Vivek in Reoprt

STUDY THE MAINTENANCE ON 220 KV SUBSTATION 2022-23
ABSTRACT
Electric power network is interconnection of generation, transmission and distribution

systems. In the traditional grid the generation, was centralized to large power plants such as
coal, nuclear and hydroelectric. With the advancement of technology, renewable energy
resources such as wind, solar and biomass are becoming more popular and widespread.
Renewable energy resources are small in capacity compared to coal and nuclear plants but
are widespread in transmission and distribution system and are located closer to the load
centres. The transmission is used to transfer electrical energy from generation to load centre.
This system consists of transmission lines and the substations with transformers and other
components used to maintain voltage as well as active and reactive power flow.
Transmission lines are characterized based on their resistance, inductance and shunt
capacitance. In Karnataka the transmission is done by KPTCL and the distribution is done by
5 organizations namely BESCOM, MESCOM, GESCOM, HESCOM and CESCOM
Mysore.
Department of EEE 1 MVJCE

CONTENTS
Title i
Certificate ii
Declaration iii
Acknowledgement iv
Completion Certificate v
Contents vii
CHAPTER 1 : ABOUT THE COMPANY 01-05

1.1 Introduction to KPTCL 01
1.2 Mission statement of KPTCL 02
1.3 Preamble 02
1.4 Plans for future 03
1.5 Loads 03
1.6 Capacity allocation to ESCOMs 03
CHAPTER 2: ABOUT THE DEPARTMENT 04-06
2.1 Daily maintenance works: (All equipment’s) 04
2.2 Weekly maintenance work: (All equipment’s) 04
2.4 Transformers 05
2.5 Breakers 05
2.6 Current transformers, Potential transformers, C.V.T.S 06
2.7 General 06
CHAPTER 3: TASK PERFORMED 07-34
3.1 Introduction to 400KV/220KV/33KV receiving station 07
3.2 Single Line Diagram 08
3.3 Substation Equipment 09

3.5 Degasification 29
3.6 Line Clearing 32
3.7 Equipment’s maintenance lists 33
3.8 General Maintenance 33
3.9 Load Flow 34
CHAPTER 4: REFLECTION TEST 35-40
4.1 Introduction 35
4.2 Transformer Test 36
4.3 Erection of voltage reactor 39
4.4 Substation visited 39
CHAPTER 5: CONCLUSIONS 41
References 42

LIST OF THE FIGURE
Fig. no Name of the Figure

Pg.no
Figure 01 Symbol of KPTCL 07
Figure 02 KPTCL corporate office 07
Figure 03 View of 400KV side receiving station 19
Figure 04 View of 220KV side receiving station 20
Figure 05 Crompton greaves made 167MV transformer 20
Figure 06 Core of transformer 21
Figure 07 Winding of transformer 22
Figure 08 Conservator tank 23
Figure 09 Silica gel inside a breather 24
Figure 10 Radiator for a transformer 24
Figure 11 HV side bushing transformer 25
Figure 12 Low voltage side bushing transformer 26
Figure 13 Current transformer 30
Figure 14 Potential transformer 30
Figure 15 Bus bar 32
Figure 16 Lightening arrestor 33
Figure 17 Circuit breaker 35
Figure 18 Isolator 38
Figure 19 Battery bank 39
Figure 20 Earthing mat for substation 40
Figure 21 Degasification process 41
Figure 22 Instrument used for degasification 45
Figure 23 Line man’s working during line clearing 46
Figure 24 Control board for opening of isolators 48
Figure 25 Line man taking resistance value of current transformer 49
Figure 26 Ratio testing of transformer 56
. Figure 27 Megger test equipment of transformer 57
Figure 28 Open Circuit transformer 58

Figure 29 Voltage Reactor 60

Figure 30 Single line diagram of 220/66/11KV 61

LIST OF TABLES
Table 1 Capacity allocated to ESCOM’S 04

Table 2 Ratings of ICT 1 transformer' 14
Table 3. Megger measured resistance values of Lightening Arrestor B-PHASE 36
Table 4 Megger measured resistance values of Lightening Arrestor Y-PHASE 36
Table 5. Megger measured resistance values of Lightening Arrestor R-PHASE 37
Table 6 Megger measured resistance values of CVT R- PHASE 41
Table 7 Megger measured resistance values of CVT Y- PHASE 37
Table 8 Megger measured resistance values of CVT B- PHASE 37
Table 9 Megger measured resistance values of CVT R-Y-B PHASE 38

CHAPTER 01
ABOUT THE COMPANY
1.1. INTRODUCTION TO KPTCL
Figure 1. Symbol of KPTCL
Figure 1.2. KPTCL Corporate Office
Figure 2. KPTCL Corporate Office

Karnataka Power Transmission Corporation Limited, also known as KPTCL, is a

registered company under the companies act, 1956 was incorporated on 28-7-1999 and is
a company wholly owned by the Government of Karnataka.
Karnataka Power Transmission Corporation Limited (KPTCL) is the sole electricity

transmission and distribution company in state of Karnataka. Its origin was in Karnataka
Electricity Board. Until 2002, the Karnataka Electricity Board (KEB) handled electricity
transmission and distribution across the state. It was then broken up, with KPTCL
established to manage the transmission business. This electricity transmission and
distribution entity was corporatized to provide efficient and reliable electric power supply
to the people of Karnataka state.
KPTCL buys power from power generating companies like Karnataka Power
Corporation Limited (KPTCL) and other IPPs (Independent Power Producers) like GMR,
Jindal, Lanco (UPCL) etc., and sell them to their respective ESCOMS. The overall
installed power capacity of Karnataka is 9500MW but only 7000MW is generated and
around 4500MW is transmitted to Bangalore for its utilization.
KPTCL is headed by a Chairman and Managing Director at the corporate office. He is

assisted by four functional Directors. The Board of KPTCL consists of a maximum of
twelve directors. KPTCL has 4Nos. 400KV station, 97 Nos. of 220KV station, 385 Nos.
of 110KV station and 602 Nos. of 66KV station. The total Transmission Line in CKMs is
34251 as on 31-03-2016. Company is governed under the purview of Ministry of Energy
Department headed by cabinet grade minister. Currently B S YEDIYURAPPA is the
minister under the Chief Minister ship of himself.
1.2 MISSION STATEMENT OF KPTCL
The mission of Karnataka power Transmission Corporation Limited (KPTCL) is to

ensure reliable quality power to its customers at competitive prices. The KPTCL is
committed to achieving this mission through.
• Encouraging best practices in transmission and distribution.
• Ensuring high order maintenance of all its technical facilities.
• Emphasizing the best standards in customer service.
To be the best electricity utility in the country, the KPTCL pledges to optimize its human
and technical resources for the benefit of all its customers.

1.3 PREAMBLE
Government of Karnataka is of the view that the existing structure of the power sector is
inadequate to satisfy the criteria of efficient management of power production and supply
bringing down T&D losses to international standards, enhancing the quality of supply and
rendering good service to the consumers. Hence, the Karnataka Electricity Reform Act,
(KERA) has been enacted in 1999.
The salient features of the Act are:
♦ Constitution of Electricity Regulatory Commission.

♦ Corporation of the erstwhile Electricity Board and formation of several distribution
… companies.
1.4 PLANS FOR FUTURE
The state has experienced a power shortage situation for twenty years and is known as
state of power shortage.it is necessary to clear this impression by ensuring adequate
power in the years to come firstly to provide a sense of confidence to the prospective
entrepreneurs and secondly to attract those industries who are having captive plants to opt
again for grid supply.
Power system planning is contemplated for a 10-year period to achieve the following
■ Projection of demand and energy requirements for a period of ten years.
■ To develop an optimal power system to meet the forecasted power demand in various
horizon years and To arrange reliable and quality power supply to all the consumers i.e.
Uninterrupted, reliable and stable power supply at rated voltages and frequencies by
taking certain measures such as improvements in stability of the system and reduction of
system T&D losses to an optimal level, consistent with load pattern and density
.
■ Generation planning for a period of decade to meet the projected load growths on least
cost options taking into consideration capital investment on evacuation lines and
transmission losses.

1.5 LOADS:
The load growth in Karnataka during 90’s is to an extent of about 6% under restricted
condition as the state was reeling under severe power shortage since 1971. As against the
unrestricted peak demand and energy requirements of 4845MW and 28500MU
respectively for the year 1999-2000, the actual peak demand and energy consumption
recorded in the state are 4066MW and 26277MU, respectively
✓ Thus, the present shortage to meet the peak demand and energy requirement is to an
extent of 16% and 8% respectively. The demand and energy requirement for the year
2009-10 are estimated to be about 9100 MV (with 15% spinning reserve) and 46,000 MU
respectively, as will be elaborated later. This projected requirement takes into the account
the following. The present shortage and a moderate growth to an extent of 6% per annum
over next one- decade
The benefit of additional energy that is expected to be available through system

improvement efforts.
✓ Bringing down the level of T*D losses from an estimated 26% to 14%
✓ Taking into the account the existing capacity additional of about 1500-4000 MW.
However, these estimates are subject to midterm as well as six-monthly reviews, for
realistic assessment of the requirement.
1.6 CAPACITY ALLOCATION TO ESCOMs:
KPTCL has stated that, the transmission charges are proposed to be collected from the
ESCOMs in the ratio of allocation of power from GOK. It has also requested to allow
collection of transmission charges from the ESCOMs on the basis of allocation as
revised KPTCL has stated that, the above allocation of generation capacity is in
accordance with the allocation of power as per government order EN 126 EMC 2010
dated 24.03.2010 which is effective from 01.04.2010.

ESCOMs
FY13 FY14 FY15
BESCOM
5643 6526 6862
MESCOM
966 1127 1197
CESC
1232 1446 1543
HESCOM
2175 2573 2772
GESCOM
1556 1805 1908
TOTAL
11572 13477 14282
.
Table 1 Capacity allocated to ESCOM’s.
Commission’s Analysis Decision:
As per the MYT Regulations, the transmission charges are to be determined based on
the total capacity contracted by the ESCOMs with KPTCL. In the hearing, sum of the
stack holders has contained that there was no capacity contracted by the ESCOM with
KPTCL and hence it is not appropriate to determine transmission tariff on the basis of
generation capacity. In the absence of the contracted capacity, the commission, in its
order dated 25.11.2009, had considered it appropriate to adopt the allocation of installed
generation capacity to the ESCOMs as made by the GOK for determination of
transmission charges.
Further, it is to be noted that, the GOK has allocated capacity as well as energy from
all the generation sources to each of the ESCOMs based on which the commission is

considering power Purchase coast for each ESCOM. The ESCOMs have entered into
power purchase agreement with the generator, based on the capacity/ energy allocated
by the GOK. As such the commission considers it appropriate to determine transmission
charges payable by each ESCOM based on capacity allocation made by the GOK for the
present. The commission here by directs KPTCL to enter into contracts with all long-
term users of the transmission system including ESCOM before the end of the current
financial year and report compliance there of to the commission.
CHAPTER 02
ABOUT THE DEPARTMENT
The mission of the Karnataka Power Transmission Corporation Limited is to ensure

reliable quality Power. This objective can be achieved by ensuring high order
Maintenance of Station equipment’s and Transmission Lines. Proper Maintenance of
Station equipment’s and Transmission Lines help to reduce scheduled outages and
increase the stability and Reliability of Power systems. Systematic and regular
maintenance works is a pre-Requisite for a healthy Power system. With this in view, The
Corporate Office has brought out detailed Maintenance schedules for Stations and Lines.
However, these Maintenance schedules are not practiced in the field, resulting in
unscheduled Power interruptions and thereby decreasing the Power
Availability/Reliability. Therefore, the need of the hour is to carry out periodical
Maintenance works in a systematic manner to achieve maximum Availability/Reliability.
The following Guidelines are suggested to be practiced while taking up preventive
Maintenance works
➢ Meticulously plan the maintenance works well in advance.
➢ Obtain the concurrence of the jurisdictional BESCOM O & M Executive Engineer,

Elec, for taking up the Maintenance works planned on a notified day.
➢ Ensure that the power shutdown Notification is notified in the Local newspapers.
➢ Organize the men and materials required for the Maintenance works.
➢ Commence and complete the work within the shutdown period notified.

➢ Create a safe working zone for the working personnel and cause supervision by
authorized personnel.
2.1 DAILY MAINTENANCE WORKS: (ALL EQUIPMENTS)
• General cleaning of control and Relay panels, Battery chargers and other equipment’s
in control room.
• Inspection of Battery charger.
• Visual inspection of Oil level in bushings, O.L.T.C, silica Gel in Breakers
• Recording number of OLTC operations in a day and recording cumulative number of

operations.
• Observing abnormal change in transformer humming sound.
• Cleaning of outdoor yard, Earth Electrode pits
• Inspection of ODY for Arcing I Oil leakages. (Day & Night peak hours)
• Operation of DG sets & to run for 10 minutes
• Review of Log Books I Reports of Shift Engineers.
• Check functioning of the cooling fans (Day & Night peak hours).
2.2 WEEKLY MAINTENANCE WORKS: (ALL EQUIPMENTS)
■ Inspection of the level of Electrolyte in Batteries and topping up with distilled water.
■ Inspection of Oil level and condition of Oil in Air compressors.
■ Draining of condensed water in Air receiver tanks of breakers.
■ Checking of Auto Start/ Stop of Compressors /Pumps of Breakers.
■ Checking of Alai 111 and lock out for Air I Gas in Breakers.

2.3 MONTHLY MAINTENANCE WORKS: (ALL EQUIPMENTS)
➢ Cleaning and applying petroleum Jelly for Battery terminals
2.4 TRANSFORMERS
➢ Quarterly
■ Cleaning of all bushings.
■ Checking of Bushings and oil level.
■ Tightening Earthing cap of Capacitor bushing.
■ Checking of fans, pumps, Oil coolers for auto start /local /remote start/stop.
■ Checking of Oil leaks, (if any) and rectification.
■ Checking OLTC and its drive melanise for local I Remote operation and
lubrication.
■ Air release in main tanks/ Buchholz Relays, bushings turret.
■ Checking transformer Alarm Trip Circuit.
■ Tightening Transformer Neutral earth connections.
➢ Half Yearly
✓ Measurement of IR values and PI for condition monitoring.
✓ Testing of bottom oil of main tank for B.D.V (By R & D wing) and taking
…………corrective action as suggested by R & D.

➢ Yearly
■ Testing of main 11 tank Oil for DGA I PPM etc
■ Replacement of OLTC oil for every 5000 operations/once in a year, whichever in

……..early.
■ Check oil level in OTI, WTI sensor pockets
■ TAN-Delta and capacitance Measurement.
■ Check operation of Buchholz Relay by Electrical air injection for Alarm trip.
■ Check the contacts for OLTC, fan, Pump control.
■ Tightening of terminals and vermin proof of marshaling box.
■ Oil temperature reading comparison with external thermometer in OTI Pocket.
■ Checking arcing horn gaps of bushings
2.5 BREAKERS
➢ Quarterly
✓ Maintenance as per manufacturers manual.
✓ Checking of compressed Air and SF6 gas pressures.
✓ Rectification of leakages, if any.
✓ Recording No of operation of counters.
✓ Lubrication of operating and linkage mechanisms as well a trip and close

…………mechanism.
✓ Replacement of oil in MOCBS as per manufacturer’s recommendations.

✓ Tightening of clamps, pump connections, auxiliary switch connections.
✓ Checking closing and tripping of breakers through local/remote switch and relays.
✓ Check capacitor tripping device operation by removing D.C supply.
✓ Checking or pneumatic drive, hydraulic fluid and SCADA operation, wherever

……provided.
✓ Check for smooth contact of all contactors and spray of rust lick for contacts
…….mechanism.
✓ Check for vermin proofing.
✓ Check control wiring.
➢ Half Yearly
■ Changing of compressor oil.
■ Measure IR values.
■ Tighten control circuit/terminals.
➢ Yearly
• C.B timing checking’s (in association with RT/Research).
• Contact Resistance (in association with RT/Research).
• Pole Discrepancy Relay check.
• Operation of lockout check
• Measurement of Tan-Delta & capacitance by RT/Research.
• Checking of Earth connections.

• Detailed checkup of breaker operating mechanism compressors/lubrication of

drive …..mechanism/pneumatic drive.
• Over hauling of breaker mechanism/ (as per manufacturer’s recommendation).
• Over hauling of breaker interrupter / (as per manufacturer’s recommendation).
2.6 CURRENT TRANSFORMERS, POTENTIAL TRANSFORMERS, …
➢ Quarterly
■ Checking for oil leaks and oil level (CT, PT & C.V.T)
■ Visual Inspection of HF point bushing for damages and earthing, if not used for
. PLCC.
■ Measurement of Voltages in marshalling box and control room.
➢ Half Yearly
• Checking & tightening of secondary wiring and vermin proof of marshalling

box.
• Check the earth connection/secondary circuit
• Checking and tightening of jumps & clamps.
➢ Yearly
■ Check earth connections.
■ Measure IR values.
■ Checking of primary jumper clamps & primary connection of CTS.
■ Vermin proof and secondary terminal box.
■ Measurement of tan delta and capacitors for 220kv only.

2.7 GENERAL
➢ Quarterly
• Check out door yard illumination & replace yard lighting (bulbs), wherever …
necessary.
• Cleaning of control and relay panel, vermin proof for cable entry, earth
connections.
• Cleaning of battery charger & checking of earth connections.
•Weighing of C02 cylinders.
➢ Yearly
♦ Checking of DC Emergency lamps in control Room
♦ Replenishing of fire extinguishers.
♦ Painting of name plates, phase indication, bay indication and earth electrodes.
♦ Earth resistance of all equipment’s

CHAPTER 3
TASK PERFORMERD
3.1 INTRODUCTION TO 400KV/220KV/33KV RECEIVING STATION:
The 400KV/220KV/33KV receiving station located in hoody is one of the very few
400KV plants located in Bangalore. It is the one among the 4 nos. of 400KV plants of
KPTCL. It gets its supply from KOLAR through High voltage line carrying 400KV.
The power to KOLAR comes from ODISSA through HVDC (High Voltage DC) line
carrying nearly 500KV of DC voltage this is done because the losses in DC
transmission are very less. The DC voltage is then converted to AC voltage in Kolar
and is sent to HOODY R/S. The Distance from Kolar to Hoody is very less its
approximately 50Km hence the losses will be less and hence its transmission is done
in HVAC (High Voltage AC).
Figure 3.. View of 400KV side receiving station

The voltage taken from 400KV side is passed through the step-down transformers
which steps down the voltage from 400KV to 220KV and 33KV. The 33KV is not used
in and around southern Karnataka regions, it’s used only in the northern parts of
Karnataka. The 220KV is then fed to Different 220KV substations in and around
Bangalore. The Hoody R/S supplies almost 70% of Bangalore’s power supply. It has 4
outgoing 220KV lines going to different place. 1 220KV line is fed to its adjacent
220KV Substation. From where supply to even Railway lines go. 2 connection from
220KV substation is given to the railways.
Figure 4.View of 220KV side receiving station
3.3.1 POWER TRANSFORMER

Figure 5. Crompton Greaves made 167MVA Transformer
Use of power transformer:
Generation of electrical power in low voltage level is very much cost effective.
Theoretically, this low voltage level power can be transmitted to the receiving end. This
low voltage power if transmitted results in greater line current which indeed causes
more line losses. But if the voltage level of a power is increased, the current of the
power is reduced which causes reduction in ohmic or I2R losses in the system, reduction
in cross-sectional area of the conductor i.e. reduction in capital cost of the system and it
also improves the voltage regulation of the system. Because of these, low level power
must be stepped up for efficient electrical power transmission. This is down by step up
transformer at the sending side of the power system network. As this high voltage power
may not be distributed to the consumers directly, this must be stepped down to desired
level at the receiving end with the help of step-down transformer. Electrical power
transformer thus plays vital role in power transmission.
There are total of 11 single phase transformers in the 400KV receiving station each of
167MVA power rating at a time simultaneously 9 single phase transformers will be
running together and feeding the main bus 2 single phase transformers are always kept
as spare if in case any transformer fails the spare transformer can be replaced with the
failed one until the repair work is done and the transformer is ready for operation.
The 9 single phase transformers are divided into 3 sets of ICTs’ known as ICT1, ICT2,
ICT3 each ICT’s has 3 phases, ICT1 has ICT1 R phase, ICT1 Y phase, ICT1 B phase
ICT2 has ICT2 R phase, ICT2 Y phase, ICT2 B phase
ICT3 has ICT3 R phase, ICT3 Y phase, ICT3 B phase

Figure 6. Core of Transformer
Primary winding - These are the winding to which the input voltage is applied
Secondary winding - These are the winding to which the output voltage is applied.
Within the voltage range classification, winding is further categorized:
• High voltage winding - It is made of copper conductor. The number of turns
made shall be the multiple of the number of turns in the low voltage winding. The
conductor used will be thinner than that of the low voltage winding.
• Low voltage winding - It consists of fewer number of turns than the high
voltage winding. It is made of thick copper conductors. This is because the current in
the low voltage winding is higher than that of high voltage winding.
Input supply to the transformers can be applied from either low voltage (LV) or high
voltage (HV) winding based on the requirement
.
Figure 7. Winding of transformers
3.3.1.3 Insulating materials:
Insulating paper and cardboard are used in transformers to isolate primary and
secondary winding from each other and from the transformer core. Transformer oil is
another insulating material. Transformer oil performs two important functions: in
addition to insulating function, it can also cool the core and coil assembly. The
transformer's core and winding must be completely immersed in the oil. Normally,
hydrocarbon mineral oils are used as transformer oil. Oil contamination is a serious

problem because contamination robs the oil of its dielectric properties and renders it
useless as an insulating medium.
3.3.1.4 Conservator tank:
The conservator conserves the transformer oil. It is an airtight, metallic, cylindrical drum
that is fitted above the transformer. The conservator tank is vented to the atmosphere at the
top, and the normal oil level is approximately in the middle of the conservator to allow the oil
to expand and contract as the temperature varies. The conservator is connected to the main
tank inside the transformer.
Figure 8: Conservator tank
3.3.1.5 Breather:
The breather prevents the moisture from entering into the transformer. Moisture can
arise when temperature variations cause expansion and contraction of the insulating oil,
which then causes the pressure to change inside the conservator. Pressure changes are
balanced by a flow of atmospheric air in and out of the conservator and moisture can
enter the system.
Silica gel crystal as tremendous capacity of absorbing moisture. when air passes
through this crystal in the breather, the moisture of the air is absorbed by them.
Therefore, the air reaches to the conservator is quite dry, and the dust particles in the air
get trapped by the oil in the oil seal cup. The oil in the oil sealing cup act as a barrier

between the silica gel crystal and air when there is no flow of air through silica gel
breather.
The color of the silica gel crystal is dark blue but when it absorbs moisture it becomes
pink. When there is a sufficient difference between the air inside the conservator and the
outside air, the oil level in the two components of the oil seal changes until the lower oil
level just reaches the rim of the inverted cup, the air then moves from higher pressure
compartment to the low pressure compartment of the oil seal. Both of these happen
when the oil acts as core filter and removes the dust from the outside air.
Chapter 3
Figure 9 Silica gel inside a breather
3.3.1.6 Radiator:
The main function of the radiator is to cool the oil in the transformer. Radiator are the
detachable device whose upper and lower portion is connected by a valve to the
transformer tank. The transformer cleaning and maintenance is done with the help of
valve to prevent the draining of the oil when the radiator is detached from the
transformer. When transformer is in the working conditions, the oil of the transformer
gets heated and moves up in the main tank and enters into the radiator through the upper
valve, where it gets cooled and from the lower valve of radiating unit the oil again enters
the transformer tank and this process continues.

Figure 10. Radiator for a transformer
3.3.1.7 Bushings:
The Bushings in the transformer are the insulating device which allows an electric
conductor to pass electrical energy safely through it. It provides electrical field. Strength
to the insulation of the conductors to withstand, when large amount of electric energy
passes through it. Solid porcelain type bushing is used in smaller transformer and oil
filled condenser type bushing is used in large transformer. The most common cause of
the failure of the bushing resulting in damage of the transformer is the entrance of the
moisture. For a transformer usually, there comes two sides of bushings one is the high-
tension side bushing connecting the high voltage end to the transformer the other is the
low voltage side bushing which gives out the lower side voltage from the transformer.
The bushings act like the entry and exit point for voltage and current to and from the
transformer
Figure 11. HV side bushing of transformer
The design of any electrical bushing must ensure that the electrical strength of the
insulated material is able to withstand the penetrating 'electrical energy' passing through

the conductor, via any highly stressed areas. It must also be capable of enduring,
occasional and exceptional high voltage moments as well as the normal continual
service withstand voltage, as it is the voltage that directs and controls the development
of leakage paths and not current.
Insulated bushings can be installed either indoor, or outdoor, and the selection of
insulation will be determined by the location of the installation and the electrical service
duty on the bushing. For a bushing to work successfully over many years, the insulation
must remain effective both in composition and design shape and will be key factors in
its survival. Bushings can therefore vary considerably in both material and design style.
Chapter 3
Figure 12. Low Voltage side bushing of transformer
3.3.1.9 Cooling Tubes:
Cooling tubes are used to cool the transformer oil. The transformer oil is circulated
through the cooling tubes. The circulation of the oil may either be natural or forced. In
natural circulation, when the temperature of the oil rises the hot oil naturally rises to the
top and the cold oil sinks downward. Thus, the oil naturally circulates through the tubes.
In forced circulation, an external pump is used to circulate the oil.
3.3.1.10 Tap Changer:

The output voltage of transformers varies according to its input voltage and the load.
During loaded conditions, the voltage on the output terminal decreases, whereas during
off-load conditions the output voltage increases. In order to balance the voltage
variations, tap changers are used. Tap changers can be either on-load tap changers or off-
load tap changers. In an onload tap changer, the tapping can be changed without isolating
the transformer from the supply. In an off-load tap changer, it is done after disconnecting
the transformer. Automatic tap changers are also available.
3.3.2 Protection of Transformers:
Since transformers are the expensive equipment in the whole station, they are protected
by many subordinate protective devices as below Relays:
A relay is an electrically operated switch which controls a circuit by a separate low power
signal, or where several circuits must be controlled by one signal. There are various relay
which are used to protect the transformer and they are Oil surge relay, Buchholz relay,
earth fault relay, over current relay etc.
3.3.2.1 Over current relay (OCR):
The relay where several circuits must be controlled by one signal. There are various
relay which are used to protect the transformer and they are Oil surge relay, Buchholz
relay, earth fault relay, over current relay etc. The inverse-time characteristic relay
usually provides the best coordination. Fast operation is not possible, since the
transformer relays must coordinate with all other relays.
3.3.2.2 Buchholz relay:
This relay is designed to detect transformer internal fault in the initial stage to avoid
major breakdown. Internal fault in transformers generates gases by decomposition of oil
due to heat and spark inside the tank. These gases pass upward towards the conservator
tank trapped in the housing of the relay, thereby causing oil level to fall.
3.3.2.3 Oil surge relay:

It is similar to Buchholz relay with some changes. It has only one float and operates
when oil surge reach and strike the float of OSR. It is used with OLTC (On Load Tap
Changer) for detection of any damage or fault inside the changer and prevents tap
changer from damages in case of low oil level in OLTC tank.
3.3.2.4 Pressure relief valve:
When the pressure in the tank raises above predetermined safe limit this valve operates
and performs the following functions:
 Allows the pressure to drop by instantaneously opening the port.
 Gives visual indication of valve operation by raising a flag.
 Operates a micro switch which gives command to breaker.
3.3.2.5 Oil temperature indicator:
It is a dial type thermometer works on the vapour pressure principle. The bulb which is
known as Probe is exposed to the temperature to be measured is connected by a length of
flexible tubing to a Burden gauge tube which is also known as ‘Operating Bellow’. This
bellow is filled with volatile liquid. The change in bulb temperature causes change in the
vapour pressure of the liquid and pointer moving on a dial calibrated in degree centigrade
indicates the consequent movement of the operating bellow. It has two pair of contacts
one for alarm and another for trip. In general the oil temperature alarm is set at 80o-85o C
and oil tripping is set at 85_90o C.
3.3.2.6 Winding temperature indicator:
This device measures the LV and HV winding temperature. A winding temperature

indicator or WTI is also used as protection of transformer. The basic operating principle
of WTI is same as OTI. But only difference is that the sensing bulb pocket on transformer
top cover is heated by a heater coil surrounded it. This heater coil is fed by secondary of
current transformers associated with transformer winding.

Hence the current through the heater coil is directly proportional to the current flowing
through transformer winding. This is because there is no scope of direct measuring of
temperature inside a winding. When load of transformer increases, the winding
temperature is also increased and this increased temperature is sensed by sensing bulb as
the heater coil surrounds it. Rest of the working principle of winding temperature
indicator is same as principle of oil temperature indicator.
3.3.3 Nitrogen injection instrument (CTR):
It Consists of fire extinguishing cubicle near the transformer, control box in control
room, fire detector on transformer tank top cover, specially designed non-retum valve in
conservator pipe between Buchholz relay and conservator tank, and signal box placed on
transformer. Fire extinguishing cubicle is connected to transformer tank by pipes for oil
drain and nitrogen injection. Cable connections are provided from signal box to Control
box and from Control box to Fire Cubicle.
Nitrogen injection fire prevention and extinguishing system designed for oil filled
transformer, shall prevent, tank explosion and the fire during internal faults resulting in
an arc where tank explosion will normally take few second explosion or external failures
like bushing fires, due to OLTC fires and fire from surrounding equipment’s.
This system works on the principle of “DRAIN AND STIR” and on activation, shall
drain a predetermine quantity of oil from the tank top through the outlet valve, to reduce
the tank pressure and inject nitrogen gas at high pressure from the lower side of the tank
through inlet valves to create stirring action and reduce the temperature of top oil surface,
below flash point to extinguish the fire. Conservator tank oil shall be isolated during tank
explosion and oil fire, to prevent aggravation of oil fire. Transformer isolation shall be an
essential precondition for activating the system. The system shall be designed to operate
manually, in case of failure of power source.
3.3.4 Current Transformer:
A current transformer (CT) is a type of transformer that is used to reduce or multiply an

alternating current (AC). It produces a current in its secondary which is proportional to
the current in its primary.

Current transformers, along with voltage or potential transformers, are instrument

transformers. Instrument transformers scale the large values of voltage or current to
small, standardized values that are easy to handle for measuring instruments and
protective relays. The instrument transformers isolate measurement or protection circuits
from the high voltage of the primary system. A current transformer provides a secondary
current that is accurately proportional to the current flowing in its primary. The current
transformer presents a negligible load to the primary circuit. Current transformers are the
current-sensing units of the power system and are used at generating stations, electrical
substations, and in industrial and commercial electric power distribution.
Figure 13 Current transformer
3.3.5 Potential Transformer:

Voltage transformers (VT), also called potential transformers (PT), are a parallel
connected type of instrument transformer. They are designed to present negligible load to
the supply being measured and have an accurate voltage ratio and phase relationship to
enable accurate secondary connected metering.
The PT is typically described by its voltage ratio from primary to secondary. A 600:120
PT will provide an output voltage of 120 volts when 600 volts are impressed across its
primary winding. Standard secondary voltage ratings are 120 volts and 70 volts,
compatible with standard measuring instrument

3.3.6 Bus bars:
In electric power distribution, a bus bar is a metallic strip or bar, typically housed
inside switchgear, panel boards, and bus way enclosures for local high current power
distribution. They are also used to connect high voltage equipment at electrical
switchyards, and low voltage equipment in battery banks. They are generally uninsulated,
and have sufficient stiffness to be supported in air by insulated pillars. These features
allow sufficient cooling of the conductors, and the ability to tap in at various points
without creating a new joint.
For any distribution assembly, the bus bar constitutes the real “backbone”. A bus bar is
designed and accordingly manufactured, sufficiently rigid to efficiently support its own
weight, and numerous forces imposed by mechanical vibration and also the
electromechanical forces provided during short circuit. The insulated bus bars are totally
enclosed in metallic enclosures of GI or Aluminum. Used in variety of configurations,
bus bars come in multitude of shapes and sizes such as solid bars, flat strips, or rods and
are commonly composed of copper, aluminum, and brass. Their cross sectional size and
material composition determine the amount of current that can be safely carried by the
bus bar.
Bus bars are popular because of:
➢ Reduced facility costs: The installation of bus bars is comparatively less

expensive and there are no outside labor costs for electrical specialists. They don’t
require routine maintenance and are less costly for remodeling or expansion. ➢ Easy
and Faster Installation: Bus bar are installed easily and quickly with no downtime.
➢ Environmentally Friendly: Depending upon the type, the bus bars require only
few installation materials and plug-in outlets are reusable and relocatable.
➢ Secure and Reliable: It replaces the cable distribution system which has its own
complication for fire hazard

Figure 15. Bus Bar
Types of Electrical bus bar arrangement
Bus bar is available in round, rectangular, cross-sectional and many other shapes. In
the power system, the rectangular bus bar is mostly used. Typically composed of
copper, aluminum and brass, a wide range of bus bar arrangement is used for power
distribution.
The various bus bar types are:
 Lightning
 Cast Resin system
 Isolated Phase Bus ducts
 Segregated Phase Bducts
 Non-Segregated Phase Bus ducts
When selecting bus bars, be sure to check its maximum temperature, amp rating,
size and VAC rating. It is equally important to determine whether you need to
purchase an enclosure or a cover for the bus bar system.
3.3.7 Lightening arrestor:
It is a device used on electric power systems and telecommunication systems to

protect the insulation and conductors of the system from damaging effects of
lightning. The typical lightning arrester has a high-voltage terminal and a ground
terminal.
When a lightning surge travels along the power line to the arrester, the current from

the surge is diverted through the arrester, in most cases to earth. Hence lightning
arrester is also called as lightning diverter. Surge protectors are the devices that are
connected between each electrical conductor in power and communications systems
and the earth. Their purpose is to limit the rise in voltage when a communications or
power line is struck by lightning strike.
If protection fails or is absent, lightning that strikes the electrical system introduces
thousands of kilovolts that may damage the transmission lines and can also cause
severe damage to transformers and other electrical or electronic devices. Lightning
arresters are used to protect electric fences.
The following are the damages that are caused by the travelling wave on the
substation equipment.
1. The high peak or crest voltage of the surge may cause flash-over in the internal
winding thereby spoil the winding insulation.
2. The steep wave fronts of the surges may cause external flash over between the
terminal of the transformer.
3. The highest peak voltage of the surge may cause external flash over between
the terminals of the electrical equipment.
Figure 16. Lightening Arrestor
3.3.8 Circuit breaker:
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. Its basic function is to interrupt current flow after a fault is detected. Unlike a
fuse, which operates once and then must be replaced, a circuit breaker can be reset
(either manually or automatically) to resume normal operation.
The generic function of a circuit breaker, a fuse, as an automatic means of removing

power from a faulty system is often abbreviated as OCPD (Over Current Protection
Device) circuit. Circuit breakers are usually installed in the electrical panel. Inside the
circuit breaker, there is usually an electromagnetic coil. When too much current flows
through the coil, it pulls on the switch, shutting the power off.
The coil reacts to immediate short circuits. There is also a bimetal strip that will bend
and pull on the switch if it gets too hot. This reacts to extended periods of too much
current. Some advanced circuit breakers monitor current electronically, and shut the
power off when an electronic sensor detects too much current. A circuit breaker does
the same job as a fuse, but unlike a fuse, a circuit breaker does not need to be replaced
to be reset, except in some severe cases such as very high-current short circuits and
lightning strikes that may damage the circuit breaker.
Operation of circuit breaker:
The circuit breaker must first detect a fault condition. In small mains and low voltage
circuit breakers, this is usually done within the device itself. Typically, the heating or
magnetic effects of electric current are employed.
Circuit breakers for large currents or high voltages are usually arranged with protective
relay pilot devices to sense a fault condition and to operate the opening mechanism.
These typically require a separate power source, such as a battery, although some
highvoltage circuit breakers are self-contained with current transformers, protective
relays and an internal control power source.
Once a fault is detected, the circuit breaker contacts must open to interrupt the circuit;
this is commonly done using mechanically stored energy contained within the breaker,
such as a spring or compressed air to separate the contacts. Circuit breakers may also

use the higher current caused by the fault to separate the contacts, such as thermal
expansion or a magnetic field. Small circuit breakers typically have a manual control
lever to switch off the load or reset a tripped breaker, while larger units use solenoids
to trip the mechanism, and electric motors to restore energy to the springs.
The circuit breaker contacts must carry the load current without excessive heating, and
must also withstand the heat of the arc produced when interrupting (opening) the
circuit. Contacts are made of copper or copper alloys, silver alloys and other highly
conductive materials. Service life of the contacts is limited by the erosion of contact
material due to arcing while interrupting the current. Miniature and moulded-case
circuit breakers are usually discarded when the contacts have worn, but power circuit
breakers and high-voltage circuit breakers have replaceable contacts.
When a high current or voltage is interrupted, an arc is generated. The length of the arc
is generally proportional to the voltage while the intensity (or heat) is proportional to
the current. This arc must be contained, cooled and extinguished in a controlled way,
so that the gap between the contacts can again withstand the voltage in the circuit.
Different circuit breakers use vacuum, air, insulating gas, or oil as the medium the arc
forms in. control lever to switch off the load or reset a tripped breaker, while larger
units use solenoids to trip the mechanism, and electric motors to restore energy to the
springs.
Figure 17. Circuit breaker

3.3.9 Capacitor bank:
A Capacitor Bank is a group of several capacitors of the same rating that are connected
in series or parallel with each other to store electrical energy. The resulting bank is then

used to counteract or correct a power factor lag or phase shift in an alternating current
(AC) power supply. They can also be used in a direct current (DC) power supply to
increase the ripple current capacity of the power supply or to increase the overall amount
of stored energy.
Capacitor banks are generally used for improving power factor of electricity consumed
by bulk consumers e.g. industry. Usually the electrical power supply companies impose a
penalty, if the average power factor over a stipulated period falls below a certain value. A
large part of load of bulk consumers are inductive in nature because of use of induction
motors. This causes low power factor (lagging because of predominately inductive loads).
Capacitors, on the other hand, constitute leading power factor load; thus, compensating a
major part of the inductive loads and result in power factor close to unity but still lagging
in nature. This improvement of power factor full fills the requirements of the supply
company. Loads with low power factor draw more current from supply than same active
load with high power factor and hence cause increased power loss in supply line. This
increase of power loss is a waste for the supply company. Further supply companies need
to install higher size transmission distribution equipment to supply the additional load
current because of low power factor.
Heavy loads are inductive in nature. Which means current will lag voltage so power
factor is less. Losses will increase. So, we need to reduce the inductive nature of the
loads. That can be done by capacitor banks. These capacitors just cancel the effect of
inductance and power factor increases. So, losses are reduced.
Capacitor banks work on the same theory that a single capacitor does; they are designed
to store electrical energy, just at a greater capacity than a single device. An individual
capacitor consists of two conductors which are separated by a dielectric or insulating
material. When current is sent through the conductors, an electric field that is static in
nature then develops in the dielectric which acts as stored energy. The dielectric is
designed to permit a predetermined amount of leakage which will gradually dissipate the
energy stored in the device which is one of the larger differences between capacitors and
batteries.

3.3.10 Isolator:
Circuit breaker always trip the circuit but open contacts of breaker cannot be visible
physically from outside of the breaker, and that is why it is recommended not to touch
any electrical circuit just by switching off the circuit breaker. So for better safety, there
must be some arrangement so that one can see the open condition of the section of the
circuit before touching it.
The isolator is a mechanical switch which isolates a part of the circuit from the system
as when required. Electrical isolators separate a part of the system from rest for safe
maintenance works. So the definition of isolator can be rewritten as an isolator is a
manually operated mechanical switch which separates a part of the electrical power.
Isolators are used to open a circuit under no load. Its main purpose is to isolate one
portion of the circuit from the other and is not intended to be opened while current is
flowing in the line.
Isolators are generally used on both ends of the breaker so that repair or replacement of
circuit breaker can be done without any danger.
Types of Electrical Isolators:
There are different types of isolators available depending upon system requirement such
as
• Double Break Isolator
• Single Break Isolator
• Pantograph type Isolator.
Depending upon the position in the power system, the isolators can be categorized as
➢ Bus side isolator - the isolator is directly connected with main bus
➢ Line side isolator - the isolator is situated at line side of any feeder
➢ Transfer bus side isolator - the isolator is directly connected with transfer bus.

Figure 18. Isolator
Operation of Electrical Isolator:
As no arc quenching technique is provided in isolator it must be operated when there is

no chance current flowing through the circuit, no live circuit should be closed or open by
isolator operation.
A complete live closed circuit must not be opened by isolator operation, and also a live
circuit must not be closed and completed by isolator operation to avoid huge arcing in
between isolator contacts. That is why isolators must be open after circuit breaker is open,
and these must be closed before circuit breaker is closed. Can be operated by hand locally
as well as by motorized mechanism from a remote position.
Motorized operation arrangement costs more compared to hand operation; hence

decision must be taken before choosing an isolator for the system whether hand operated
or motor operated economically optimum for the system. For voltages up to 145 KV
system hand operated isolators are used whereas for higher voltage systems like 245 KV
or 420 KV and above motorized isolators are used.
3.3.11 Batteries:
In large power stations or substations, the operation of lighting, relay system, or control
circuits are powered by batteries. These batteries are connected to a part of the
accumulator cell based on the operating voltage of the particular DC circuit.
Batteries acts like the heart of the substation without battery the substation can never
operate the batteries used in the Hoody Receiving station have a capacity of 220V DC

power there were usually two sets of batteries, if any set of battery fails to operate the
other set kept as spare comes into picture there were 11 sets each of 2V capacity. Since
for the operation of relays circuit breakers, and pic need DC supply without batteries
neither of this operates thereby doesn’t provide proper protection for the power system
equipment’s. Hence battery providing DC supply is called as the heart of the substation.
Figure 19. Battery Sets
3.4 Earthing:
In an electrical installation, an earthing system or grounding system connects specific

parts of that installation with the Earth's conductive surface for safety and functional
purposes. The point of reference is the Earth's conductive surface. The choice of earthing
system can affect the safety and electromagnetic compatibility of the installation.
Regulations for earthing systems vary considerably among countries, though most follow
the recommendations of the International Electro technical Commission.
In addition to electric power systems, other systems may require grounding for safety or
function. Tall structures may have lightning rods as part of a system to protect them from
lightning strikes. Telegraph lines may use the Earth as one conductor of a circuit, saving
the cost of installation of a return wire over a long circuit. Radio antennas may require
particular grounding for operation, as well as to control static electricity and provide
lightning protection.

Figure 20. Earthing mat for substation
Types of Earthing:
■ Neutral Earthing: Deals with the earthing of system neutral to ensure system security
and protection.
■ Equipment Earthing: Deals with earthing of non-current carrying parts of equipment

to ensure safety to personnel and protection against lightning.
3.5 Degasification
Transformers play an important role in the electrical power industry. Transformers

convert power to appropriate levels for other system components to safely use.
Transformers need to be maintained to guarantee long life. Moreover, a good quality and
clean oil is essential for the transformer to provide efficient performance.
Transformer oil tends to degrade over time. The oil is exposed to undesirable materials
like acids, metal dust, moisture etc. When transformers contain dissolved gases, dust, and
other contaminants, it is time to take action for the oil to be filtered and purified.
Transformer maintenance and services centers maintain high quality equipment for
treating oil using in line transformer oil filtration techniques. These techniques help
sustain an excellent performance, safety and ease of operation for transformer
maintenance staff.
Oxygen found in transformer oil leads to oxidation and significantly reduces the
dielectric strength of the oil and the insulating system. In general, under normal

atmospheric pressure, the insulating oil contains approximately 10% of atmospheric air.
The higher the temperature, the better the dissolution of air in oil will be. It is highly
important to understand that the composition of atmospheric air and the air dissolved in
oil, differ greatly.
Figure 21. Degasification process
Atmospheric air is comprised of 78% nitrogen and 21% oxygen. When that same air is
dissolved in oil, it becomes comprised of 69.8% nitrogen and 30.2 oxygen. Transformer
oil degassing is a complex of processes targeted at the removal of water, gasses, and
mechanical impurities from the dielectric oil. The following methods may be used for
drying the oil.
Oxygen found in transformer oil leads to oxidation and significantly reduces the
dielectric strength of the oil and the insulating system. In general, under normal
atmospheric pressure, the insulating oil contains approximately 10% of atmospheric air.
The higher the temperature, the better the dissolution of air in oil will be. It is highly
important to understand that the composition of atmospheric air and the air dissolved in
oil, differ greatly. Atmospheric air is comprised of 78% nitrogen and 21% oxygen. When
that same air is dissolved in oil, it becomes comprised of 69.8% nitrogen and 30.2
oxygen. Transformer oil degassing is a complex of processes targeted at the removal of
water, gasses, and mechanical impurities from the dielectric oil. The following methods
may be used for drying the oil.
3.5.1 Centrifugation:

In this case, mechanical impurities and water are removed from oil, influenced by
centrifugal forces. In practice, this method is applied mainly for oils that will be used for
equipment with a voltage of no less than 35 kV.
3.5.2 Adsorption:
Water and impurities are removed by using mineral and synthetic adsorbents. This
method allows for the removal of water dissolved in the oil;
1)Vacuum drying:
Oil is heated up and then is pumped through a degasifier. Vacuum processing is

considered to be the most effective method since it removes dissolved water and gasses
from the oil. This process is realized either by spraying oil in vacuum chambers or using
special heaters that are evenly distributed in the vacuum chamber utilizing Raschig rings
and grid packing’s. There are special oil degassing units used to perform the degassing
and vacuumising processes.
The main part of such equipment is a degasifier that consists of two tanks. The vacuum in
the tanks is created by vacuum pump system. Additionally, there are spraying devices on
the tank cap that distribute oil evenly in the vacuum chamber. Oil Degassing takes place
when oil flows in thin streams on the surface of Raschig rings. The method of vacuum
spraying is based on the spraying of the oil and water solution in the vacuum by a
pulverizing jet into a special tank. These processes allow for the removal of free and
dissolved moisture as well as dissolved air. If the level of oil dispersion is adequately
thin, it easily gets rid of moisture.
Vacuum drying includes three main stages such as:

1. Breakdown voltage increases very sharply due to the removal of emulsion water.
2. There are minor changes of the breakdown voltage of oil (60 kV) At this time

dissolved and loosely-coupled water is removed.
3.5.4 Transformer Oil and Its Functions:
➢ As cooler: When voltage goes up/down, the temperature of the transformer’s

windings increases, oil is used to cool down the condition.
➢ As insulator: It acts as an insulator between the windings. It increases the resistance

between them and avoids short circuit.
➢ For security: It operates the level of oil inside the transformer. The temperature
display of oil describes the inner condition of transformer and shows any short circuit
status. In this way, you will prevent the transformer from being severe losses and
damages.
3.5.5 Types of insulating oil
1. Paraffin based - derived from special crudes that contain substantial amount of n-
…..paraffin. This type of insulating oil is less oxidized than naphtha based.
2. Naphtha based - derived from special crudes that contain low amount of n- paraffin.
During the usage of insulating oil, it may be exposed to materials which can affect its
quality. It fails to function due to factors such as excessive high temperature, oxidation
and many more. Consequently, the oil darkens in color and the acid in it begins to
increase. Oil impurities are one of the major causes of transformers deterioration, hence
oil tests are to be conducted regularly for proper protection of transformer.
3.5.6 Benefits of transformer oil filtration …

 .Insulation properties of the oil is improved.
 Longer life span of transformers.
 Lessens transformer’s breakdown.
 Good returns on investment for having a quality machine.
Once the insulating oil fails to undergo this process, it can lead to:
 Arcing - formation of an electric arc which causes breakdown of the system.

 Overheating - oil overheating.

 Corona discharges - electrical discharge caused by the ionization of fluid.
 Insulating strength of the transformer oil will decrease.
> These properties are to be tested to determine the qualities of the insulating oil:
■ Water Content.
■ Neutralization Value.
■ Interfacial Tension.
■ Colour and appearance.
■ Test for Oxidation Stability.
■ Specific Resistance (Resistivity).
■ Flash Point.
■ Pour Point.
■ Viscosity.
■ Sludge Test.
■ Dissolved Gas Analysis (DGA).
■ To further understand how the transformer oil is tested, below is the process.
■ Insulating oil filtration process.
■ Rising oil temperature.
■ First step is to raise oil temperature up to 65°C to give latent heat which separates
moisture and gases. Heating the oil will make it easier to filter because of the
decrease in oil viscosity.
■ Removal of dirt and impurities.
■ Second step is to remove sludge and dirt from the insulating oil. There are 2 ways
to eliminate dirt in the transformer oil.
■ By filter candles.
■ Insulating oil filtration by filter candles can be classified by using classical edge
filter or depth type filter. However, new advancements were made in which
transformer oil filtration machines use filter cartridges instead of edge type paper
filters.
■ By centrifuging action.
■ Another method for separating dirt from oil is through centrifuging. With this

process, you can save recurring cost of changing filters.

■ Dehydration and de gasification of insulating oil.
Figure 22. Instrument used for degasification
Degasification process was conducted in the hoody receiving station on ICT 1 ‘B’
phase transformer and the oil was sent for suitable tests to the KPTCL laboratory.
3.6 Line Clearing:
Line clearance is process where the transmission line connecting two sub stations or
two receiving stations are opened for the purpose of maintenance or for the purpose of
repairing any damaged equipment.
Before opening the line, the permission should be taken from the Load Dispatch
Centre located at Anand Rao Circle in Bangalore they will be given a LC code after
obtaining this code only the two substations should contact each other mutually and
simultaneously the line should be opened at both the stations, by tripping the circuit
breaker and proper care should be taken that in no case without any prior, notice the
line should be charged. In the Hoody Receiving station the line clearance was taken
from 14th of July 2019 to 17th of July ontheNelmangala-1 and Nelmangala-2 line for
the purpose of extending a line to Kolar through the way of this transmission line.
During this process various equipment’s in the receiving station were checked for
their proper functioning and they were properly checked for their insulation. The
isolators were applied with petroleum jelly so that it protects them from rusting and for

smooth operation of the equipment’s.
Figure 23. Line Mans Working during line clearing
Meggering readings for some of the instruments in the Nelamangala-1 line during the
line clearing is as shown in the tables:
Lightning Arrestor:
B- PHASE
Table 3. Megger measured resistance values of Lightening Arrestor B- PHASE
Time period T15 T60 T180
1st Top - 116 G ohm 126 G ohm
2nd 91.3 G ohm 163 G ohm 185 G ohm
3rd 15.6 G ohm 41.6 G ohm 58.3 G ohm
Bottom 2.55 G ohm 2.74 G ohm 2.84 G ohm
Y-PHASE

Table 4. Megger measured resistance values of Lightening Arrestor Y- PHASE
Time Period T15 T60 T180
1st Top 18.5 G ohm 0.7 G ohm 62.7 G ohm
2nd - 8.7 G ohm 81 G ohm
3rd >1.9 G ohm 3.3 G ohm 81.7 G ohm
Bottom Z.55 G ohm .74 G ohm 2.84 G ohm
R-PHASE
Table 5. Megger measured resistance values of Lightening Arrestor R- PHASE
Top >2.6 G ohm 7.4 G ohm 59.0 G ohm
Mid >5.6 G ohm 71 G ohm 72.5 G ohm
Bottom 18.6 G ohm 5.7 G ohm 48.9 G ohm
CVT:
R- PHASE
Table 6. Megger measured resistance values of CVT R-PHASE Y-PHASE

Top 100 G ohm >26 G ohm 586 G ohm
Mid 243 G ohm >08 G ohm 587 G ohm

Bottom 16.5 G ohm 8.0 G ohm 120 G ohm
Top >.08 G ohm 160 G ohm 428 G ohm
Mid 13.4 G ohm >00 G ohm 708 G ohm

Table 7.
Bottom 17.6 G ohm >44 G ohm 180 G ohm Megger
measured resistance values of CVT Y-PHASE B-PHASE
Table 8. Megger measured resistance values of CVT B-PHASE

Time Period I T15 I T60 I T180
Top 18.1 G ohm .03 T ohm 500 G ohm
Mid 266 G ohm >33 G ohm 908 G ohm
Bottom £6.5 G ohm 17 G ohm 670 G ohm
Table 9. Megger measured resistance values of CT R-Y-B-PHASE

T15 T60 T180
Time period
R-PHASE 20.8 G ohm 27.4 ohm 25.2 G ohm
Y-PHASE 22.9 G ohm 30.1 ohm 26.6 G ohm
B-PHASE - 27.3 ohm 26.3 G ohm

Figure 24. Control board for opening of isolators
charging of line also the in-charge members from both the station should contact each
other simultaneously and then the line charging should be taken place. The procedure
carried out during the line charging process is that, after the work is completed the
earthing rods connected to all the equipment’s and the earthing of the substation should
be removed so that when the line is charged no current should pass through the ground , if
such a large amount of current passes through the ground then it would cause a large
disaster in the surroundings, Hence a large amount of care should be taken that the
earthing should never be connected during the line charging.
After seeing to this the members in charge in both the stations should communicate with
each other and should inform the load dispatch center and obtain a LC code after
obtaining the LC code both should inform each other about the code and only if the code
matches with each other than the line should be charged until then the line should never
be charged. Once the line is charged all the equipment’s should be checked for their
proper operation and if any fault it should be rectified and sorted out immediately without
any delay.
The line clear in Hoody receiving station was taken from 14th of July and the line was
charged on 17th of July during his period all the equipment’s were thoroughly inspected
and proper servicing were done to the equipment’s which needed servicing.

Figure 25. Line man taking resistance value of Current Transformer
3.7 Equipment’s maintenance lists:
➢ GOS:
■ Tightening or replacing of clamps, bolts, and nuts on the basis of thermo vision
scanning readings which is done every month.
■ Applying petroleum jelly for male and female contacts.
■ Oiling for rotary or moving joints.
➢ 4 Relays and meters:
■ To check the calibration of relays and meters yearly by RT staff.
➢ Current transformer:
■ Checking the secondary connection in marshalling box.
■ IR test is done and its values should be of minimum value (500 M ohm).
■ Tightening or replacing of clamps, bolts and nuts on the basis of thermo vision
➢ Breaker:
■ Checking of auto start/stop of compressor motors for maintaining air pressure of

breaker at rated pressure.
■ Checking SF6 gas and air leakage points.
■ Checking of contacts of breaker on monthly basis.
■ Checking of compressor oil on quarterly basis.

■ Checking of air and SF6 gas pressure by taking the values daily.
■ The Megger values must be of 500M ohm.
➢ Conductors:
■ In case of de-stranded conductors or deteriorated conductors will be replaced new.
■ If conductors are carbonized/ melts and if it loses its conductivity then it will be
replaced new.
➢ Bus bar:
■ Bus conductors will be strengthened while carrying out maintenance work and all junction clamps
will be tightened as per thermo vision scanning report.
■ Tightening or replacing of clamps, bolts and nuts on the basis of thermo vision scanning readings
which is done every month.
> Power transformers:
■ Checking of bolts and nuts on either side of HV and LV bushings.

■ To release the air pressure collected in the buchholz relay.
■ In breather, the colour of silica gel is checked. If the colour is changed from bluish to pinkish
white then the gel will be replaced for healthy working conditions.
■ In tap changing, the winding contacts are checked.
■ Oil conditions are examined every year.
■ Visual inspection of oil level in OLTC and conservative tank is verified.
■ Cooler fan bearing, motor, radiator bolts, oil pipeline valves and tubes are checked
on quarterly basis.
■ IR test will be carried out on monthly basis.

➢ Feeders:
■ To check the values of Amps/Volts/MW hourly to record consumption of particular

feeders.
■ For 11KV breakers/ switchgear, the checking of tripping and closing circuits is done
every half year.
■ Vacuum interrupter maintenance will be carried out quarterly to keep up the healthy
operation of breaker.
■ Spring charge mechanism is also checked.
■ The operation of switchgear on relays is checked.
➢ Capacitor bank:
■ Individual cells are checked, if the capacitance is lower than the required standard
value then the respective cell is replaced.
■ To maintain constant standard MV AR values.
■ Tightening or replacing of clamps, bolts, and nuts on the basis of thermo vision
➢ DG set:
■ Cleaning and checking of oil and fuel once in every half yearly.
➢Nitrogen injection instrument (CTR):
■ Replacing of nitrogen gas cylinder after every usage once in a year.
■ Nitrogen injector (CTR) will be locked while carrying out maintenance work to
avoid malfunctioning.

➢ Batteries:
■ Cleaning and applying petroleum jelly for battery terminals.

■ The specific gravity of the batteries are daily inspected which should lie in between the range of
1190-1240 C
■ Each cell should carry a voltage in between 1.8-2.2 V.
■ To check pilot cell readings on daily basis.
■ Adding Sulphuric acid if the standard value of electrolyte is low and adding distilled water if the
specific gravity is above 1240 C.
3.8 General Maintenance:
1. Checking of DC emergency lamps in control room.
2. Painting of transformers, Breakers, structures etc. once in 5 years.
3. Painting of Nameplates, Phase indicators, Bay indicators and earth electrodes.
4. Outdoor yard illumination, checking and replacement of bulbs etc.
5. Cleaning of control and relay panels (Internal), Vermin proof for cable entry, earth
……….connections.
6. Cleaning of battery charger and checking of earth connections.
7. Checking DC positive and negative voltages with references to earth to know any ………..DC
………..leakage. .
8. Operation of DG set if provided and to run for 10 minutes for its battery charging.
3.9 Load Flow

Load flow is known as the amount of load that flows from the substation. A regular
maintenance of load flow should be done every day in the substation, load details on each
and every line will be taken on hourly basis and noted done 24 hours around the clock,
there will be a shift wise in charges for taking down this reading and the in charge of one
shift should report the details of any line clearing or any line open instances to the

upcoming shift in charge.
CHAPTER 4
REFLECTION TEST
4.1 Introduction
From this internship we’ve observed the maintenance done in a regular basis to ensure
proper functioning of the equipment. Since any major damage can cause a lot of loss,
maintenance is very important so to avoid it. KPTCL being a company which is
required to provide a continuous reliable supply takes care of the equipment thoroughly,
failing to do so, leads to major damage and loss.
The personnel over there all actively perform the maintenance to achieve this. We have
also visited various substation and maintenance over there as well. The specialty of each
substation has been observed. We have learnt the task being carried out, as daily,
weekly, and monthly routine checking of equipment for efficient running on a daily
basis. We have every reading of the equipment’s which is already in above phrases. We
have learnt the Maintenance of all the equipment’s of substation and voltage reactor
erection and battery discharging ways has been taught in detail.
4.2 Transformer Test
4.2.1 Ratio test
The performance of a transformer largely depends upon perfection of specific turns or

voltage ratio of transformer. So, transformer ratio test is an essential type test of
transformer. The voltage should be applied only in the high voltage winding in order to
avoid unsafe voltage.
Ratio Test of Transformer and Check of Phase Displacement
Actually, the no load voltage ratio of transformer is equal to the turn ratio.
Procedure of Transformer Ratio Test:
1. First, the tap changer of transformer is kept in the lowest position and LV
terminals are kept open

2. Then apply 3-phase 415 V supply on HV terminals. Measure the voltages

applied on each phase (Phase-phase) on HV and induced voltages at LV terminals
simultaneously.
3. After measuring the voltages at HV and LV terminals, the tap changer of

transformer should be raised by one position and repeat test.
The above transformer ratio test can also be performed by portable transformer turns
ratio (TTR) meter. They have an in-built power supply, with the voltages commonly
used being very low, such as 8-10 V and 50 Hz. The HV and LV windings of one phase
of a transformer are connected to the instrument, and the internal bridge elements are
varied to produce a null indication on the detector.
Let’s have a discussion on transformer turns ratio (TTR) meter method of turn ratio test
of transformer. A phase voltage is applied to the one of the windings by means of a
bridge circuit and the ratio of induced voltage is measured at the bridge. The accuracy
of the measuring instrument is this theoretical turn ratio is adjusted on the transformer
turn ratio tested or TTR by the adjustable transformer as shown in the figure above and
it should be changed until a balance occurs in the percentage error indicator.
Figure 26. Ratio testing of transformer
The reading on this indicator implies the deviation of measured turn ratio from
expected turn ratio in percentage. Out-of-tolerance, ratio test of transformer can be due
to shorted turns, especially if there is an associated high excitation current. Open turns
in HV winding will indicate very low exciting current and no output voltage since open
turns in HV winding causes no excitation current in the winding means no flux hence no
induced voltage.
But open turn in LV winding causes, low fluctuating LV but normal excitation current

in HV winding. Hence open turns in LV winding will be indicated by normal levels of

exciting current, but very low levels of unstable output voltage. The turn ratio test of
transformer also detects high resistance connections of the lead circuitry or high contact
resistance in tap changers by higher excitation current and a difficulty in balancing the
bridge .
4.2.2 Megger test
Insulation Resistance or IR Test is carried out by maintenance engineers to ensure the

healthiness of overall insulation system of an electrical power transformer. It reflects the
presence or absence of harmful contamination, dirt, moisture and gross degradation.
IR will be usually high (several hundred Mega ohms) for a dry insulation system.
Maintenance engineers use this parameter as an index of dryness of the insulation
system. This test is performed at or above rated voltage to determine if there are low
resistance paths to ground or between winding to winding as a result of winding
insulation deterioration. The test measurement values are affected by variables such as
temperature, humidity, test voltage, and size of transformer. This test should be
conducted before and after repair or when maintenance is performed. The test data
should be recorded for future comparative purposes. The test values should be
normalized to 20°C for comparison purposes.
Figure 27 Megger test equipment of transformer
4.2.3 Open Circuit test:
The open-circuit test, or "no-load test", is one of the methods used in electrical

engineering to determine the no-load impedance in the excitation branch of a transformer.

The secondary of the transformer is left open-circuited. A wattmeter is connected to the
primary. An ammeter is connected in series with the primary winding. A voltmeter is
optional since the applied voltage is the same as the voltmeter reading. Rated voltage is
applied at primary.
Figure 28. Open circuit test of transformer
If the applied voltage is normal voltage then normal flux will be set up. Since iron loss
is a function of applied voltage, normal iron loss will occur. Hence the iron loss is
maximum at rated voltage. This maximum iron loss is measured using the wattmeter.
Since the impedance of the series winding of the transformer is very small compared to
that of the excitation branch, all of the input voltage is dropped across the excitation
branch. Thus, the wattmeter measures only the iron loss. This test only measures the
combined iron losses consisting of the hysteresis loss and the eddy current loss. Although
the hysteresis loss is less than the eddy current loss, it is not negligible.
The two losses can be separated by driving the transformer from a variable frequency
source since the hysteresis loss varies linearly with supply frequency and the eddy current
loss varies with the square. Since the secondary of the transformer is open, the primary
draws only no-load current, which will have some copper loss. This no load current is
very small and because the copper loss in the primary is proportional to the square of this
current, it is negligible. There is no copper loss in the secondary because there is no
secondary current.
The secondary side of the transformer is left open, so there is no load on the secondary

side. Therefore, power is no longer transferred from primary to secondary in this

approximation, and negligible current goes through the secondary windings. Since no
current passes through the secondary windings, no magnetic field is created, which means
zero current is induced on the primary side. This is crucial to the approximation because
it allows us to ignore the series impedance since it is assumed that no current passes
through this impedance.
4.3 Erection of voltage reactor:
This technical article deals with transformers and their installation so we restrict
ourselves here to the procedures associated with their commissioning. Transformers
should be inspected for internal or external damage, particularly if they have been
dropped or tipped over.
This should include such items as:
1. Drain valves, selector switches,
2. Conservator tanks,
3. Buchholz relays and
4. Winding temperature indicators.
All transformers must be tested for winding insulation resistance and the readings
confirmed as acceptable. However, HV D.C. tests on a cable connected transformer
cannot be done because the windings of the transformer short out the dc test set. If
between-core tests are required on transformer feeder cables after installation then a link
box must be provided to disconnect the cable from the transformer windings,If
transformer covers are taken off to achieve internal disconnection the tools used must be
clean and secured externally by white tape so that they may be recovered if
inadvertently dropped.
Waterproof covers should be provided during the period when the transformer tank is
open. If it is not possible to disconnect the cables after jointing they must be tested
beforehand. This means that the jointing and testing program must be carefully planned
to avoid leaving cable ends unsealed for long periods.

Transformer diagrams should be inspected and the phasing diagram confirmed as

correct. Also, before energizing, the voltage selector must be set on the appropriate
tapping having regard to the voltage level of the system.
Transformers which are to operate in parallel must be set on the same tapping and
they should be checked as having the same impedance. Voltage selectors should be
locked in their set position and if they are of the ‘off-circuit’ type they must not be
adjusted without the supply being first switched off. Where special tests for losses, ratio,
phase angle or winding resistances are specified the assistance of the manufacture
should be sought.
Figure 29. Voltage Reactor
4.4 Substation visited:
4.4.1 220KV substation located at Hoody
Single line diagram is the simplified way of representing three phase power system. The
electrical elements such as circuit breakers, transformers, capacitors, bus bars and
conductors are shown by the standardized schematic symbols.
The below diagram shows the single line diagram of 220/66/1 l1kv receiving station of
hoody. It consists of two bus bars, six incoming lines from Hebbal, Nelamangala, Begur,
Malur, Railway-1 and 2. It consists of three auto transformers, capacitive voltage
transformers, potential transformers, bus couplers and outgoing lines are Hoody-1 and2,
BMRCL, ITI, Shantiniketan, HAL-1 and 2, Graphite India, EPIP, Brigade metropolis,
EPIP 1 and 2, HP, Kadugodi, Pottery Road.

Figure 30 220KV substation located at Hoody
CHAPTER 5
CONCLUSION
Substation forms an important link between two transmission networks or between the
transmission line and distribution network. It has vital influence on reliability of service.
Apart from ensuring efficient transmission and distribution of power, the substation

configuration should be such that it enables easy maintenance of equipment and

minimum interruption in power supply.
By seeing the above Scenario, we can finally conclude that the Hoody Receiving station
which is found to be one of the most important receiving station for the Bangalore
region. The station was built a way long back and all the equipment’s have been used
for almost several years and the equipment’s need proper maintenance and few
equipment’s have become so old that they have to be replace.
Here one more speciality of the station is there is an open type lead acid battery, excide
made are still in service with their fine D.C backup and the maintenance department
take special care about this battery continuously throughout the day since they act as the
heart of the substation. Every hour the acidity level of distilled water is checked using
the hydrometer.
Construction of voltage reactor is taking place so that it can protect the costly
transformers as the starting current of the transformers will be high such high starting
current will damage the windings of transformers hence for protection such voltage
reactor is necessary which is being constructed now.
REFERENCES
1. KPTCL training report “Remote Substation Monitoring and Control through SC AD

A”, 05-09 October 2009 Paper presented
2. Martin Chartrand, “Dual Redundant Controller Systems”, Control Microsystems

White Paper, October 2004.
3. Chandrashekar, Mallakkappa S “Integrated Extended SC ADA project KPTCL” IES

Summary, October 31 2007. Manuals and website
4. ABB RTU560A Manual. www. KPTCL. com and www. abb. com




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STUDY THE MAINTENANCE ON 220 KV SUBSTATION 2022-23

Electric power network is interconnection of generation, transmission and distribution

Department of EEE 1 MVJCE

CHAPTER 1 : ABOUT THE COMPANY 01-05

Department of EEE 2 MVJCE

Department of EEE 3 MVJCE

LIST OF THE FIGURE

Fig. no Name of the Figure

Department of EEE 4 MVJCE

Figure 29 Voltage Reactor 60

Department of EEE 5 MVJCE

Table 1 Capacity allocated to ESCOM’S 04

Department of EEE 6 MVJCE

ABOUT THE COMPANY

1.1. INTRODUCTION TO KPTCL

Figure 1. Symbol of KPTCL

Figure 1.2. KPTCL Corporate Office

Figure 2. KPTCL Corporate Office

Department of EEE 7 MVJCE

Karnataka Power Transmission Corporation Limited, also known as KPTCL, is a

Karnataka Power Transmission Corporation Limited (KPTCL) is the sole electricity

KPTCL is headed by a Chairman and Managing Director at the corporate office. He is

1.2 MISSION STATEMENT OF KPTCL

The mission of Karnataka power Transmission Corporation Limited (KPTCL) is to

• Encouraging best practices in transmission and distribution.

• Ensuring high order maintenance of all its technical facilities.

• Emphasizing the best standards in customer service.

Department of EEE 8 MVJCE

♦ Constitution of Electricity Regulatory Commission.

1.4 PLANS FOR FUTURE

■ Projection of demand and energy requirements for a period of ten years.

Department of EEE 9 MVJCE

The benefit of additional energy that is expected to be available through system

1.6 CAPACITY ALLOCATION TO ESCOMs:

Department of EEE 10 MVJCE

Commission’s Analysis Decision:

Department of EEE 11 MVJCE

The mission of the Karnataka Power Transmission Corporation Limited is to ensure

➢ Meticulously plan the maintenance works well in advance.

➢ Obtain the concurrence of the jurisdictional BESCOM O & M Executive Engineer,

Department of EEE 12 MVJCE

2.1 DAILY MAINTENANCE WORKS: (ALL EQUIPMENTS)

• Inspection of Battery charger.

• Visual inspection of Oil level in bushings, O.L.T.C, silica Gel in Breakers

• Recording number of OLTC operations in a day and recording cumulative number of

• Observing abnormal change in transformer humming sound.

• Cleaning of outdoor yard, Earth Electrode pits

• Operation of DG sets & to run for 10 minutes

• Review of Log Books I Reports of Shift Engineers.

2.2 WEEKLY MAINTENANCE WORKS: (ALL EQUIPMENTS)

■ Checking of Auto Start/ Stop of Compressors /Pumps of Breakers.

Department of EEE 13 MVJCE

2.3 MONTHLY MAINTENANCE WORKS: (ALL EQUIPMENTS)

➢ Cleaning and applying petroleum Jelly for Battery terminals

■ Checking of Bushings and oil level.

■ Tightening Earthing cap of Capacitor bushing.

■ Checking of Oil leaks, (if any) and rectification.

■ Air release in main tanks/ Buchholz Relays, bushings turret.

■ Checking transformer Alarm Trip Circuit.

■ Tightening Transformer Neutral earth connections.

✓ Measurement of IR values and PI for condition monitoring.

Department of EEE 14 MVJCE

■ Testing of main 11 tank Oil for DGA I PPM etc