CARMEL POLYTECHNIC COLLEGE

PUNNAPRA – 688 004

DEPARTMENT OF ELECTRICAL AND ELECTRONICS

ENGINEERING

INDUSTRIAL TRAINING REPORT

220kV SUBSTATION KALOOR

CARMEL POLYTECHNIC COLLEGE

PUNNAPRA – 688004
DEPARTMENT OF ELECTRICAL AND ELECTRONICS
ENGINEERING
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 CERTIFICATE
This is to certify that the report entitled “Industrial Training Report” is a bonafide record of
five days Industrial training done by SHUHAIB NASSAR at 110 KV Substation, Kaloor,
Ernakulam towards the partial fulfilment of the award of Diploma in Electrical and
Electronics Engineering under the Board of Technical Education Kerala during the academic
year 2019-2020.

Lecturer in-charge Head of Section

Internal Examiner External Examiner

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 ACKNOWLEDGEMENT
This report is an outcome of the contributions made by some people . It is my
radiant sentiment to place on record my best regards, deepest sense of gratitude
to our Respected Principal Mr. D. BIJU DAS for providing opportunity for
carrying out this Industrial visit. We thank our Respected HOD Mrs. LIZZ
JOSEPH for encouraging us for this great attempt.
We express our sincere thanks to our training guide Smt. POORNIMA PAPPU
,who is the Station Engineer, for introducing us to the substation, providing
valuable information about substation and encouraging us throughout our
training.
We express our sincere thanks to all our friends and well-wishers for their co-
operation and moral support that has been given during the training period.

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 CONTENTS

1. INTRODUCTION

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 INTRODUCTION

A substation is a part of an electrical generation, transmission, and distribution system.

Substations transform voltage from high to low, or the reverse, or perform any of several
other important functions. Substations generally have switching, protection and control
equipments, and transformers. Substations are of different types. A transmission substation
connects two or more transmission lines and a distribution substation transfers power from
the transmission system to the distribution system of an area. In Kerala, the major substations
include five 400 KV sub-station, and seventeen 220 KV substations. The department of
Electrical and Electronics Engineering of Carmel Polytechnic College, Alappuzha gives a
chance to their students to spend one weeks in industrial companies. This training gives the
student the opportunity to see what they have studied and how to deal with practical life. My
training program was in the period from 17th june 2019 to 21th june 2019 at 110kV
substation, Kaloor, Ernakulam. The present day electrical power system is AC i.e.; electrical
power is generated, transmitted and distributed in the form of alternating current. The
electric power is produced at the power station, which are located at favorable places,
generally quite away from the consumers. It is delivered to the consumer through a large
network of transmission and distribution. At many places in the line of power system, it may
be desirable and necessary to change some characteristics (e.g. Voltage, AC to DC
frequency, power factor etc) of electric supply. This is accomplished by suitable apparatus
called substation for example, generation voltage (11kV/6.6kV) at the power station is
stepped up to high voltage of transmission of electric power. Similarly near the consumer’s
localities, the voltage may have to step down to utilization level. This job is again
accomplished by suitable apparatus called substation. Page | 5 A substation may include
transformers to include voltage levels between high transmission voltage levels and lower
distribution voltages, or at the interconnection of two different transmissions. The word
substation comes from the days before the distribution system became a grid. As central
generation station became larger, smaller generation plants were converted distribution
stations, receiving their energy supply from a larger plant instead of using their own
generators. The first substations were connected to only one power station, where the
generators were housed, and were subsidiaries of the power station. Substations generally
have switching, protection and control equipments, and transformers. Devices such as
capacitors and voltage regulators may also be located at a substation.

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 COMPONENTS OF THE SUBSTATION

TRANSMISSION PATH INSIDE THE SUBSTATION

A: Primary power line's side

B: Secondary power line's side
1. Primary power lines
2. Ground wire
3. Overhead lines
4. Potential or Voltage transformer
5. Disconnect switch
6. Circuit breaker
7. Current transformer
8. Lightning arrestor
9. Main transformer
10.Control building
11.Security fence
12.Secondary power lines

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 SITE SELECTION AND LAYOUT OF 110kV SUBSTATION

110kV substation forms an important link between Transmission network and Distribution
network. It has a vital influence of reliability of surface. Apart from ensuring efficient
transmission and distribution of power, the substation configuration should be such that it
enables easy maintenance of equipment and minimum interruptions in power supply.
Substation is constructed as near as possible as the load centre. The voltage level of power
transmission is decided on the quantum of power to be transmitted to the load centre. Main
points to be considered while selecting the site for grid substation are as follows: The site
chosen should be as near to the load centre as possible.

 It should be easily approachable by road or rail for transportation of

equipments. Land should be fairly leveled to minimize development cost.
 Source of water should be as near to the site as possible. This is because water
is required for various construction activities (especially civil works), earthing
and for drinking purposes etc.
 The substation site should be as near to the town/city but should be clear of
public spaces, aerodromes and military/police installations.
 The land should have sufficient ground area to accommodate substation
equipments, buildings, staff quarters, space for storage of material, such as store
yards and store sheds etc. with roads and space for future expansion.
 Set back distances from various roads such as National highways, state
highways should be observed as per regulations in force.
 While selecting the land for the substation, preference is to be given to
government land over private land.
 The land should not have water logging problem.
 Far away from obstructions, to permit easy and safe approach termination of
high voltage overhead transmission lines

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 FUNCTIONING OF THE SUBSTATION RESPONSIBILITIES AND
DUTIES
1. Operating crew of substation comprises of one Assistant Engineer as operator and
one Overseer as Shift Assistant. Operator on duty shall carry out all the operations
required for normal functioning of the substation as per the directions followed.
2. Sub Engineer (Electrical/Maintenance) attends to all maintenance work connected
with lines and equipments of substation including routine and breakdown
maintenance. He will assist the AE in the preparation of monthly returns and allied Db
works.
3. Station Engineer holds overall charge of the substation.

OPERATIONS IN GENERAL

The following operating instructions may be strictly followed for the smooth operation
of the substation:
1. The operator, taking over the shift charge shall record the time of taking over the duty
with name and signature. He / She shall also record the name of shift assistant in the
diary and log book.
2. Handover the charge with clear explanation in brief regarding the substation and
feeders such as PW/IC/NBC in force, trouble noted in any of the equipments etc.
Handing over time and dated signature with the name of the relieving operator should
invariably be recorded.
3. An operator should primarily check protective and alarm circuits of the individual
feeders and also the control supply system including the battery system. Then the
overall inspection of the control room and yard equipments should be conducted.
Check and confirm the reliability of emergency lights and accessibility of fire fighting
equipments.
4. Read carefully previous operations and make a thorough picture regarding the
substation feeder positions. Record all entries with time and sequence of operations
performed. The tripping and any major events requiring special attentions should be
recorded in red ink and scheduled interruptions like switch off and permit to work
should be recorded in green ink.
5. Message book and phone call register are to be maintained by the operator on duty.
Phone message received and transmitted shall be recorded with date and time and
confirm the authenticity of the person at the other end. Confirm that the messages are
communicated to the right person to whom it is intended and act according to the
seriousness of the matter contained therein.
6. Visit the yard frequently and watch the various equipments and their functions
carefully.
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7. Promptly record hourly and half hourly readings with utmost care.
8. The operator on duty shall see that the substation equipments and panels in the control
room are kept clean.
9. Station clock timings should be checked and corrected if necessary.
10.Check the specific gravity and the cell voltage of the pilot cells of the station battery
and record them in the log sheet by the 1st shift assistant operator every day.
11. Take suitable steps to avoid overloading of equipments and feeders.
12.Maintain the system voltage within the statutory limits with appropriate tab selections
as far as possible.
13. Carry out various routine operations symmetrically as scheduled below separately

OPERATIONS TO BE CARRIED OUT

 FAULTS ON TRANSFORMERS
If the circuit breaker of a transformer has tripped, the alarms may be accepted, the
relay indications carefully checked and noted. If the tripping is an Overload, switch off
all the outgoing feeders from the transformers. Reset the relays and test charge the
transformer on no load. Then charge the outgoing` feeders one by one and ensure that
the load is not more than the capacity of the transformer. If the tripping is for any
other reason other than the over current, the transformer may be charge only after
consulting the higher officials.
 INCOMING FEEDERS
If the incoming feeders are tripped on over current relay, reduce the load on the
transformer by switching off outgoing feeders from the transformer. Reset the relay
and charge the incoming feeder. Then charge the incoming feeder one by one. If the
incomer is again tripped, the outgoing feeder last charged may be kept open and other
feeders charged suspecting fault on the particular feeder. The load on the transformer
may closely be watched and if found exceeding the admissible limit, the distribution
authorities may be directed to limit the current.
 OUTGOING FEEDERS EXCEPT AUXILIARY
In case an outgoing feeder is tripped, accept the alarm, note the relay indication, reset
the relay and accept the alarm and test charge the feeder. If the feeder trips instantly or
any apparent Page | 14 fault or heavy fluctuations in the supply system, flashing the
cubicle are noted, the feeder may be declared as faulty after confirming that the fault
exists on the feeder beyond the outdoor isolation point by isolating the AB switch and
charging the cable portion from the control room. Inform the distribution section to
rectify the fault. If a feeder trips on OC relay, only three test charging may be
attempted. Avoid further test charging until confirmation from distribution authority is
received that the load on the feeder has been reduced.
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 AUXILIARY FEEDER
The method in the case of other outgoing feeder may be adopted in this case also. But
as the station supply is taken from the beach feeder, when the feeder is faulty, open the
AB switch in the 11kV outdoor structure and charge the breaker for taking the
auxiliary supply, inform the matter to distribution section.

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 SUBSTATION EQUIPMENTS

 LIGHTNING ARRESTOR

henever an incoming comes to a substation, initially the line is connected through a

lightning arrester. This is for the protection of the station. Generally a lightning
arrester seems like a set of insulators connected together with a ring in the top. This
ring is called grading ring. The purpose of grading rings is that in case of heavy
voltage surges the charge is distributed uniformly through the ring and then the
discharge occurs. An ammeter is connected with the maximum current passed through
it. The ammeter is reset. The ammeter in the arrester carrying the topmost conductor
will have maximum current passing through it

 WAVE TRAP

Wave trap is also known as line trap. It is an instrument used for tripping of the wave.
The function of this trap is that it traps the unwanted waves. Its shape is like that of a
drum. It is connected to the main incoming feeder so that it can trap the waves which
may be dangerous to the instruments in the substation. The wave trap traps the high
frequency communication signals sent on the line from the remote substation and
diverting them to the telecom / tele protection panel in substation control room
through the coupling capacitor and LMU. This is relevant in Power Line Carrier
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 Communication (PLCC) systems for the communication among various substations
without dependence on the telecom company network. The signals are primarily
teleprotection signals and in addition, voice and data communication signals. Line
signals sent on the line from the remote substation and diverting them to the telecom /
teleprotection panel in the substation control room. The wave trap offers high
impedance to the high frequency communication signals thus obstructs the flow of the
signals to the substation bus bars. If they were not to be there, then signal loss is more
and communication will be ineffective or probably impossible.

 Line Isolator

Unlike a Circuit breaker a Line isolator has no protection capability and is used to
physically disconnect any circuit when repairs are being done. In a substation
switchyard an IS switch would be used to physically disconnect any incoming HV
lines to allow work on the transmission line to be performed.

 Current Transformer (CT)

A Current Transformer is an instrument transformer, used along with measuring or

protecting devices, in which the secondary current is proportional to the primary current.

 Potential Transformer (PT)

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 Potential transformer is a voltage step-down transformer which reduces the voltage of
a high voltage circuit to a lower level for the purpose of measurement. These are
connected across or parallel to the line which is to be monitored.
 Circuit Breaker (CB)

A circuit breaker is an automatically operated electrical switch designed to protect an

electrical circuit from damage caused by excess current from an overload or short
circuit.

Types of CB
 Oil circuit breaker
 Minimum Oil circuit breaker
 Air blast circuit breaker
 Sulphur hexafluoride circuit breaker(SF6)
 Vacuum circuit breaker
 Air break circuit breaker
 Earth Switch (ES)

Earth switch is used to discharge the charges that are trapped in line after opening of
line by circuit breaker.

 Earth Mat

The substation grounding system comprises of a grid (earth mat) formed by a

horizontal buried conductors.
The grounding system in substation is very important. The functions of grounding
systems or earth mat in include:
 To ensure safety to personnel in substations against electrical shocks.
 To provide the ground connection for connecting the neutrals of stat connected
transformer winding to earth (neutral earthing).
 To discharge the over voltages from overhead ground wires or the lightning masts to
earth. To provide ground path for surge arresters.
 To provide a path for discharging the charge between phase and ground by means of
earthing switches.
 To provide earth connections to structures and other non-current carrying metallic
objects in the sub-station (equipment earthing).

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 DIFFERENT EQUIPMENTS AND GROUND CONNECTIONS

Apparatus Parts to be Earthed Method of Connection

Power transformer Transformer tank Connect the earthing bolt

on transformer tank to the
station earth
High Voltage circuit Operating mechanism, Connect the earthing bolt
breakers frame on the frame and the
operating mechanism of
Circuit breaker to earthing
system
Surge arrestor Lower earth point To be dir To be directly
connected to earth mat
Support of bushing Device flange or base plate Connect the earthing bolt
insulators, lightning of the device to the station
arrestors, fuse, etc. earthing system
Potential transformer Potential Transformer tank, Connect the transformer
LV neutral earthing bolt to earthing
system. Connect LV
neutral of phase lead to
case with flexible copper
conductor
Isolator Isolator frame, operating Weld the isolator base
mechanism, bed plate frame, connect it to the bolt
on the operating
mechanism, base plate and
station earth
Current transformer Secondary winding and Connect secondary
metal case winding to earthing bolt on
transformer case.

 Air Break Switch (AB)

The switch whose contacts open in the air and quenching of an arc achieves by
compressed air, such type of switch is called an air break switch. The air acts as a
dielectric medium for the AB Switch. It is more effective and reliable as compared to
another switch. The air break switch is operated manually when their handle is placed
in ground level.

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  Capacitor Bank

The main purpose of providing capacitor bank in case of power system is to supply
reactive power to the system and they are installed at the receiver end, this is also
called as VAR Compensation. The capacitor banks are called Static VAR
Compensator.
 Battery House

Battery house is known as the heart of the substation. The relays and control panel
gets necessary DC input from the battery. Without battery house a substation is
incomplete.
 Battery Plant

It is the system of battery connected seriously to produce a necessary voltage to

provide for the control panels and relay. They are classified as load and battery.

 Battery Charger

A battery charger is a large device used in substation in order to charge the battery
used in a substation. The DC from the battery is used only when the AC input to the battery
charger is off. All the remaining time the necessary DC input for the relays are provided by
the battery charger itself.

 Control Panels

The substation control panel is designed to form automated control systems (SCADA)
of the traction substations, using digital protection and programmable logic controllers.

Substation control panel provides:

 Tele-mechanical control of the substation (sending/receiving signals of Tele-

commands, telemetry and Tele-signalling)
 Remote control of the substation (using integrated controls and indicating devices)
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  Collection and transmission of the telemetry and diagnosing data via digital
channels of the data transmission network (DTN)

With the substation control panel any traction substation may be reconstructed with gradual
connection of the new smart controllers and bay terminals, while the unmodified equipment
is still controlled with the existing telecommunications panel.

Substation control panel includes:

 An operator station for remote equipment control.

 A controller of the overall substation signalling.
 A substation controller functioning as a concentrator of the substation
information-control network.
 An uninterruptible power system.
 Interface convertors with galvanic separation.
 Protective Relays
Relays are one of the most important parts of substation. The function of a relay is mainly
incorporated in the control panel section of the substation. A protective relay is mainly
incorporated in the control panel section of the substation. A protective relay is a device that
detects the fault and initiates the operation of the CB to isolate the defective element from
the rest of the system. The relay detects the abnormal condition such as voltage, current,
frequency, phase angle and temperature. The substation has control panels for its incoming
as well as outgoing feeders and each control panel has various relays. The different types of
relays which are used here are
 Distance protection relay
 Auto reclose relay
 Synchronizing relay
 Differential relay
 Over current relay
 Earth fault relay
 Auxiliary relay
 Distance Protection Relay


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 It is a special type of relay used to know at which place the line has failed. The lines are
divided into zones. The relay will indicate the rough distance between the station and the
point at which the breaking has occurred. The connection to the main relay is made through
an auxiliary relay. This relay is very helpful in remote areas. The control panel has 2 types
of distance protection relays.

 Auto Reclose Relay

Auto reclose relay is of mechanical type. It helps in speedier tripping and making up of the
connection after fault rectification. Synchronizing Relay Advantages of bus couplers can
be obtained only if the voltage and frequency of the bus bars to be coupled are the same.
 Synchronized relay

does the function of constantly comparing the two voltages and frequency and thereby
initiating the tripping mechanism at time of fault. The synchroscope aids it.

 Differential Relay

The relay is activated at difference in current flowing through the relay. In case of
equipments like CT the relay is connected in between the equipments. In normal conditions
the current through the relay is the same as the equipment current but when any fault
occurs in the line enclosed ten there is a rise in current through the relay at the fault side
above that which is on the other side. This activates the relay, tripping occurs.

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 Over Current Relay
The relay activates when current exceeds the permissible limits. It will be connected to the
circuit breaker in case of any fault due to over current. The relay acts and activates the
circuit to the breaker hence tripping the breaker. DC supply is always given to the relay as
it should trip even if there is an interruption in the power supply.
 Earth Fault Relay
It will be activated when there is any fault in the earthing of the equipment. It is also
connected to circuit breaker to help tripping the circuit. The main applications of this relay
are in control, alarm, indication and other auxiliary duties in AC or DC systems. CAA &
VAA relays are current and voltage operated respectively. These relays are attracted in a
armature units of compact design supplied with reset contacts. Standard contacts are of
silver or copper alloys. When it is necessary to break heavy or highly inductive DC loads,
heavy duty magnetic blow type contacts are used. They use the magnetic field of a small
permanent magnet to force the arc onto the arcing horns away from the contact tips. The
new control panel uses automatic semaphore (mimic) indicators for better control.

 Double Bus

substations with the double bus double breaker arrangement require twice the
equipment as the single bus scheme but are highly reliable. Load balancing between
buses can be achieved by shifting circuits from one bus to the other. This scheme is
typically found in EHV transmission substations or generating stations.

 Switch Gear
In an electric power system, switchgear is the combinations of electrical disconnect
switches, fuses or circuit breakers used to control, protect and isolate electrical
equipment. Switchgear is used both to de-energize equipment to allow work to be
done and to clear faults downstream. This type of equipment is directly linked to the
reliability of the electricity supply.

 Meters & Transducers

Many electrical panels require Multi-Function Meters for local display of parameters
as well as electrical transducers to provide analogue signals (4-20mA) to DCS. At
present MFM is installed on the panel front. Transducers are used for providing
analogue signals to DCS.

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  Feeder Protection

Feeder protection, or more exactly protection for overhead lines and cables, is the
most commonly used type of protection. The protection has to ensure that the power
grid continues to supply energy. In case of a fault, it must be prevented from spreading
to healthy parts of the network. The relays also have to minimize damage to the cables
and other connected equipment and to ensure safety for everyone.

 Busbar Protection

Busbars, being one of the most critical components of a switchyard where all the
power system equipment’s are connected, needs an important attention from
protection and from reliability point of view. Any maloperation may lead to threat for
system stability but instant clearance is needed during a fault to avoid cascaded
tripping. Many protection schemes have been devised starting from over-current
protection to differential schemes using numerical to microprocessor based analysis in
recent times.

TRANSFORMERS
A transformer is a static electrical device that transfers electrical energy between two or
more circuits through electromagnetic induction. A varying current in one coil of the
transformer produces a varying magnetic field, which in turn induces a varying
electromotive force (emf) or "voltage" in a second coil. Power can be transferred between
the two coils, without a metallic connection between the two circuits. Faraday's law of
induction discovered in 1831 described this effect. Transformers are used to increase or
decrease the alternating voltages in electric power applications.

Two Types:

1. Step-up Transformer.

2. Step-down Transformer

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 CONSTRUCTIONAL DETAILS OF TRANSFORMER

 Laminated Steel Cores

In all types of transformers the magnetic circuit is made of a laminated iron core. The
core is laminated in order to reduce eddy current loss. The laminations are insulated
from each other by a light coat of core plate varnish or an oxide layer on the surface.
The thickness of lamination varies from .35mm for 50Hz to .5mm for 25Hz. In
addition to eddy current loss hysteresis loss occurs in the core as it is subjected to
alternate magnetization and demagnetization. Hysteresis loss depends on area of
hysteresis loop of the core material. Special silicon steel having a steel content of 4-
5% is used for the lamination. The core loss can be minimized by employing
laminations of special steel sheet having high silicon content. CRGO silicon steel
laminations are used for the construction of transformer core. Each lamination is
insulated from its neighbors by a thin no conducting layer of insulation (paper
insulation).
 Windings
The conduction material used for the winding depends upon the application, but in
all cases the individual turns must be electrically insulated from each other so that
the current travels throughout every turns. For small power and signal transformers,
in which currents are low and the potential difference between adjacent turns are
small, the coil are often wound from enamel magnet wire such as formvar wire.
Larger power transformers operating at high voltages maybe wound with copper
rectangular strip conductors insulated by oil impregnated paper and blocks of
pressboard. The LV winding is placed on the inner side nearer to the core due to the
advantages such as reducing the insulation between core and windings, easier in
connecting tap changer to the HV winding.
 Cooling
The main source of heat generation in transformer is its copper loss or I2 R loss.
Although there are other factors that contribute heat in transformer such as
hysteresis & eddy current losses but contribution of I2 R loss dominate them. If this
heat is not dissipated properly, the temperature of the transformer will rise
continually which may cause damages in paper insulation and liquid insulation
medium of transformer. So it is essential to control the temperature within
permissible limit to ensure the long life of transformer by reducing thermal
degradation of its insulation system. Electrical Power transformer we use external
transformer cooling system to accelerate the dissipation rate of heat of transformer.
There are different transformer cooling methods available for transformer: AN- Air
natural cooling

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 AB- Air blast cooling
ON - Oil immersed air natural cooling
OB - Oil immersed air blast cooling
OFN - Forced oil air natural cooling
OFB - Forced oil air blast
OFW - Forced oil air water cooled
 Terminals
Very small transformers will have wire leads connected directly to the ends of the
coils, and brought to the base of the unit for circuit connection. Larger transformers
may have heavy terminals, bus bars or high insulated bushings made of polymers or
porcelain. A large bushing can be a complex structure since it must provide careful
control of electric field gradient without letting the transformer leak oil.
 Conservator tank
Conservator tank consist of oil level which depends on the operation of the
transformer. The oil expands in summer with increase in load and the oil level
decreases with the load. Conservator is a small auxiliary oil tank that may be
mounted above the transformer and connected to the main tank by a pipe. Its main
function is to keep the main tank of the transformer completely filled with oil in all
circumstances. When the oil in the tank contracts then the conservator gives the oil
to maintain the oil level in the tank. When the oil in the tank expands then the
conservator takes the oil.
 Breather and Explosion Vent
Breather is connected to one side of the conservator. It consists of a drying agent
CaCl2 or Silica gel which absorbs the moisture from air and allows dry air to enter
to the conservator. Thus sludge formation is avoided. Explosion vent consists of
large diameter steel pipe fitted on the transformer tank. It is usually at an angle to
the vertical. The pipe has an elbow at its end. A thin glass relief diaphragm is placed
at the top of the device. This diaphragm will rupture whenever the pressure in the
transformer rises to a dangerous value.
 Bushings
The bushings consist of a current carrying element in the form of a conducting rod.
Up to 33kV ordinary porcelain insulators can be used, above this voltage ratings oil
filled or capacitor type bushings are used. Page | 50 Bushing is very important to the
overall transformer because without it, conduction would not be possible. The
bushings are necessary to complete the conductive energy of the walls that are
transferred within the transformer so that they can the move through the medium
such as air and gas, including the grounding barriers that each unit is designed with.
These are some figures of bushings.
 Tappings
To enable transformers to supply a range of secondary voltages to different part of a
circuit it is common for power transformers to have the tapped windings, i.e.

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 windings split into various sections by using a number of connections brought out
from a single winding, each one at a particular number of turns along the winding.

 Buchholz Relay

The gas and oil actuated (Buchholz) relay is designed to detect faults as well to
minimize the propagation of any damage which might occur within oil-filled
transformers, capacitors and reactors supplied with oil conservator.

OPERATION OF A BUCHHOLZ RELAY

Slight faults:

When a slight fault occurs in the transformer, the small bubbles of gas, which pass upwards
to the conservator, are trapped in the relay housing, thus causing its oil level to fall. As a
result, the upper float rotates on its hub and operates the alarm switch, thus operating an
external alarm device.

Serious faults:

When a serious fault occurs in the transformer, the gas generation is violent and causes the
oil to rush through the connecting pipe to the conservator. In the relay this oil surge hits the
flap fitted on the lower float (located in front of the hole for the oil passage) and causes the
rotation of the float itself, thus operating the tripping switch and disconnecting the
transformer. The float remains in the trip position even if the oil flow comes to a stop (the
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reset is done by means of the push-button). The tripping device is regulated in such a way
that in transformers having forced oil cooling, the surges resulting from the starting of the oil
circulating pump will not cause mal-operation of the relay. An oil leak in the transformer
causes the oil level in the relay to fall, thus operating first the alarm (upper) float and then
the tripping (lower) float. The ingress of air into the transformer, arising from defects in the
oil circulating system or from other causes, operates the alarm float

KVA RATING OF TRANSFORMER

In relation to transformers, the 'kVA rating' of a transformer tells you how much
apparent power can flow through a transformer without exceeding a temperature rise
associated with the rating.

Temperature rise in transformers is due to 2 types of losses:-Iron loss which depend

on the applied voltage, and the Copper losses which are dependent on the current flowing
through windings.As these power losses are independent of load power factor, so the
temperature rise is governed by kVA and not kW. That's why the power rating of
transformers is in kVA and not in kW.

AUXILIARY TRANSFORMERS
Apart from all distribution transformers, Auxiliary transformers in a substation is used to
supply low voltage for AC power system inside substation such as lighting,air conditioners
and other AC supply system and DC power system such as protection relays, batteries,
SCADA & telecom system and other DC supply system.

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 CONDUCTORS
In physics and electrical engineering, a conductor is an object or type of material that allows
the flow of an electrical current in one or more directions. Materials made of metal are
common electrical conductors.

There are four major types of Conductors:

 Aluminium Conductors Steel Reinforced (ACSR)

These conductors are formed by several wires of aluminium and galvanized steel, stranded in
concentric layers.

The wire or wires which form the core, are made of galvanized steel and the external layer or
layers, are of aluminium. Galvanized steel core consist normally of 7, 19, 37 and 61 wires.
The diameters of steel and aluminium wires can be the same, or different.

Conductors Current Carrying Capacity (Amps)

Squirrel 70
Weasel 100
Rabbit 148
Mink 167
Raccoon 197
Dog 254
Tiger 296
Wolf 343
Lynx 385
Panther 427
Kundah 726
Zebra 737
Moose 880
Finch 1000

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  All Aluminium Conductors (AAC)

This type is sometimes also referred as aluminium stranded conductor which is made
up of strands of electrical conductor grade aluminium.AAC conductor has conductivity about
61%.Because of its poor strength;AAC has limited use in transmission and distribution line.

It is principally used in urban areas where spacing is short and the supports are close. It can
be used in coastal regions owing to its high degree of corrosion resistance and is also used
extensively within the Railway and Metro industries.

 All Aluminium Alloy Conductors (AAAC)

These conductors are made from aluminium alloy which has high strength consist of
aluminium-magnesium-silicon alloy. This alloy conductor offers good electrical conductivity
(about 52.5%) with better mechanical strength.

25
AAAC are used as a bare conductor cable on aerial circuits that require a larger mechanical
resistance than the AAC and a better corrosion resistance than the ACSR. The sag
characteristics and the strength-to-weight ratio of the AAAC conductor cable are better than
both AAC and ACSR.

 Aluminium Conductor- Alloy Reinforced (ACAR)

These conductors are formed by wrapping strands of high purity aluminium on high strength
aluminium-magnesium-silicon alloy core.ASCR has better electrical as well as mechanical
properties than other conductors. This type of conductors are may be used in overhead as
well as distribution line.

ACAR has got better mechanical and electrical properties as compared to an equivalent
ACSR, AAC or AAAC. A very good balance between the mechanical and electrical
properties therefore makes ACAR the best choice where the capacity, strength and light
weight are the main consideration of the line design. These conductors are extensively used
in overhead transmission and distribution lines.

INSULATORS

An electrical insulator is a material whose internal electric charges do not flow freely;
very little electric current will flow through it under the influence of an electric field. This
contrasts with other materials, semiconductors and conductors, which conduct electric
current more easily.

The property that distinguishes an insulator is its resistivity; insulators have higher
resistivity than semiconductors or conductors.

26
Types of Insulators:

 Pin Type Insulators

A pin insulator is a device that isolates a wire from a physical support such as a pin (a
wooden or metal dowel of about 3 cm diameter with screw threads) on a telegraph or utility
pole. It is a formed, single layer shape that is made out of a non-conducting material, usually
porcelain or glass.

It is thought to be the earliest developed overhead insulator and is still popularly used in
power networks up to 33 KV. Single or multiple pin insulators can be used on one physical
support, however, the number of insulators used depends upon the application's voltage.

 Suspension Type Insulators

It consists of the number of disc connected in series by metal links in the form of a string.

 Strain Insulators

27
When there is a dead end of the line or there is a corner sharp curve the lineis subjected to
greater tension. In order to relieve the line of excessive line i.e.; straying insulator are need
for10v lines less than 11kv, shackle insulators are used as string insulator.

 Shackle Insulator

In early days, the shackle insulators where used as strain insulators but now a days, they are
frequently used for 10v voltage distribution line such insulators can be either in a horizontal
position or in a vertical position. They can be directly fixed to the pole with bolt.

 Stay Insulator

Fig.12.5

They are usually mounted at the height of 3 meter from the ground.

 Polymer Suspension Type Insulator

 Light weight
 Stable behaviour at extreme dynamic conditions.
 Long term surface hydrophobicity.
 Suitable for polluted environment, salty atmospheres
 High mechanic strength

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 

AN OVERVIEW OF 110KV SUBSTATION, KALOOR, ERNAKULAM

INCOMMING FEEDERS : 110kV KLKA

110kV EPKA

33kV OUTGOING FEEDERS : 33kV METRO 1

33kV METRO 2
33kV THAMMANAM 1
3KALU 2
3KALU 3
3KALU 1
3KALI 1
3KALI 2
33kV THAMMANAM 2

110kV OUTGOING FEEDERS : 1KAEK1

1KAEK 2

66kV OUTGOING FEEDERS : KAMD

11kV OUTGOING FEEDERS : HIGHWAY

POTTAKUZHY
JANATHA
KATHRUKADAVU
GIRINAGAR
MUTHOOT
THAMMANAM
EDAPPALLY
MAMANGALAM
ELAMAKKARA
PONOTH
AZAD ROAD
KALOOR BUSSTAND
STATION AUXILIARY

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 TRANSFORMERS :

12.5 MVA 110/11 kV TRANSFORMER : 1

20 MVA 110/11 kV TRANSFORMER : 2

25 MVA 110/66 kV AUTO TRANSFORMER : 2

10 MVA 66/11 kV TRANSFORMER : 1

25 MVA 110/33 kV TRANSFORMER : 2

12.5 MVA 11O/11 kV TRANSFORMER

BAY EQUIPMENTS

NAME RATING MAKE OPERATION

110kV BUS 123kV SMC MANUAL
ISOLATOR
110kV CB (SF6 31.5KA, 800A HBB REMOTE/LOCAL/MANUAL
spring charged)
110kV CT 75/1-1A TELK
110kV LA 96kV WS
TRANSFORMER 10/12.5MVA, TELK
110/11kV
HV:52.5/65.7
LV:525/657
11kV LA 96kV RMS WS

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 25 MVA 11O/66kV AUTOTRANSFORMER
BAY EQUIPMENTS

NAME RATING MAKE OPERATION

110kV BUS 123kV SMC MANUAL
ISOLATOR
110kV CB (SF6 31.5KA, 800A HBB REMOTE/LOCAL/MANUAL
spring charged)
110kV CT 150/1-1A TELK
110kV LA 96kV RMS WS
TRANSFORMER 25MVA, ANDREW
110/66kV YULE AND CO
HV:65.6/131.2 LTD
LV:109.3/218.7
66kV LA 96kV RMS WS
66kV CT 500-250/1-1A AMEI
66kV CB 25KA,2000A ABB REMOTE/LOCAL/MANUAL
66kV BUS 72.5K S&S MANUAL
ISOLATOR

10 MVA 66/11kV AUTOTRANSFORMER

BAY EQUIPMENTS

NAME RATING MAKE OPERATION

66kV BUS 72.5kV C&G MANUAL
ISOLATOR
66kV CB (SF6 40KA, 800A ALSTOM REMOTE/LOCAL/MANUAL
spring charged)
66kV CT 400-200-100/1-1- VICTRANS
1A ENGINERS
66kV LA 96kV
TRANSFORMER 10MVA, APEX
66/11kV HV:87.5
LV:524.9
11kV LA 96kV WS

31
32
 CONCLUSION

Working at the 110kV substation, Kaloor, Ernakulam as industrial visiting was a very nice
experience. I learned a lot about electrical substation system and the importance of
substations in electrical generation, transmission and distribution. This industrial visit
provided an insight on how substations work and thus helps in efficient transmission of
electricity. We also studied about different substation equipments in detail. It has given us
useful information related to our course which cannot be visualized in lecture classes such as
transformers which is as big as one-fourth of an average room, which we learnt about but
never saw in the college labs. In the beginning of this visit I was not aware about the merits
we were going to receive from the visit but at the end I realised it was a very good
experience which i would have regretted if I missed. Also the training was an opportunity for
me to increase my personal relations both socially and professionally

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NOTES

34