Mitigation of Hot Spots in S&S and Siemens make Isolators

at POWERGRID, Khammam SS
--V.V.V.Gangaji

Introduction:
Khammam Substation is having 11 numbers of 400KV Lines, 03 numbers of ICTs, 5 No.s of Shunt Reactors with 46 No.s of
400KV Bays & 03 no.s of 220KV Bays.

Out of the 11 Lines, 06 no.s lines with associated Bays are assets of M/s TS Transco which are mentioned below.

1. 400KV Khammam- Mamidipally-1

2. 400KV Khammam- Mamidipally-2
3. 400KV Khammam- Asupaka
4. 400KV Khammam- Kalpaka
5. 400KV Khammam- KTPS-1
6. 400KV Khammam- KTPS-2

The 400KV bays of the first 04 feeders were fitted with S&S make Isolators (22 no.s), Horizontal Center break model and
remaining 02 feeders were fitted with Siemens make Isolators (08 no.s), horizontal double break model isolators.

Case Study-1:
Problem: During, thermo vision scanning of Switch yard equipment, the Hotspots are identified terminal Studs of S&S isolators
in Asupaka Line Main Bay, Kalpaka Line main Bay, Maidipally-1 & 2 associated bays. The images of the thermo vision scanning
are shown in the table-1

Table-1
The temperature of these hotspots is found to be varying depends upon the current flow and ambient temperature.

The defects are generally attended on priority based on the temperature of the hotspot.

The Outline drawing of S&S make, Center Break Isolators with the Terminal stud indicated with pointer is as shown in Picture-1
below

Picture-1
The images of the defect noticed while attending the hotspots are shown in Table-2

Table-2

Root Cause Identification: The Terminal studs of the Isolator are made with Copper Metal, whereas the terminal
connector/Clamps are made with Aluminum Metal. These metals are having different coefficients of thermal expansion. Due to
the atmospheric temperature variation, the metals undergo expansion and contraction which will affect its physical shape due to
which the gap will be formed between two different metals in a joint.
To avoid the above said problem, the bi metallic sleeves (shown in pic-2 below) are generally provided in the joints having
different metals.

Different sizes of Bi-metallic Sleeves

Picture-2

These bi-metallic sleeves were found missing in the most of the S&S isolators, where in the hot spots were developed over a
period of time. Thus, the root cause of the problem is found to be missing bi-metallic sleeves in the Terminal Connectors of the
isolators since the commissioning stage of the isolators itself.

Corrective Action: As mentioned above, the isolators are belongs to M/s TS Transco, the problem was explained and asked
them to provide the material (Suitable bi-metallic Sleeves) so as to rectify the same as the maintenance of the same is being
done by POWERGRID. Meanwhile some of the isolators which are having hotspots with critical temperature at Terminal
connectors (identified in thermo vision scanning) are attended with the spares available (on replenishment basis) with
POWERGRID
Case Study-2:
Problem: Similarly during thermo vision scanning of Switch yard equipment, the Hotspots are identified in Siemens make
isolators in KTPS-1 & KTPS-2 Line associated bays. The images of the thermo vision scanning are shown in the table-3.

Table-3

The Siemens make, Horizontal Center Break model isolator, DBR type is shown in Picture-4 below.
These isolators are having horizontal moving, double side sliding type contact arrangement between male and female contacts.

It is observed that, the these sliding mechanism is having very less contact overlap surface with male type stud at Terminal

Connector, which is leading to formation of pitting and carbonization of contacts due to insufficient contact surface (as shown

the picture-5 below). This problem is leading to formation of Hotspot at the Terminal connectors.

Corrective Action: The problem was rectified by replacing Defective Copper blades of female contact and grinding/polishing
the carbonized area on Male stud at Terminal connector.