacity of 19,291 MW from its commitment to provide quality
power; all the operating stations of NTPC located in the National Capital Region &
western have acquired ISO 9002 certification. The service groups like Engineering,
Contracts, materials and operation Services have also bagged the ISO 9001
certification. NTPC Dadri, Ramagundam, Vindhyachal and Korba station have also
bagged ISO 14001 certification.

Today NTPC contributes more than 3 / 5th of the total power generation in India.

Station At Glance
 NTPC dadri is model project of NTPC . also it tit the best project of NTPC also
known as ncps ( National capital power station ). Situated 60 kms away from Delhi
in the Distrct of gautam budh Nagar, Uttar Pradesh. The station has an installed
capacity of 1669 MW of power – 840 MW from Coal based units and 829 MW Gas
Based Station . the station is excelling in performance ever since it’s commercial
operation . consistently in receipts of meritorious projectivity awards, the coal based
units of the station stood first in the country in terms of PLF for the financial year
1999 – 2000 by generating an all time national high PLF of 96.12 % with the most
modern O & M Practices. NTPC – Dadri is committed to generated clean and green
Power. The Station also houses the first HVDC station of the country (GEP project)
in association with centre for power efficiency and Environment protection
(CENEEP) – NTPC & USAUID. The station has bagged ISO 14001 & ISO 9002
certification during the financial year 1999 – 2000, certified by Agency of
International repute M/s DNV Netherlands M/s DNV Germany respectively.

Index:
Sl. No. Description Page No.
 1. Introduction 1
2. Objective 2
3. Power Transformers 3
4. Generator Transformer 4
5. Specification of Generator Transformer 5
6. Unit Auxiliary Transformer (UAT) 6
7. Station transformer 7
8. Interconnecting Transformer 8
9. Specifications of I.C.T 9
10. Parts of Transformer 10
11. Conservator 11
12. Breather 12
13. Bushing 13
14. Tap Charger 14
15. Cooling of transformer 15
16. Types Of Cooling 16
17. Fans and Pumps for Cooling 17
18. Transformer Protections 18
19. Temperature indicators 19
20. Oil Temperature indicator 20 - 21
21. Buchholz relay 22
22. Lightning Arrester 23
23. Bushing testing 24 - 25
24. Oil sampling , testing 26 - 28
25. Conclusion 29
26. Preferences 30
27. Switchgear 31 - 34
28. Generator (steam turbine) 35 – 40
29. 220 KV switchyard equipment descriptions 41

1.0 INTRODUCTION:

The testing of the generator Transformer (GT) of Unit # 2 at NCPS, Dadri was done
during the annual overhauling of the Unit. The transformer maintenance group is
responsible for the maintenance of the transformer and the testing group is
responsible for all the testing of the transformer during overhaul. The maintenance
group has taken the PTW (Permit to Work) before starting of work on transformer.
After taking all the clearances, they have started isolation and earthing of the
transformer.
The servicing of the all fans was carried out at the site. The oil filtration of the
transformer oil was done through oil filtration unit the rest values of the oil like BDV
(Break Down Voltage), moisture ppm. Tan - δ values was under acceptable limits.
The oil filtration is done through vaccum pulling and using heaters and filters.
After completion of oil filtration the settling time of at least 48 hours must be given
before commencement of the testing to settle down the oil. After the settling time of
24 hours transformer test started on the transformer. The capacitance & Tan delta
test on bushing of HV side and transformer winding magnetized current test, winding
resistance test, turns ratio test and insulation resistance test were performed on the
transformer.
After these testing the protection testing were performed in the protection testing the
proper functioning of all protection devices was tested through simulated conditions.
The protection devices consist of Pressure relief valve (PRV), Bucchulz relay,
winding temperature indicator (WTI), winding temperature indicator (WTI) of LV and
oil temperature indicator (OTI). The alarm and trip settings of the Buchholz relay.
OTI and WTI were got checked.
In this project report the transformers protective devices and its working testing types
are given first in this all the type of testing are given.
Then the details of the instruments used during the actual testing are given. The
accuracy ranges and types of instruments used affect the value of the reading during
testing. The knowledge of how to use a measuring instrument is very important for
finding out the accurate results.
The safety of the personal performing the tests is of utmost important. The safety
measures are given next. Then the same of the limitations and the problem faced
during the test at site are discussed. The test results are given in li standard test
format of the testing methods used on the site and for getting the best interpretation
from the test results.

2.0 OBJECTIVE

• To study the power transformer Equipments & Protections.

• To study the site testing of generator transformer during O/H of unit at NTPC
Dadri and to study of the testing method and maintenance practices adopted at
NTPC.
• To study the safety measures and precaution taken during any testing of the
transformer.
• To achieve maximum generation with minimum cost and downtime.
• To study benefits of advanced maintenance practices.
METHODOLOGY: - Analysis of different type of testing technology, advance
maintenance practices & healthiness checking of protective equipments for power
transformer. Testing at site for generation of data, interpretation of data for condition
monitoring of EHV Transformer.

3.0 POWER TRANSFORMERS

Transformer is a device or a machine with two or more stationary electrical circuits

that transfer electrical energy from one electrical circuit to another electrical through
the medium of magnetic field without change in frequency.

The electrical circuits which receive energy from the supply mains is primary winding
and the other circuit which delivers electrical energy to the load is called the
secondary winding. transformer is a electromagnetic energy conversion device. The
windings are not electrically connected but they are magnetically coupled to each
other by a common time varying magnetic field. the voltage level at the primary and
secondary windings are usually different and any increase of, decrease of the
secondary voltage is accompanied by corresponding decrease of increase in
current. Transformers are among the most efficient machines, efficiency of the order
of 99% is achievable in high capacity range.
Power transformers are backbone of the large grid. The power is generated at low
voltage level and has to be carried to far away load centers. Typically the power is
generated at the pit heads i.e. power source like coal, water. It is uneconomical carry
the bulk power at low voltage levels. Depending upon the requirement the voltage
level is stepped up to the transmission level i.e. 220 or 400 KV. At higher voltages
the transmission losses are less. Similarly at the remote end the voltage is stepped
down the distribution level. To accomplish the task power transformers are installed
and act as bi- directional element in the system.
Transformer is a device or machine with two or more stationary electrical circuits that
transformer electrical energy from one electrical circuit to another electrical circuit
through the medium of magnetic field without change frequency. Transformers are
among the most efficient machines, efficiency of the order of 99 % is achievable in
high range. Different types of transformers are used at NTPC Dadri as per
requirement some of them are given below;

3.1 Generator Transformer (G.T.)

3.2 Unit Auxiliary Transformer (U.A.T.)
3.3 Station Transformer (S.T.)
3.4 Interconnecting Transformer (I.C.T)

3.1 Generator Transformer:

The generator is connected to this transformer by means of isolated bush ducts. This
transformer is used to step up the generating voltage 16.5 KV to 220 KV. It is an
important unit because the failure of any one causes the unit to trip. Only one
generator transformer is installed per unit. This transformer is generally provided
OFAF cooling system consists of six numbers of oil pumps & 12 fans. It is provided
with off circuit taps on the high voltage side.
Specification of Generator Transformer:

Make BHEL
No. One per unit
Rating 270 MVA
Phase 3
No. Load Voltage HV 235 KV
No. load Voltage LV 16.5 KV
Rated current HV 664.12 A
Rated current LV 9458.15 A
Type of Cooling OFAF

TABLE -1 Specification of Generator Transformer.

Tap Lead HV line terminals IU, IV, IW LV line terminal 2U, 2V,
Position Connection 2W
Line Voltage Line current Voltage current
(KV) ( Amps) (KV) ( Amps)
1 (Max.) 5-6 240.875 647.93
2 5-7 235.000 664.12
3 4-7 229.125 981.15 16.5 9485.75
4 4-8 223.250 699.08
4 3-8 217.375 717.97

TABLE -2 Specification of Tap Change of Generator Transformer.

3.2 Unit auxiliary transformer (UAT) :

The UAT draws its input from the main bus duct connecting generator to the
Generator transformer. There are two unit auxiliary transformers for each unit. It
steps down the voltage from 16.5 KV to 6.6 KV which is required for major plant
auxiliaries to drive conveyors, BFP, FD fans, PA Fan, ID Fans, bowl Mills, CWP,
CEP, ESP and crushers. These transformers have a capacity of 16 MVA each.
 Spe
cification:

Make NGEF Ltd. Bangalore

No. 2 per unit
Rating 16 MVA
Voltage ratio 16.5 / 6.9 KV
Type of cooling ONAN / ONAF

Table-3 Specifications of Unit Auxiliary Transformer (UAT)

3.3 Station Transformer :

 The station transformer is required to feed to the auxiliaries during start ups.
This transformer is normally rated for the initial auxiliary load requirements of
unit. There are two station transformer provided to step down the voltage form
220 KV to 6.6 KV. One station transformer for two units. These transformers
have capacity of 27.5 MVA. They serve as the standby source of supply to
auxiliaries.

Specification:

Make NGEF Ltd. Bangalore

No. 2 per unit
Rating 55 MVA
Voltage ratio 220/ 6.6 KV
Type of cooling at different rating ONAN ONAF OFAF
60% 80% 100%

3.4 Interconnecting Transformer:

At NTPC Dadri interconnection of 220 KV switch yard to 400 KV switchyard carried out by bank of
single phase 400/220 KV Interconnecting transformer. Autotransformers are used when
transformation ratio is between 1 and 2 and above 315 MVA, due to size and weight constraints
all the transformers single phases. Three such single phase transformers three phases to make
one bank of transformer.

The three bank of transformers are installed to evacuate power from the 220 KV switchyard
generated by 4 X 210 MW thermal Units.

All these transformers are star-star connected transformers with neutral solidly grounded. A third
winding called tertiary winding at much lower voltage i.e. 33 KV, is also provide and is connected
in delta to facilitate the flow of third harmonic current to reduce distortion of in the output voltage.
To reduce overall size of the transformer, the transformer is provided with oil force and air forced
type cooling at its 100% rating. However, to save the energy, the cooling system is controlled by
the temperature of the winding.

The transformers are also equipped with On Load Tap Changer to meet the change in voltage
variation. Typically the Tap changer provides variation between ± 10 % of the nominal voltage. i.e.
400 KV with a variation of 0.5% at each Tap.
 Specification of ICT:

Make Compton Greaves

No. 3
Rating 167*3=500MVA
Tap 17
No Load Voltage KV (HV side) 400√3
No Load Voltage KV (IV side) 220√3
No Load Voltage KV (LV side) 33 KV
Line Current Amp. ( HV side) 289.25, 433.88, 723.13
Line Current Amp. ( IV side) 525.91, 788.87, 1314.78
Line Current Amp. ( LV side) 1688.48
Connection symbol YNaOd11 for three bank
Type of cooling ONAN / ONAF / OFAF
Frequency 50 Hz.

Table - Specification of ICT

4.0 PARTS OF TRANSFORMER:

4.1 Main Tank

Transformer winding would on the core is placed in the tank which is filled with insulating or
transformer oil. A pipe that connects main tank to conservator tank is provided for oil expansion.
Oil circulates through radiating tubes or fins provided in the radiator banks to dissipate heat into
the atmosphere. This tank is sealed to avoid ingress of’ moisture and air.

4.2 Magnetic core And Winding:

Core of transformer is made of stampings of Cold-Rolled Grain Oriented (CRGO) silicon

steel. These stampings arc insulated from each other by applying thin layer of varnish to reduce
eddy current loss.
Transformers for use at power or audio frequencies have cores made of many thin laminations of
silicon steel. By concentrating the magnetic flux, more of it is usefully linked by both primal) and
secondary windings. Which are made of copper? Since the steel core is conductive, it too, has
currents induced in it by the changing magnetic flux. Each layer is insulated from the adjacent layer
to reduce the energy lost to eddy current heating of the core. The thin laminations arc used to
reduce the eddy currents, and the insulation is used to keep the laminations from acting as a solid
piece of steel. The thinner the laminations, the lower the eddy currents, and the lower the losses

4.3 Conservator:

The transformer is filled with oil. As the oil heated its density reduces and thus volume increases
and when oil is cooled, it contracts thus creating vacuum. To take care of the oil expansion and
contraction conservator is provided and it is open to air through silica gel breather. Even though
silica gel absorbs the moisture entering into the conservator. however it not completely moisture
free. The oil absorbs oxygen and moisture from the air and starts degrading. To prevent the oil
degradation large transformers are provided with air bag in the conservator. Air hag prevents the
contact of air with the oil and provides the suitable expansion space for oil.

4.4 Breather:

It is outside the main tank and is connected with the conservator tank. During expansion of oil. the
oil level inside the conservator increases and air cell contracts and thus air inside is pushed out.
But hen oil cools down. air cell expands and air is sucked inside. This atmospheric air contains
moisture and if it comes in contact with oil, the property of oil degrades. This is avoided by placing
drying agent in the breather i.e. Silica Gel, which sucks the moisture from air. In normal conditions
colour of silica gel is blue: when colour changes to Pale Pink it should be replaced

4.5 Bushing:
Porcelain bushings are provided on both sides of the tank from which end terminals of HV and LV
windings are connected to external circuit. These bushings insulate the winding terminals from the
body. Bushings are also filled with the transformer oil, which serves two functions i.e. cooling and
insulating.

4.6 Tap changers:

Windings on both the primary and secondary of power transformers may have external
connections (called taps) to intermediate points on the winding to allow adjustment of the voltage
ratio. Taps may be connected to an automatic/manual, on-load tap changer .or off-load tap change
for voltage regulation of distribution circuits

4.0 COOLING OF TRANSFORMER:

During operation of transformer, the temperature of oil and the winding in the transformer
increases w.r.t. load current. For proper operation, temperature of transformer oil and winding must
be kept within limit respectively by cooling of transformer
5.1 Transformer oil for cooling:

The oil helps cool the transformer. Because it also provides part of the electrical insulation
between internal live parts, it must remain stable at high temperatures over an extended period. To
improve cooling of large power transformers, the oil-filled tank may have radiators through which
the oil circulates by natural convection. Very large or high-power transformers (with capacities of’
millions of watts) may have cooling fans. oil pumps and even oil-to-water heat exchangers. Large
and high-voltage transformers undergo prolonged drying processes, using electrical sell-heating.
(lie application of a vacuum, or both to ensure that the transformer is completely free of water
vapor before the cooling oil is introduced. This helps prevent corona formation and subsequent
electrical breakdown under load.

It is EHV grade Naphthenic based transformer oil. The various desirable properties of’ the
transformer oil is as follows:

Higher Breakdown Voltage

More Resistivity
Lesser Dissipation Factor
Higher Flash Point

5.2 Types of Cooling:

During operation of transformer, the temperature of oil and the winding in the transformer
increases w.r.t. load current. For proper operation. temperature of transformer oil and winding must
he kept within limit i.e. below So C and 90 C respectively. In transformer there are three types of
cooling systems:

1 .O.N.A.N

2. O.N.A.F

3. O.N.A.F

Oil Natural Air Natural (ONAN)

In this type of cooling system. oil and air flows naturally.

Oil Natural Air Forced (ONAF)

When load on the transformer is between 125 MVA this type of cooling is provided. As natural air
is not so efficient to cool down the oil and bring it to safe limits. So air is forced on the radiating fins
with help of fans installed below the radiator fins.

Oil Forced Air forced (OFAF)

With further increase in load, more heat is generated which necessitates forced cooling of oil. This
is achieved by energizing the pumps placed at the bottom near the main tank. These pumps force
the oil to flow frequently through the radiating fins for cooling of the transformer.
5.2 Fans and pumps For Cooling:

The fans are intended for blowing air vertically upwards on the bank of radiators to increase the
rate of cooling in radiators to increase the rate of cooling in radiators.

The circulating oil pump set for transformers consists of a centrifugal pump with in-line suction and
delivery openings at 900 to each other. The pump has top delivery arid end suction. This pump is
driven by a three phase, 50 cycles, two pole, and squirrel cage induction motor suitable for
operation at 4 15 ±10%. The set can he mounted on the transformer. The oil is sucked from the
tank of the transformer and after flowing through the transformer oil cooler returns to the tank.
Thus, this is a closed cycle operation and the pump is required to just develop the pressure
necessary for overcoming the frictional head during the flow through the cooler.

6.0 TRANSFORMER PROTECTIONS:

For protection of transformer different types of protective equipments arc used some of them are
given bellow;

1. Temperature Indicators

OTI High Alarm& Trip

WTI High Alarm& Trip

2. Oil Level Indicator

Low Oil Level Alarm

3. Buchholz Relay

Alarm & Trip

4. Pressure Relief Valve Alarm& Trip

5. Magnetic Oil Flow Indicator Oil Flow Low Alarm

6. Lightning Arrester

7. Mulsifire Protection

8. Differential Protection

9. Directional Over Current Protection

10. Restricted Earth Fault Protection

11. Over Fluxing Protection

6.1 Temperature Indicators

Temperatures indicators are precision instruments, specially designed for protection lion of
transformers perform the following functions. Indicate maximum oil temperature and maximum or
hottest spot temperature of winding. Operate an alarm or a trip circuit at a predetermined
temperature, Switch on the cooling equipment when the winding attains a preset high temperature
and switch it off when the temperature drops by an established differential. Two separate
instruments arc used for indicating oil and winding temperatures.
6.11 Oil Temperature Indicator
The equipment operating on the principle of liquid expansion provides local indication of the top oil

temperature. The temperature is given by a thermometer bulb with is connected by capillary tubing

to the local indicator. The pocket of the indicator is to he filled with oil. The indicator is fitted with

maximum pointes and two mercury switches. Out of which one is used for alarm and other is
for tripping switches are suitable for 5A, 250V AC or D.C. oil alarm temperature is 80°C and

tripping temperature is 90°C.

6.12 Winding Temperature Indicator:

This equipment gives continuous indication of the temperature of the windings and initiates alarm

when the temperature exceeds a certain limit and trip the transformer from the circuit.

The winding temperature transmitter is places in an oil filled pocket on the transformer tank cover.

Inside the transmitter is fitted with a heating resistance, which is fed by current proportional to the

loading current of transformer from a current transformer associated to the loaded winding of the

transformer. The temperature increase of the leading resistance is thereby proportional to the

ten1perature of the winding over the top oil temperature.

The winding temperature transmitter is located in the zone of hottest oil. Therefore, it senses both

the temperature. increase of the heating resistance & lop oil temperature. In this ay transmitter

measures the temperature in the hottest part of the winding i.e. hot spot temperature.

When temperature approaches at 55°C and give the commend to start of fans. Capillary tubing to

the local indicator connects thermometer bulb. The indicator is fitted with a maximum pointer and

tour mercury switches. Out of the four one contact is for alarm, other for tripping, third one is for
controlling fan and Fourth is spare itches are suitable for 5A. 250 V AC’ or DC. Winding alarm
temperature is 90°C and tripping temperature is 105°C.

6.2 Oil Level Indicator:

Normally all transformers are provided with an expansion vessel called conservator, to take care of
expansion in the oil volume due to rise in temperature. When the load on the transformer increases
or due to increase in ambient temperature. 1’he oil level in the conservator consequently goes up.
Conversely, it Falls when the temperature or load reduces.
It is essential that the oil level in the conservator is maintained above pre—determined minimum
level. The audible alarm operates in the event of oil level drop to near empty position in the
conservator. A bloat is used as a sensor which moves with rise and fall of the oil level. The pointer
is also magnetically operated and picks tip the correct oil level.

6.3 Buchholz relay

The relay serves as main protection for any minor or major faults that may develop inside a
transformer. Such faults always result in generation of gases which causes the operation of
mercury switches giving signal for audible alarm or isolates the transformer from the network.
It comprises a cast housing which contains two pivoted buckets, each bucket being counter-
balanced by a weight. Each assembly carries a mercury switch, the leads from which are taken to
a mounded terminal block.
The relay is mounted in the pipe at an inclination of 3-7 degree. In healthy condition of the
transformer, the relay is full of oil and both mercury switches are open. In the event of a minor fault
like damage to core bolt insulation, local overheating etc., the arcing causes slow generation of
gas in the oil. this passes up in the pipe and gets trapped in the relay housing. As gas
accumulates, the oil level in the relay falls, leaving the top bucket full of oil.
When a sufficient volume of gas is collected in the relay, the top bucket, because of its extra
weight due to oil contained tilts. overcoming the balance weight which closes the mercury switch
and initiates an audible alarm.
With a major fault like short-circuit between turns, coils or between phases; the generation of
gases is rapid and the gas and the displaced oil surges through the relay and impinges on the
baffle plates, causing the lower assembly to tilt and close the mercury switch and provide signal for
tripping the circuit breaker, which disconnects the transformer from the network.

6.6 Lightning Arrester:

Generally LA’s are installed in the switchyard at the entry point of the transmission line and on

both sides of large power transformers to protect the equipments from Lightening and switching
surges. The lightening arrestors provide protection against the high voltage lightening waves

on the transmission line and from the switching surges. All the windings of the transformers are

protected with the LA’s against switching surges and lightening waves. The LA’s are installed to

protect the windings of the transformers. The present practice is to install Metal oxide i.e. ZnO type

LA’s because of the superior characteristic.

Test Report Of Bushing Tan Delta And Capacitance

Phase Voltage Before overhauling After overhauling

Capacitance Tan delta% Capacitance Tan delta%
pf pf
R 10 V Avg 389.6 .425 384.7 00. 36 1

Y 10 V Avg 379.3 .410 372.7 00.197

B 10 V Avg 379.5 .402 379.4 00.471

9.8 Transformer Earth Pit Resistance Measurement:

Purpose: - To check the healthiness of Earthing of transformer and neutral grounding

Neutral Grounding:
The process of connecting neutral point of transformer to earth either directly or through some
circuit element is called neutral grounding.

Neutral grounding provides protection personal and equipment. It is because during earth fault the
current path is completed through the earthed neutral and the protective devices operate to isolate
faulty conductor from the rest of the system.

Observation: Ambient Temp.32

EARTH RESISTANCE IN OHM AVERAGE EARTH

S. REF VALUE OBSERVED VALUE PIT RESISTANCE
No.
1 .01 .01
2 .01 .01 0.26 Ω
3 .08 1.01
4 .01 .01

Table – 12 Earth Pit resistance test report

Note: - Measured Value Should Not Be More Than 0.5 Ohm.

9.9 Oil Sampling, Testing

(Before shut down/Prior to charging/24 Hrs after charging)

The oil provides an electrically insulating and cooling medium. The service reliability of an
immersed transformer is therefore mainly depending on the oil quality. In service oil is subjected or
normal deterioration due to the condition of use mainly due to water, and solid particles/sediment.

The oil should be maintained as per the guidelines of IS I 86 periodic test of oil is necessary.
Oil in transformer can he sampled through sampling valve for Break down Voltage
(B.D.V) .Dissolved Gas Analysis (DGA) water content etc.

Gases To Be Analyzed And Criteria:

1. Gases to be analyzed normally 02, N2, H2, Co, Co2, CH4

2. Gases to estimate abnormality H2, CH4, C2H2, C2H4, C2H6
3. Gases to estimate deterioration Co, Co2, CH4

Gas Content In Oil By Faults In Transformer Oil:

S. No. Type of faults Decomposable gases in transformer oil

1. Overheat of oil CH4, C2H4, H2, (C2H6, C2H2, C3H6, C3H8)
2. Arcing in oil H2. C2H2, (CH4, C2H4)
3. Overheat of’ solid insulating materials CO. C02, (H2, C2H4)
4. Overheat of oil arid paper combination CH4, C2H4, CO, C02, H2.
5. Arcing of oil and paper combination H2, C2H2, CO, C02, (C2H2)

Standard Norms for oil As per IS: 1866

Tests on oil Sampling a) BDV Min. 60 KV
bottles b) Moisture Min 10 ppm
Oil lest kits c) Resistivity Mm. 0.IX 1012 at
d) 1FT 9QU
e) Tan delta Mm. 15 mN/m
f) Acidity Max. 0.2 at 90 0C
Max. 0.3 mgKOH/g
Oil DGA Oil sampling bottle DGA Dissolved Gas As per ANSI / IEEE
test instrument Analysis (C57.104-1991)
Maximum gas limits
are as follows:
H2 100 ppm
CH4 120 ppm
C2H2 35 ppm
C2H4 50 ppm
C2H6 65 ppm
CO 350 ppm
CO2 2500 ppm
Oil Test Report After Overhauling:

BRFAK DOWN VOLTAGF. (B.D.V.)

1……….85…..........KV 2. ……....90………….KV 3. ………….92………… KV
4……… 87……….. KV 5………...88…………...KV 6………….... 87............. KV
2) Resistivity At 90°c -- Ohm-Cm.
3) Tan Delta At 90°c -- .050
4) DISSOLVE GAS ANALYSIS (DGA) -- (In ppm)

Date H2 CH4 CO CO2 C2H4 C2H6 C2H2 C3S

26.10.06 3 14 51 922 0 2 0 0

Table- 13 Oil Test Report.

Remarks: The test results are within the permissible limit.

9.10 Oil temperature indicator (OTI) Winding Temperature Indicator (WTI) Calibration
Purpose: — To check the OTI & WTI and comparison of OTI / WTI temperature readings with
standard thermometer at different temperature.

Calibration Result:
0 0 0
S. No. Standard OTI C WTI C WTI-II C
Thermometer 0C
1. 30 31 30 31
2. 35 36 36 36
3. 40 41 42 41
4. 45 46 45 46
5. 50 51 52 51
 6. 55 54 54 54
7. 60 62 60 60
8. 65 66 65 65
9. 70 71 70 70
10. 75 74 73 74
11. 80 81 81 81
12. 85 86 87 86
13. 90 91 90 91
14. 95 97 96 96
15. 100 101 103 101
16. 105 106 106 106

Table – 15 OTI, WTI Calibration Report.

13.0 CONCLUSION

Routine testing of transformers is very much essential to ensure good health of

transformer with more and more stress on quality and availability of power.

availability of transformer which is the vital link between generation and

transmission! distribution is must. To achieve the objective of availability and

efficiency regular testing with modern testing techniques have evolved as the most

effective means. Combination of off line testing and on line condition monitoring with

complimenting technique have been successfully used to identify and pin point

potential problems hug before they manifest as failure. All the testing elaborated in

this paper and inference derived are with reference to the tested transformer.
14.0 REFERENCES:

1. THE PERFORMANCE AND DESIGN 01: A/C Machines

BY- M.G.SAY,
CBS PUBLISHERS & DISTRIBUTORS, NEW DELHI
THIRD EDITION

2. BOOK- ELECTRICAL MACHINES

By- P.S. BHIMBRA,
KI IANNA PUBLISHERS, NE\V DELHI- 6
THIRD REVISED EDITION

3. BOOK- ELECTRICAL M/C DESIGN

B- A.K.SAWHNEY.
 DHAN PAT RAI & SONS NEW DELHI- 6
FIFTH EDITION

4. POWER TRANSFORMER INSTRUCTION MANUAL. (VOLUME-2) BHEL Ltd.

5. SCOPE OF OVERHAULING FOR ELECTRICAL, EQUIPMENT CORPORATE

OPERATION SERVICES (NTPC)

SWITCHGEAR

SF6 245KV BREAKER

1. ELECTRICAL DATA

1. Make BHEL
2. Type 3Avl SF-6
3. Rated voltage 245KV
4. Rated normal current 2000A
5. Rated short circuit 40 KA
6. Rated duration of the short circuit 3 Sec

2. ERATING TIMES (MAX)

1. Minimum command duration 50 sec

2. Closing time 110m Sec
3. Operating time 50m Sec
4. Arching time at 50Hz 21m Sec
5. Break Time at 50 Hz 71 m Sec
3. D
E
T
AI
L
S

OF OIL /SF6/N2 LOCKOUT VALUES/ ALARMS:

1. General lock out SF6 6.5 + 0.05 bar at 20 0C

2. Loss of SF6 6.7- 0.1 bar at 20 0C
3. General lockout oil 253-3 bar ( open lockout)
4. Minimum pressure lockout oil 273-3 bar (close lockout)
5. Pump control on 313-3
6. General lockout N2 315-3

6.6KV SWITCHCEAR (VACUUM BRAKER)

1. ELECTRICAL DATA

Sr. No. Make SIEMENS

1. Type 8 BK 20 metal clad draw out
2. Rated Voltage 6.6 KV
3. Max System Voltage 7.2 KV
4. Short Circuit at stand current and at rated Voltage 31.5 KVA
5. Degree of protection IP 40
6. Rated current 2500.630 Amp
7. Minimum clearance in air between plates 135 mm
8. Rated Symmetrical interrupting current 31.5 KA
9. One second current carrying capacity 31.5 KA
10. Rated current of bus bar 4000 A
 2. OPERATING TIME AND OTHER DIMENSION DETAILS

1. Dimension of breaker W*H*D 800*2050*1775

2. Type of vacuum bottle 3 AF
3. Closing time 75m Sec
4. Opening time 60m Sec
5. Closing time 80m Sec
6. Spring charging time 15 Sec

10.5 KV SF6 GENERATOR CIRCIJIT BREAKERS

One of the unique features of this plant is that a circuit breaker is provided between the

generator output terminals and the unit transformer input terminals. No such circuit breaker

is present in a coal— based plant. This circuit breaker eliminates the requirement of a

station transformer. When auxiliaries are required to be charged and the unit is not in

operation. The generation transformer terminals are kept open and unit transformer is back

charged for the grid. Once the unit transformer is charged the auxiliaries are charged using

the unit auxiliary transformer. By this means the high cost of station transformer is

eliminated.
 1. ELECTRICAL DATA

1. Make ABB Germany

2. Type HKK-3
3. Rated current 10300 amps @ 40 0C
4. Rated voltage 24 KV @ 50 Hz
5. Operating voltage 10.5 KV @ 50 Hz
6. Type of power drive Compressed air
7. Rated short time current 1 Sec 100000 A
8. Peak making current 300000 A
9. Rated breaking current 100000A & 135000A
10. Rated making current 300000A

2. OPERATING TIMES AND OTHER DATA

1. Circuit breaker closing time 53m sec

2. Circuit breaker break time 47m Sec
3. Close open operating time 90m Sec
4. SF6 gas Pressure 0.62 Mpa
5. Actuating air pressure 0.96 Mpa
6. Control Voltage 220 V DC
7. Compressor start (Auto) 0.93 Mpa
8. Compressor stop 0.96 Mpa
9. Safety vale operation 1.09 Mpa
10. Breaker blocking ( closed operation) 0.90 Mpa

GENERATOR (STEAM TURBINE)

The generator is hydrogen cooled with direct hydrogen cooling for rotor winding and indirect

hydrogen cooling for stator winding. The heat losses in the generator interior are dissipated to the

secondary coolant through hydrogen. The hydrogen cooler is a shell and tube type heat
exchanger. The heat removed from hydrogen is dissipated through the cooling water. The cooling

water flows through the tubes, while the hydrogen is passed around the finned. The stator winding

is a fractional pitch two layer types consisting of two individual bars. The stator winding is

connected iii the generator interior. The stator winding connections are brought out to the bushings

located at the exciter end.

1. ELECTRICAL DATA

1. Make BHEL Hyderabad

2. Type THRI – 1000 – 3GP
3. Code VDE 530, ICE 34
4. Type of cooling Hydrogen
5. Ratings 198.1 MVA
a) Rated output 154.5 MW
b) Active power 18.5 KV or 10%
 c) Terminal voltage 3000 RPM ( 50 Hz)
d) Rated Speed 10618 A
e) Power factor 0.8 (LAG)
f) Rated current 10618 A
11. Insulation class F
12. Phase connection YY ( 2 path per phase )
13. Hydrogen pressure 3.0 bar
14. Field current at full load/ at no load 2362/802 A
15. Rated field voltage 272 V
16. Continuous permitted unbalance current 8% of rated current
17. Generator efficiency at full load 98.75 %
18. Generator reactive capacity 146.2 MVAR ( over excitation )
91.6 MVA ( Under excitation )
19. Generator losses at full load 2094 KW
20. Stator winding resistance between phases 0.0005845 at 20 0C
21. Rotor winding resistance 0.08529 at 20 0C
22. Nos. Terminals 6 ( 3 Phase, 3 Neutral)

2. MATERIAL

1. Rotor shaft 26 Ni Cr Mov 145

2. Rotor copper Cu AgO IPF30
3. Rotor wedges Cu Ni 2 Si
4. Retaining rings X 8 Cr Mn N 1818 K
5. Slip rings ST 52-3
6. Labyrinth ring outer G- Al Si 10 Mg WA
7. Stator frame Rst 37-2
Electrical sheet steel V350-65A-ST
1.3/gen.502.10
Stator copper E-Cu 58 F20
Bearing Sleeves GS+ Lg Sn 80 Fs

3. SLIP RING / CARBON BRUSHES:

1. Nos. 30 at +ve side

a) Slip Ring 30 at –ve side
 2. Rotor grounding 4 Nos.
3. Brush dimensions
a) Slipping 64 / 32 / 32
b) Grouping 28 / 8 / 32

4. CRITICAL SPEED ETC.

1. First critical speed 1425

2. Second critical speed 3906
3. Materials
Rotor shaft 28 26 Ni Cr Mov 115
Material of retaining forgings X8 Cr Mn N 1818 K
Material of rotor wedge Cu Ni Si

5. SLIP RING / CARBON BRUSHES LIMIT FOR WEAR

1. Slip ring – original size 450mm

- Minimum 430mm
2. Brush holder type 27-0703 (slip ring)
27- 0707 (grounding )
3. Brush Qty. 16 Nos. ( Slip ring )
04 Nos. ( grounding )
4. Slip ring brush – normal size 32 / 32 / 64mm
- Min. size 32 / 32 / 20mm
5. Rotor grounding brush
- Normal size 20 / 8 / 32 mm
- Minimum size 20 / 8 / 12 mm

6. EXCITATION SYSTEM

1. Make BHEL
2. Type Thyristor controlled / static
3. Range of voltage
a) In auto 90 to 110 % En.
b) In manual 75 % No load current to 2110% of
full load field current.
4. Frequency range of operation 47 to 52 Hz
5. Response time
- Rated current 2855 A
- Rated voltage 350 V
- Ceiling current rating 4728 A
- Ceiling voltage rating 566 V for Seconds
- Limiters in service Rotor current limiter 2362 Amp.
Stator Current limiter 10618 Amp.
 Under excitation limiter ( 906
MVAR at rated voltage ) power
System stabilizer .

7. EXCITATION TRANSFORMER

1. Manufacturer BHEL
2. Type Dry cast resin
3. Capacity 2300 KVA
4. Voltage 10.5 KV/0.460 KV
5. Current HV / LV 126.5 A/28886.8A
6. Parentage impedance 7.2+10 %
7. Vector group DY 5
8. Insulation level 75 KVP , 28 KV RPM
9. Type of cooling Natural with addition (AF) forced
cooling also.
10. Class of insulation F
11. Degree of protection IP 20

7. GAS SYSTEM DATA :

1. volume of Hydrogen 55 m3
2. Space in generator cooling gas flow 24 m3/sec
3. Purity of Hydrogen required >98%
4. Leakage of H2 by volume per data at rated H2 Pressure 12m
5. Cold gas temperature ( Rated) 42 0C
6. Max. hot gas Temperature ( Before cooler) 75 0C
7. Max. hot gas temperature ( after cooler ) 55 0C
8. Hydrogen pressure 3 bar
9. Hydrogen flow at a 42 0C 24 m/ sec
10. Heat dissipating capacity 2350 KW
11. Cold gas temperature 42 0C
12. Gas pressure drop 20 mm of WC
13. Cooling water flow / cooler M3/hr
14. Maximum water infer temperature 3.6 0C
15. Pressure drop on water side 0.5 bar

8. SEAL OIL COOLER

Design data for the seal oil cooler Material and pressure

type: 4x 3C – 2720 – 4050 – 060 ad ( 2

sections of 100% each)
Oil flow 3.33 dm3/s Tubes Adm. Brass
Heat dissipating capacity 140 KW Tubes Sheets Cu ZN40
Oil inlet temperature 65 0C Water sheets with protective

coating
0
Oil outlet temperature 40 C
Oil pressure Drop ( approximate ) 0.75 bar Design pressure 10 bar
Cooling water flow 40 m3/hr Test pressure 15 bar
Maximum water inlet temperature 36 0C Oil side pressure
Water outlet temperature 40 0C Designed pressure 10 bar
Water pressure drop 0.7 bar Test pressure 15 bar

220 KV SWITCHYARD EQUIPMENT DESCRIPTIONS

1. Circuit Breaker type SF6 10 Nos.

2. Isolator without earth switch Staggered type 05 Nos.
1600A
3. Isolator with two earth switch 1250 A 06 Nos.
4. Isolator with two earth switch 2500A 02 Nos.
5. Isolator without earth switch Staggered type 12 Nos.
1250A
6. Isolator with one earth switch 1600 A 03 Nos.
7. Isolator with two earth switch 1600 A 03 Nos.
8. Isolator with one earth switch 1250 A 06 Nos.
9. Current transformer 27 Nos.
10. Capacitor voltage transformer 06 Nos.
11. Post insulators 74 Nos.
12. Current transformer with extended current 150% 03 Nos.
13. Lightening arrester 18 Nos.