A

Summer Training Report

ON
33/11 KV Sub Station

Completed At 33/11 KV
Sub Station Old Power House Karnal
Duration
09 July 2018 to 02 Sept. 2018
Submitted by

UDAY

Roll no. - 1511160021

B.Tech,4th Year

Electrical Engineering Department

Ch. Devi Lal State Institute of Engineering& Technology,

Panniwala Mota,Sirsa-125077
 ACKNOWLEDGEMENT

I feel profound happiness in forwarding this industrial training report as an image of sincere
efforts. It is almost inevitable to ensure indebtedness to all who generously helped by sharing
their valuable experience & devoting their precious time with us, without whom this seminar
report would have never been accomplished.

First & foremost I extend my thanks & gratitude to the entire unit of “33/11 KV Old Power
House City Sub Division Karnal” whose guidance, teaching and invaluable suggestions
provided me a deep insight in my chosen field of technology, enhanced my knowledge and
supported in widening my outlook towards the industry.

Uday
 DECLARATION
I Uday, STUDENT OF BACHELOR OF TECHNOLOGY, IN THE
DEPARTMENT OF ELECTRICAL ENGG. CH. DEVI LAL STATE INSTITUTE OF
ENGINEERING AND TECHNOLOGY PANNI WALA MOTA , SIRSA UNDER CLASS ROLL
NO:- 1511160021, FOR THE SESSION:- 2015-2019 HEREBY DECLARE THAT ENTITLED, “
HAS BEEN COMPLETED BY ME IN 7th SEM . THE MATTER EMBODIED IN THIS
REPORT HAS NOT BEEN SUBMITTED EARLIER FOR AWARD OF ANY DEGREE TO THE
BEST OF MY KNOWLADGE & BELIEF

UDAY
TABLE OF CONTENTS

1. Introduction to Sub Station

1.1 ELEMENTS OF SUB STATION

1.2 ENERGY CONSERVATION

1.3 VISION

1.4 MISSION

1.5 INTRODUCTION OF TRANSFORMER

1.6 IDEAL TRANSFORMER

1.7 BASIC NEED OF TRANSFORMER

2. Transformer

2.1 WHAT IS A TANSFORMER ?

2.2 ROLE OF TRANSFORMER

2.3 We need transformer at every Stage

2.4 TYPES OF TRANSFORMER

2.5 PRINCIPLE OF TRANSFORMER

2.6 TRANSFORMER LOSSES
2.7 PHASE DISPLACEMENT:
2.8 TESTING OF TRANSFORMER AT SITE
2.9 ACCEPTABLE VALUES of TRANSFORMER:
2.10 TRANSFORMER NEUTRAL RESISTANCE BELOW ONE
OHM
2.11 VARIOUS PARTS OF TRNSFORMER
2.12 PROTECTIVE DEVICES MOUNTED ON TRANSFORMER

3. Maintenance Of Transformer

3.1 CAUSES OF FAILURE OF TRANSFORMER

3.2 TYPES OF FAULT ON TRANSFORMER
i
 3.3 PROBLEMS RESULTING FAILURE OF TRANSFORMER
3.4 MAINTENANCE SCHEDULE OF TRANSFORMER
3.5 CONDITION & MONITORING OF TRANSFORMER
3.6 PROPERTIES OF OIL

3.7 ENEMIES OF TRANSFORMER4

4. MAINTENANCE OF SUB-STATION EQUIPMENTS

4.1 WHY MAINTENANCE REQUIRED?
4.2 HALF YEARLY AND YEARLY MAINTENANCE OF ISOLATORS
4.3 MAINTENANCE OF C.Ts, P.Ts.& L.As. :
4.4 REASON OF FAILURE OF CTs
4.5 ACCEPTABLE NORMS OF CTs
4.6 MAINTENANCE OF BATTERY BANK:

4.7 MAINTENANCE OF V.C.B

4.8 IMPORTANTS INSTRUMENTS USED IN GRID
5. Electrical Safety
5.1 Why Safety is required ??
5.2 Electrical Safety Principles
5.3 How to Start The Work
5.4 SFT
5.5 ADVISE

ii
LIST OF FIGURES

Fig. 1.1 3 Phase Transformer

Fig.1.2: a power Transformer
Fig 1.3 Arrangement of simple transformer
Fig 1.4 connection of transformer
Fig.2.1 complete view of transformer

Fig.2.2 a generating station

Fig 2.3 naming of transformer parts
Fig. 2.4 Transformer

Fig 2.5 transformer tank

Fig 2.6 conservator tank

fig 2.7 core of transformer

Fig 2.8 arrangement of radiator

Fig 2.9 breather

Fig. 2.10 high & low voltage bushing

Fig 2.11 tap changer

Fig 2.12 position of tap changer

Fig 2.13 arrangement of thermo siphon filter

Fig 2.14 diagram of buchholz relay

Fig 2.15 temperature Indicator

Fig 2.16 oil level indicator

Fig 2.17 oil level indicator

Fig 2.18 PRV

Fig 2.19 SPR

Fig 2.20 oil surge relay

Fig. 3.1 Transformer

Fig. 3.2 failure of transformer

iii
Fig 3.3 side view of transformer

Fig 3.4 working transformer

Fig 3.5 installation of transformer

Fig 4.2 connection of instruments transformer

Fig 4.3 connection of lightening arrestor

Fig 4.4 view of switch yard

Fig. 4.5 Capacitor Bank

Fig 4.6 front view of VCB

Fig 4.7 installation of VCB

Fig 4.8 megger

Fig 4.9 earth resistance tester

Fig 4.10 capacitance meter

Fig 4.11 Variac

Fig4.12 multimeter

Fig 4.13 oil testing equipment

Fig 4.14 oil gauge meter

Fig 5.1 sign of danger

iv
1. INTRODUCTION TO SUB STATION

A power substation is a subsidiary station of an electricity

generation, transmission and distribution system where voltage is transformed from high or
medium to low or the reverse using transformers. Electric power flows through several
substations between generating plant and consumer changing the voltage level in several
stages.
A substation that has a step-up transformer increases the voltage with decreasing current,
while a step-down transformer decreases the voltage with increasing the current for
domestic and commercial distribution. The word substation comes from the days before the
distribution system became a grid.
At first substations were connected to only one power station where the generator was housed
and were subsidiaries of that power station.

1.1 ELEMENTS OF SUB STATION

Fig. 1.1 3 Phase Transformer

Substations generally contain one or more transformers and have switching,

protection and control equipment. In a large substation, circuit breakers are used to
interrupt any short-circuits or overload currents that may occur on the network. Smaller
distribution stations may use re-closer circuit breakers or fuses for protection of branch
circuits. A typical substation will contain line termination structures, high-voltage
1
 switchgear, one or more power transformers, low voltage switchgear, surge
protection,
controls, grounding (earthing) system, and metering. Other devices such as power
factor correction capacitors and voltage regulators may also be located at a substation.

Substations may be on the surface in fenced enclosures, underground, or located in special -

purpose buildings. High-rise buildings may have indoor substations. Indoor substations are
usually found in urban areas to reduce the noise from the transformers, to protect
switchgear from extreme climate or pollution conditions.

1.2 ENERGY CONSERVATION

• Don't keep Electrical Gadgets "ON" in idle condition.

• Always provide doors & windows to admit natural light ( Sunlight ) to
avoid using electricity in homes or offices during the day.
• To avoid leakage always use Earth Leakage Circuit Breaker / Residual
Current Circuit Breaker in circuit.
• Always buy fewer bulbs of higher wattage rather than many of lower
wattage.
• Always buy electrical gadgets with capacity according to your needs &
not of much higher rating e.g.larger refrigerators consume more
electricity.
• Use Compact Fluorescent Lamps to reduce electricity consumption
substantially
• Ensure proper Earthing in your premises.
• Use electronic regulators for ceiling fans.
• Avoid storing hot / warm food in refrigerators.
• Turn-off decorative & non-essential lights especially in unoccupied areas.

1.3 VISION:
To be amongst the most admired and most trusted integrated utility
companies in the world.
To deliver reliable and quality products and services to all customers at
7
competitive costs, with international standards of customer care- thereby
creating superior value for all stakeholders.
To set new benchmarks in: standards of corporate performance and
governance, through the pursuit of operational and financial excellence,
responsible citizenship and profitable growth.
2
 1.4 MISSION:

• To attain global best practices and become a world-class utility.

• To provide: uninterrupted, affordable, quality, reliable, safe and clean
power to our customers.
• To achieve excellence in: service, quality, reliability, safety and customer
care.
• To earn: trust and confidence of all customers and stakeholders
by exceeding their expectations, and make the company a
respected household name.
• To work: with vigour, dedication and innovation keeping total
customer satisfaction as the ultimate goal.
• To consistently achieve: high growth with the highest levels
of productivity.
• To be: a technology driven, efficient and financially sound organisation.
• To be a responsible corporate citizen nurturing human values and
concern for society, the environment and above all, people.
• To contribute: towards community development and nation building.
• To promote a work culture that fosters: individual growth, team sprit
and creativity to overcome challenges and attain goals.
• To encourage: ideas, talent and value systems.

To uphold the guiding principles of: trust, integrity and transparency in all

aspects of interactions and dealings.

1.5 INTRODUCTION OF TRANSFORMER:

Transformer is a static device which consist of two or more stationary
electric circuits interlinked by a common magnetic circuit for the purpose
of transferring of electrical energy between them without changing its
frequency.

3
 Fig.1.2: a power Transformer

A transformer is a very common magnetic structure found in many

everyday applications.

AC circuits are very commonly connected to each other by means of

transformers.

A transformer couples two circuits magnetically rather than through any

direct connection.

It is used to raise or lower voltage and current between one circuit and the
other, and plays a major role

in almost all AC circuits.

Application Example: Transformers are a necessary part of all

power
supplies. Application Example: Electric power systems.

Transformers find many applications in electric power distribution where

they are employed for increasing or decreasing voltage levels.

4
1.6 IDEAL TRANSFORMER
An ideal transformer consists of two conducting coils wound on a common
core, made of high grade iron.

There is no electrical connection between the coils, they are connected to

each other through magnetic

flux. The coil on input side is called the primary winding (coil) and that on
the output side the secondary. When an AC voltage is applied to the primary
winding, a time-varying current flows in the primary winding and causes
an AC magnetic flux to appear in the transformer core. The arrangement of
primary and secondary.

windings on the transformer core is shown in figure 9 below. The voltage,

current and flux due to the current in the primary winding is also shown.

This flux links with the secondary winding due to the mutual magnetic
coupling, and induces a voltage in secondary winding (Faraday’s Law).
Depending on the ratio of turns in the primary and secondary winding, the
RMS secondary voltage can be greater or less than the RMS primary
voltage.

For analyzing an ideal transformer, we make the following

assumptions:

• The resistances of the windings can be neglected.

• All the magnetic flux is linked by all the turns of the coil and there is
no leakage of flux.

Fig 1.3 Arrangement of simple transformer

5
 Fig 1.4 connection of transformer

1.7 BASIC NEED OF TRANSFORMER:

❑ Transformers are used for generating stations to utilization for

stepping up the voltage over long distance transmission.

6
❑ Reducing the voltage at different stages of distributions for final
utilization.
❑ Any Power system the installed Transformation Capacity is around
six to eight times the installed Generating Capacity.
❑ Transformer is a most Vital equipment as whole supply network from
transmission and distribution mostly depends on its reliable , safe and
uninterrupted operation.
❑ Transformer is static piece of equipment, is quite reliable and most
efficient machine
❑ About 95 % efficiency in lower capacity range and 99 % in higher
capacity Range.
❑ It is one of costliest equipment of power system network.

1.7.1Why need for transformer maintenance?

To Ensure highest availably.

To ensure serviceability at all times

To ensure safety of men and material.

To extend Useful Life.

1.7.2 Basic Concepts of maintenance:

❖
Most reliable, dependable for efficient and effective transmission as well
as distribution of power.

❖
Modern power transformer capable of working as long as 20-25
Yrs minimum or long without need of repair, if operated properly.
❖ Periodical/ timely repair and maintenance by
❖ maintenance team.
Repair work is so called maintenance work depend up technical
parameters of Transformer.
❖
Maintenance is not saved the money but also improved the
reliability index.

7
 CHAPTER-02

PRINCIPLE AND CONSTRUCTION

OF
TRANSFORMER

2.1 WHAT IS A TANSFORMER ?

fig.2.1 complete view of transformer

Transformer is a static device which transfer power from one circuit

to another circuit through the magnetic field without changing the
frequency.
The transformer requires less care compared with other electrical
equipment. The
degree of maintenance and necessary inspection for its operation
depends on its

8
 capacity, on the importance within electrical system, the place of
installation within the system, on the weather conditions, and the
general operating conditions.
In this part of the manual the operating instructions and
maintenance is supplied. Our
intention is to provide the necessary assistance to the maintenance
personnel to facilitate a periodic inspection of the transformer and
to indicate the steps that they should follow to effect a more detailed
examination of the active part in case that is require.

2.2 ROLE OF TRANSFORMER:

Transformer plays very vital role in the power system.

Fig.2.2 a generating station

9
2.3 We need transformer at every
Stage:

• Generation

• Transmission

• Distribution

2.4 TYPES OF TRANSFORMER:

Fig 2.3 naming of transformer parts

2.4.1 On the basis of construction:

• Core type
• Shell type

2.4.2 On the basis of usage in power sector

• Power transformer
• Distribution transformer
• Current transformer

10
• Potential transformer

2.4.3 On the basis of special purpose usage

• Traction transformer
• Furnace transformer

2.5 PRINCIPLE OF TRANSFORMER

Transformer is a static device which transfer power from one circuit to

another circuit through the magnetic field without changing the
frequency.
It is based on Farady’s laws of electromagnetic induction,according to
which if one coil is connected to a source of alternating voltage, and
alternating flux is set up in the laminated core, most of which is linked
up with the other coil in which it produces mutually induced emf. If the
second ckt. is closed,a current flows in it .
So elecrtric energy is transffered (entirely magnetically) from the first
coil (primary wdg.) to the second coil(secondary wdg.)

E=4.44 f N Ø

E2/E1 = N2/N1

2.6 TRANSFORMER LOSSES

2.6.1 Core loss :

Also known as iron loss, these are hysteresis losses and eddy current losses
resulting from alternations of magnetic flux in the core. These are
constant and independent of load variation.

2.6.2 Copper loss : Also known as I²R losses , this loss occurs due to
resistance of the conductor when on load it carries current. This
losses varies as the square of load current.

2.6.3 Stray loss : It results from leakage fields inducing eddy currents
in the tank, channels, tie rods etc

11
2.7 PHASE DISPLACEMENT:

Angular difference between the vector representing the induced

emf between line to neutral (in the case of Delta be imaginary)
terminal of HV and LV side.

Eg : Dyn11
D= delta connected HV
y= star connected LV
n= neutral of star
11= 30º lead phase displacement

Vector of emf induced in star connected LV, leads vector of emf

induced in delta connected HV by 30º

2.7.1 Phase displacement Group:

The groups into which connections are classified are ;

Group 1: Zero Phase displacement (Yy0, Dd0, Dz0)

Group 2: 180º Phase displacement (Yy6, Dd6, Dz6)
Group 3: 30º lag Phase displacement (Dy1, Yd1, Yz1)
Group 4: 30º lead Phase displacement (Dy11, Yd11, Yz11)

Phase displacement plays significant role in parallel operation of

Transformers.
Transformers lying in the same group should only be connected in
Parallel other wise it will result in excessive circulating current in the
system.

2.8 TESTING OF TRANSFORMER AT

SITE:

 IR Value
 Turn ratio/Voltage ratio
 Magnetic balance
 Magnetizing current
 Wdg. Resitance
 Short Ckt.

12
 Prior to testing of transformer , ensure its isolation From high volage &
low voltage side and earthing.

2.8.1 Short ckt test:

This test is conducted to detect failure of winding.

Single phase or phase to phase supply is applied and current of both
HV side and LV side is measured.
One phase at a time should be tested in case of faulty transformer
to detect the defective phase.
Result measured should be matched by calculation using % impedence
mentioned in rating plate of trf.

2.9 ACCEPTABLE VALUES of

TRANSFORMER:
• Transformer

• Tan delta of bushing- 0.007

• Contact Resistance of bushing – 10 Micro-Ohm

• Tan delta of winding at 20 degree C – 0.005

• Rate Rise of Tan Delta ( Bushing/ winding – 0.001 per year ( Max)

• Magnetic Balance Test – Value of supply Voltage ( 230V) in one

phase is equal to sum
in other two phase. When Supply Voltage in Middle Limb Voltage
induced in outer limb should equal and roughly half of supply Voltage

• Winding Resistance - + 0.5% difference between phases or from

factory tests.

Voltage Ratio ( TTR) - + 0.5% difference between phases or from factory

tests.

• IR Value of Winding ( Min) –

11 KV – 300 M Ohm 33
KV – 400 M Ohm 66
KV – 500 M Ohm

13
2.10 TRANSFORMER NEUTRAL RESISTANCE –
BELOW ONE OHM:

Polarization Index – IR value at 10 min. to one min.

Less Than One Dangerous

1.0 to 1.1 Poor
1.1 to 1.25 Questionable
1.25 to 2.0 Fair
2.0 to 4.0 GOOD
Above 4.0 EXCELLENT

2.11 VARIOUS PARTS OF TRNSFORMER

Fig. 2.4 Transformer

 Transformer tank
 Conservator
 Core
 Winding
 Radiators
 Breather

14
 Bushings
 Tap changer
 Insulating oil

2.11.1 TRANSFORMER TANK:

Fig 2.5 transformer tank

2.11.1.1 Tank body provides containment for:

- Core
- Winding
- Transformer oil

15
Tanks have gasketted joints on the top or bottom according to the type of
tank used to take out core & winding when ever any inspection is required.

2.11.2 Conservator

Fig 2.6 conservator tank

Conservator is mounted on top cover of

main tank to :
- Allow expansion and contraction of oil due to
- change in temp. of oil.
- Ensure total submerging of winding and core with oil for its
cooling.
- It reduces the areas of interface between air & oil which in turn
reduces level of dissolved oxygen in oil .
- Two types of conservator are used in power trf.
Air cell sealed
Non sealed

16
 2.11.3 CORE:

fig 2.7 core of transformer

Core is made up of CRGO (cold rolled grain oriented) silicon

steel.Amorphous core is also in use but not so popular at present
.Thickness of each laminated sheet is 0.28mm to 0.3 mm. It
provides low reluctance path to magnetic flux to induce emf in
respective coils.

2.11.4 WINDINGS:

LT winding:

-It is placed over the core to minimize the insulation required between HT
and core.

HT winding:- It is placed over the LT winding.

Copper strips covered with paper insulation is used to make

windings.

17
 2.11..5 RADIATORS:

Fig 2.8 arrangement of radiator

Radiators serves the purpose of cooling by circulating oil through

the fins and cooling it.
Transformers is cooled by adopting following methods :

ONAN

ONAF

OFAF

18
 2.11.6 BREATHER :

Fig 2.9 breather

Silica gel breather is mounted on top of conservator tank. It ensures dryness

of air that
enters in conservator tank.Silica gel has a great capacity to absorb moisture
up to 10% of its
own weight. It is of dark blue color in active stage and turns pink after
abosrbing moisture.

2.11.7 TRANSFORMER OIL:

• Insulation - Transformer oil has many times the insulating properties
of air.

• Cooling - The oil circulates throughout the transformer and keeps the
coils at a safe and even temperature. Extra cooling is often arranged by
circulating the oil through radiators cooled by fans.
The insulating oil used for Transformers should meet the following
requirements:
• Provide a high electric strength

19
• Have low specific gravity-In oil of low specific gravity particles which
have become suspended in the oil will settle down on the bottom of the
tank more readily and at a faster rate.
• Oil with low viscosity will cool transformers at a much better
rate.
•
Oil with low pour point will cease to flow only at low
• temperatures.
Oil should be filtered to meet the standard requirements.

20
2.11.7.1 Transformer oil standards:

(As per IS:335 & 1866)

Density at 27°C 0.89 g/cm3 (max)

Viscosity at 27°C 27 c St(max)
Flash Point 140°C (min)
Pour Point -9°C (max)
Neutralization Value. 0.03mg KOH/g
(max)
Water Contents 50 PPM ( max.)
Inter Facial Tension at 27°C 0.04 (min) N/m
Dielectric Strength (BDV): 30 KV (min)
Specific Resistivity at 90 °C 30x 10 ^12 Ω-cm (Min)
Tan Delta at 90 °C 0.005(Max)

2.11.8 HV and LV BUSHING:

Fig 2.9

Fig. 2.10 high & low voltage bushing

21
 ▪
Bushing is an insulating structure, which provides a central
passage for conductor.
▪
It is used to insulate conductor with transformer tank.
▪
Plain oil filled porcelain bushings are mounted up to 33 kV voltage
rating levels and condensor bushings are used for 66 kv and above.
▪
Condensor bushings are used in higher ratings and in this
conducting layers are arranged within the insulating matl. for
controlling the distribution of electrical field of the bushing
both axially and radically.

2.11.9 TAP CHANGER:

Fig 2.11 tap changer

Tap changer is provided to maintain the system voltage within prescribed

limits for better quality of electrical power . Tap Changer is divided into
two categories:
OCTC
OLTC
OLTC are installed in two ways :
Intank and Sidemounted
Tap Changers has following main parts
Tap selector having fixed & moving contacts.

22
Diveter switch with transition resistance
Driving mechanism.

Fig 2.12 position of tap changer

2.11.10 THRMO SYPHON FILTER :

Fig 2.13 arrangement of thermo siphon filter

This is an online filter arrangement. A tank filled with Alumina is attached

to transformer tank.
Oil passes through it during circulation and moisture in it is aborbed by
alumina filled inside
The filter. Alumina is replaced after regular interval.

23
2.11.11 SPECIFICATION: 20 MVA Trf.

Rated Capacity 20 MVA

Rated Voltage HV : 66KV
LV : 11KV
Amperes HV : 174.9 A
LV : 1049.7 A
Cooling Method ONAN
Frequency 50 Hz
Vector Group Dyn11
Temp rise above amb. Oil : 40 °C
Winding : 50 °C
Insulation level HV :140 KV/325 KVp
LV : 28 KV/75 KVp
% Impedance at Tap 1 14.454%
Tap 5 14.091%
Tap 17 13.315%

24
2.12 PROTECTIVE DEVICES MOUNTED ON
TRANSFORMER:

 Buchholz relay
 Temp. Indicators
 Oil level Indicator
 Pressure relief device
 Sudden pressure relay
 Oil surge

25
2.12.1 BUCHHOLZ RELAY:

Fig 2.14 diagram of buchholz relay

It is a Gas detector relay used to detect the fault in trf such as arcing
,local overheating which normally results in generation of gas. The
relay is mounted in the pipe connected between main tank and
conservator at an inclination of 3-7 deg to ensure that all the
gases are directed to this relay housing and actuates an alarm/trip
contact.
This relay also responds to the abnormally high oil flow from
main Tank to the conservator which ocuurs during serious faults.
Trip contact is acutated during such case.
If oil level of trf. drops below the level of the relay, alarm/trip
Contact closes and unit is tripped.

2.12.2 TEMPERATURE INDICATOR

Fig 2.15 temperature Indicator

26
Two types of temp. indicators are used for protection of trf.’s.
Wdg. temp. Indicator.

2.12.2.1 Oil temp. Indicator.

They are provided :

- To indicate the temp. of the wdg. & oil.

- To operate an alram & trip ckt. at a predetermined temp.
- To switch on oil pump, fans for cooling when the wdg. temp. rises
above a preset temp. and switch off when the temp. drops by an
established differential.
- They work on the principle of liquid( alcohol/ mercury) expansion
sealed in the bellows.

2.12.3 OIL LEVEL INDICATOR:

Fig 2.16 oil level indicator

fig 2.17 oil level indicator

27
It is provided in the conservator to view the changes of oil level.
The changes of oil level occur due to effect of temperature
Or due to oil leakage. Two types of oil level indicator are used.

- Glass oil level gauge.

- Magnetic oil level gauge.( Float type.)

MOG also incorporates a mercury switch to actutae an alarm in the

event of oil level dropping.

12.2.4 PRESSURE RELIEFE DEVICE:

Fig 2.18 PRV

It plays a vital role in the protection of transformers from excessive

pressure inside which may occur due to internal fault.

If the pressure is not released immediately, the trf. tank will get
Bulged and rupture with oil spreading every where creating a fire
Hazard.

One type of devices are used :


Diaphragm type relief vent ( Explosion vent pipe.)

28
12.2.5 Sudden pressure relay:

fig 2.19 SPR

In addition to PRD, protection of SPR is also provided in power

transformers to minimise the damage to the transformers in case of
fault.
It is having NO/NC contacts and it operates if pressure of around 0.3
kg/cm sq. is created in the main tank.

12.2.6 OIL SURGE RELAY:

fig 2.20 oil surge relay

As buchholz realy is used in main tank, OSR is used in OLTC.

It operates on oil surges generated due to fault in OLTC tank and also
if oil level of OLTC conservator goes down.

29
 CHAPTER -03

MAINTENANCE OF TRANSFORMER

Fig. 3.1 Transformer

3.1 CAUSES OF FAILURE OF TRANSFORMER:

Fig 3.2 failure of transformer

30
TYPES OF MAINTENANCE

1. Breakdown maintenance:
It means that people waits until equipment fails and repair it. Such a thing
could be used when the equipment failure does not significantly affect the
operation or production or generate any significant loss other than repair
cost.

2. Preventive maintenance:
It is a daily maintenance (cleaning, inspection, oiling and re-tightening),
design to retain the healthy condition of equipment and prevent failure
through the prevention of deterioration, periodic inspection or equipment
condition diagnosis, to measure deterioration. It is further divided
into periodic maintenance and predictive maintenance. Just like human life
is extended by preventive medicine, the equipment service life can be
prolonged by doing preventive maintenance.

2a. Periodic maintenance (Time based maintenance -

TBM):

Time based maintenance consists of periodically inspecting, servicing and

cleaning equipment and replacing parts to prevent sudden failure and
process problems.

2b. Predictive maintenance:

This is a method in which the service life of important part is predicted
based on inspection or diagnosis, in order to use the parts to the limit of
their service life. Compared to periodic maintenance, predictive
maintenance is condition based maintenance. It manages trend values, by
measuring and analyzing data about deterioration and employs a
surveillance system, designed to monitor conditions through an on-line
system.

3. Corrective maintenance:
It improves equipment and its components so that preventive maintenance
can be carried out reliably. Equipment with design weakness must be
redesigned to improve reliability or improving maintainability

4. Maintenance prevention:

31
It indicates the design of a new equipment. Weakness of current machines
are sufficiently studied ( on site information leading to failure prevention,
easier maintenance and prevents of defects, safety and ease of
manufacturing ) and are incorporated before commissioning a new
equipment.

3.1 As per findings of CIGRE survey main

causes of failure of transformers in service
can be summarized as follows :

Causes
◼ Design 36%
Manufacturing
◼ Problem 28%
Material
◼ Defects 13%
Poor
◼ Maintenance 17%
Lightening
◼ Surges 04%
◼ Short Circuits 02%

3.2 TYPES OF FAULT ON TRANSFORMER:

◼
Phase to Earth faults
◼
Phase to Phase faults
◼
Inter turn faults
◼
Over fluxing of transformer
◼
Over loading of transformers
◼
Core faults
◼
Loss of oil due to leaks
◼
Uncleared system faults

3.3 PROBLEMS RESULTING FAILURE OF

TRANSFORMER:
◼
Rise in Temperature
◼
Electrical Troubles
◼
Mechanical Troubles
◼
Oil Troubles
◼
Other Troubles

32
 3.4 MAINTENANCE SCHEDULE OF
TRANSFORMER:

Fig 3.3 side view of transformer

3.4.1 CHECKS & INSPECTION CAN BE

PLANNED AS:

1. Hourly
2. Daily
3. Monthly
4. Quarterly
5. Half yearly.
6. Yearly
33
3.4.1.1 Hourly:

1. Load current ; Over current can be either due to overloading or

circulating current which may be caused by improper ratios or
impedences in parallel circuits . Load should be immediately
reduced, other wise heating can deteriorate insulating material.
2. Load Voltage; Over voltage can be either due to selection
ofimproper Tap Position or high system voltage. Proper Tap selection
should be made inorder to avoid over excitation and excessive core
loss.

3. Oil & Wdg.Temperature: High temp. can be due to over current,

over voltage, insufficient cooling, low oil level , sludged oil,
short circuited core. Change the circuit voltage, reduce load,
maintain oil level, filter oil, clean radiators & core coil assembly,
inspect and repair core.

4. Ambient Temperature: Should be noted for analysis of rise of

oil and wdg. temp. above ambient.

3.2.1.2 Monthly:

1. Oil Leakages

Check for oil leakages from bushings, top cover, air release plug
washers, welding joints etc.

If tightening the bolts does not stop leakage ,replace gaskets,

washers, oil seals as required.

2. Check H.V.& L.V. connections for tightness of nuts & bolts

& clamps .

3. Use proper tightness & firm contact connectors on H.V.

side & use lugs of proper size on L.V.cable.This not
only helps in
avoiding overheating of bushings but also helps in
improvement
of
voltage

34
3.2.1.3 Half Yearly:

➢
Check transformer tank and other external
parts for rusting. They should be cleaned
thoroughly to prevent corroison.
➢
Check gasket joints for leaks
➢
Check cable boxes for cracks in compounds
➢
Check oil & wdg.temperature indicators

3.2.1.4 Yearly:

Testing of transformer oil. (As per IS:335 & 1866)

Testing of OLTC oil.

Testing of bushing (Tan delta & Capacitance)

Testing of Earth Resistance of neutral and transformer

Earthing

Testing of transformer.(IR value, Turn Ratio, open circuit, short

circuit, magnetic balance,& Wdg. Resistance, Tan Delta &
Capacitance)

Testing of protection circuit

35
3.2.1.5 10 Yearly:

• Major reconditioning/Capital maintenance

• Over all inspection including lifting of core coil assembly.

• Reconditioning of core coil assembly.

• Replacement of gaskets, oil seals.

• Replacement of oil.

• Painting of transformers.

3.5 CONDITION & MONITORING OF

TRANSFORMER:

Fig 3.4 working transformer

36
• Condition monitoring begins right from the time of installation of
transformer.

• Proper levelling of transformer on properly levelled Plinth should

be ensured.

• Free entry of air/oxygen should not be allowed in conservators right

from the beginning.

• Replacement of silica gel & attending of oil leakage in time will

slow down aging process.

Outside entry of sulphur must not be permitted at all. Poor quality hose pipes
of filter machine are major source of entry of sulphur inside the
transformers. So during filteration it should be noted hose pipe used should
be of good quality.

3.5.1 TOOLS FOR CONDITIONING &

MONITORING:

Fig 3.5 installation of transformer

37
1. Furfural Analysis (FFA)

2. Dissolved Gas Analysis (DGA)

3. Frequency Response Analysis(FRA)

4. Partial Discharge Measurment (PD)

5. Recovery Voltage Measurments (RVM)

6. Thermo Vision Scanning

7. Degree of Polymerizations(DP)

FFA & DGA are the most common tools for conditioning
monitoring.

3.5.1.1 Furfural Analysis (FFA):

◼
The condition of the insulation can be monitored by conducting Furan
Analysis on oil.

◼
The good insulation will generally have 2-Furfural content less than
0.1 ppm in a healthy transformer and the insulation ,which has
finished its life will have more than 5 ppm.

◼
Furan analysis would not be correct to conduct where oil replacement or
mixing has taken place during last 3 months.

◼
It is very important to carry out samples in dark bottles , as furans are light
sensitive.

3.5.1.2 Dissolved Gas Analysis (DGA):

Regular monitoring of dissolved gases reveals useful information about

healthiness of a transformer and prior information of fault can be achieved
by observing the trend of various gas contents.

38
 ◼
Oil overheating : C2H4, C2H6, CH4
Apart from Methane, Ethane and Ethylene traces of acetylene with
smaller qty. of H2 may be evolved.
◼
Overheated cellulose : CO, CO2
Large qty. of carbon monoxide are evolved.
◼
Partial discharge in oil : H2, CH4
Ionisation of high stressed area where gas/vapour filled voids are
present or wet spot produces hydrogen. Methane and small qty. of
other hydrocarbons.
◼
Arcing in Oil : C2H2, H2
Large amount of hydrogen and acetylene are produced with minor
qty’s of methane and ethylene.

3.5.2 ALLIED EQUIPMENTS OF GRID:

• Power Transformer

• HV Circuit Breaker

• Isolators

• HV CTs

39
• PTs/CVTs

• LV Circuit Breakers

• Station Distribution Transformer

• Battery Bank and charger – for DC supply

• C&R Panel

3.5.2.1 PROGRAMME:

• 10-00AM TO 11-00AM – VIDEO FILM

• 11-00AM TO 11-15AM – TEA BREAK

• 11-15AM TO 1-15PM - DISCUSSION ON BEST MAINTENANCE

PREACTICE OF EHV EQUIPMENTS.

• 1-15 PM TO 1-45 PM – LUNCH BREAK.

• 1-45PM TO 3-15PM – EVENING TEA BREAK

• 3-15PM TO 4-30PM – DISCUSSION COUNTINUE

• 4-30PM TO 5-00 – QUESTION ANSWER ?

• 5-00PM -5-15PM – CLOSING OF SESSION.

40
 Factor Affecting the Life of Transformers:
Main Objective of Transformer maintenance are :

• To maintain the Vital Organ of Transformer in good condition for

supporting the uninterrupted supply.

• To prevent the damage of equipments which involve huge capital

cost.

3.5.2.2 MOST VITAL ORGANS:

Transformer Oil

Insulation

Laminated iron Core

Winding

Function of Oil

To create the acceptable level of insulation

To provide cooling medium.

3.6 PROPERTIES OF OIL:

3.6.1 Electrical Property:

High Breakdown Voltage

High Volume Receptivity

Low dissipation factor

41
 3.6.2 Physical property:

High Flash Point

Low Pour Point

High thermal conductivity

Low viscosiy

Low density

Low Water Content

Less Affinity to water

3.6.3 Chemical property:

Non Reactive to any of Transformer construction material

Low acidity / Alkalinity

Chemically Stable

High Resistance of Oxidation.

Should not produce any product , which effect on property

of Oil.

Oxidation Product should be soluble in Oil

3.7 ENEMIES OF TRANSFORMER:

Enemies obstruct the reliability and effect the life and satisfactory operation
Moisture

Sediment / Solid particles

Fibers

Oxygen

Acid

Sludge
42
Voltage Stress

Surge

Over Voltage

Low Frequency

Temperature

CHAPTER– 04

MAINTENANCE OF SUB-STATION
EQUIPMENTS (isolator , instrument
transformer, battery bank & VCB) :
 4.1 WHY MAINTENANCE
REQUIRED?

To check moving contact travel and replace

if necessary.
A. Quarterly Maintenance :

To check porcelain portion for hair cracks.

To tighten all nuts and bolts of porcelain

insulator.

To lubric To tighten the earth connection of

earth switch.

To check the operating handle and vertical guide rod for its
• alignment and free movement.
• To check earthling connection of the operating handle.

4.2 HALF YEARLY AND YEARLY

MAINTENANCE OF ISOLATORS:

4.2.1 Half-Yearly Maintenance :

To check and tighten the P.G tee and bi-metallic clamps and jumper.

44
To check and clean the auxiliary contacts and check semaphore indications.

To check the inter-locking solenoid coil.

To clean thoroughly and applying of light oil.

To clean the box containing the solenoid coil and to check its proper closing.

To check the box containing auxiliary switch and to tighten connections.

4.3 MAINTENANCE OF C.Ts, P.Ts.& L.As. :

Fig 4.2 connection of instruments transformer

4.3.1 C.Ts. :

To wipe out dust and general cleaning of the body of

the C.Ts.

To check the porcelain portion for hair cracks

.
To check oil level and to observe the colour of the oil.

To check the tightness of the mounting nuts and bolts and

jumper

45
4.3.2 P.Ts.:

• To clean all porcelain and metallic parts.

• To check the porcelain portion for hair cracks.
• To check oil level and to check the colour of the oil of
the P.T.
•
To check the tightness of the mounting nuts and bolts and
jumpers

4.3.3 L.As. :

Fig 4.3 connection of lightenning arrestor

Fig 4.4 view of switch yard

46
 To clean the porcelain and metallic parts.

• To check the porcelain portion for hair cracks.

• To check the tightness of the mounting nuts and bolts and

jumpers.
•
To check I.R values of various sections of L.As. and surge
counter reading
•

4.4 REASON OF FAILURE OF CTs :

• ABNORMAL AGEING – 60 %

• OIL
-
1
LEAK 2
AGE %

47
• POOR IMPREGNATION – 8%

• IMPROPER INSULATING PAPER WRAPPING ( Manufacturing

Defect) – 3%

• MOISTURE ENTRY – 8%

• OTHERS – 9 %

4.5 ACCEPTABLE NORMS OF CTs

• SPECIAL PROTECTION CLASS PS

• IT IS USED FOR DIFFERENTIAL , REF , DISTANCE

PROTECTION.

• HIGH ACCURACY , HIGH SATURATION LIMITS. KNEE

POINT TEST ED WITH CT ANALYSER.

4.6 MAINTENANCE OF BATTERY BANK:

Fig. 4.5 Capacitor Bank

4.6.1 MONTHLY MAINTENANCE :

48
SHOULD HAVE MONTHLY MAINTENANCE:

To clean all the cells.

To check the sp.gravity/voltage of each cell.

To check and maintain the level of electrolyte of

each cell.

Tocheck the covers.

To check D.C. cables, switches and contacts from battery

room.

To check and clean the terminal connections and apply

petroleum jelly.

To check and clean the porcelain supports.

4.7 MAINTENANCE OF V.C.B:

Fig 4.6 front view of VCB

• Cleaning of Control Cubical and checking of Loose connection
• Checking of ON/OFF indicator, spring charge indicator
• Checking of manual and electrical operation
• Checking of Vacuum of Interrupter by application of High Voltage.

• Checking of erosion of contacts by erosion marks on operating rod or

measurement of Gap specified in close position of contacts ( wherever
provided)
Replacement of Vacuum interrupter

49
4.7.1 ACCEPTABLE VALUES OF CIRCUIT
BREAKERS:

Fig 4.7 installation of VCB

Contact Resistance – 40 -100 Micro ohms

Breaking time – 40 to 100 Msec.

Variation – Depend upon ageing and number of operation

4.8 IMPORTANTS INSTRUMENTS USED IN

GRID:

4.8.1 MEGGER:

The main purpose behind the Megger test is so that you will be
able
to test for electrical leakage in wires. They are helpful in detecting issues
and leakage that other devices, such as the ohm detector, might not. This is
because you will actually be running current through the device while you
are testing it.

50
 Fig 4.8 megger

4.8.2 EARTH RESISTANCE TESTER:

An earth resistance test set is commonly made up of a voltage source, an

ohmmeter to measure resistance directly, and switches to change the
instrument’s resistance range. Extension wires connect terminals on the
instrument to the earth and reference electrodes or ground rods, as will be
described. A battery-powered oscillator supplies the required current and you
read resistance in ohms from a pointer on a scale or a digital readout.

51
 Fig 4.9 earth resistance tester

4.8.3 CAPACITANCE METER:

A capacitance meter is a piece of electronic test equipment used to

measure capacitance, mainly of discrete capacitors. Depending on the
sophistication of the meter, it may display the capacitance only, or it
may also measure a number of other parameters such
as leakage, equivalent series resistance (ESR), and inductance. For
most purposes and in most cases the capacitor must be disconnected
from circuit; ESR can usually be measured in circuit.

Fig 4.10 capacitance meter

52
4.8.4 HI POT SET:

Fig 4.11 variac

4.8.5 MULTIMETER:

A multimeter or a multitester, also known as a VOM (Volt-Ohm

meter), is an electronic measuring instrument that combines several
measurement functions in one unit. A typical multimeter would
include basic features such as the ability to
measure voltage, current,and resistance. Analog multimeters use a
microammeter whose pointer moves over a scale calibrated for all the
different measurements that can be made. Digital multimeters
(DMM, DVOM) display the measured value in numerals, and may
also display a bar of a length proportional to the quantity being
measured. Digital multimeters are now far more common than analog
ones, but analog multimeters are still preferable in some cases, for
example when monitoring a rapidly-varying value.

Fig4.12 multimeter

53
4.8.6 OIL TESTING EQUIPMENT BDV

The dielectric breakdown voltage test is an important test to

determine the withstanding capacity of any insulating oil or liquid.
There is a degradation of transformer oils or ingress of moisture
and it is necessary to test the insulating oils periodically. BDV test
is one of the most common tests done on all Insulating fluids, but a
very critical one. Breakdown (BDV) test is a test of choice because
it takes very less time to conduct and is a precursor to the condition
of the insulating liquid, before carrying out extensive series of tests.
Power Electronical offers accurate Automatic Oil BDV Test sets
and Motorised Oil Breakdown testers in variety of maximum test
voltages

Fig 4.13 oil testing equipment

4.8.7 OIL GAUGE METER

Many of the processes in the modern world involve the measurement and
control of pressurized liquid and gas systems. This monitoring reflects
certain performance criteria that must be controlled to produce the desirable
results of the process and insure its safe operation. Boilers, refineries, water
systems, and compressed gas systems are but a few of the many applications
for pressure gauges.

The mechanical pressure indicating instrument, or gauge, consists of an elastic

pressure element; a threaded connection means called the "socket"; a sector and
pinion gear mechanism called the "movement"; and the protective case, dial,
and viewing lens assembly. The elastic pressure element is the member that
actually displaces or moves due to the influence
54
of pressure. When properly designed, this pressure element is both highly
accurate and repeatable. The pressure element is connected to the geared
"movement" mechanism, which in turn rotates apointer throughout a
graduated dial. It is the pointer's position relative to the graduations that the
viewer uses to determine the pressure indication.The most common pressure
gauge design was invented by French industrialist Eugene Bourdon in 1849.
It utilizes a curved tube design as the pressure sensing element. A less
common pressure element design is the diaphragm or disk type, which is
especially sensitive at lower pressures. This article will focus on the Bourdon
tube pressure gauge.

Fig 4.14 oil guage meter

55
 CHAPTER– 05

ELECTRICAL SAFETY

Fig 5.1 sign of danger

5.1 Why Safety is required ??

To save human life .Human Being are most precious of all Safety has
got to be foremost.
Each year Hundreds of people are killed and hundreds are injured
with Electrical accident. Many of death / Incident could avoided by

56
 use of appropriate electrical Safety techniques and equipments
personal working on.

5.2 Electrical Safety Principles :

When planning and performing work on electrical systems and equipment,

keep these principles in mind.

• Plan every job.

• Think about what could go wrong.

• Use the right tools for the job.

• Use procedures, drawing and other documents as tools to do

•
the job.

Isolate the equipment from energy sources and never forget earthling
of electrical equipment before starting any maintenance activity on it.

• Identify the electric shock and arc flash, as well as other hazards that
may be present.

• Minimize the hazard by guarding or approach limitations.

• Test every circuit, every conductor, every time before you

touch.
•
Use personal protective equipment as a last line of defense in case
something goes wrong

Ask yourself, “Do I have the skills, knowledge, tools and

experience to do this work safely.”

5.3 How to Start The Work

Precaution -- Before commencing any work on the power transformer

ands associated equipment, the following safety matters should be
ensured.

1. Keep The Mind Cool

57
The transformer and associated equipment must be out of service, isolated
and earthed while carrying out general maintenance checks.

Obtain a “Permit to work ( PTW) “ from the Operation Engineer/Shift

Engineer.

Obtain the keys to the transformer compound as well as the associated

equipment with which the work is involved.

PTW: Permit to work (PTW) is safety document specifying the equipment,

the work/testing to be carried out and the actions taken to achieve safety
from the systems.

5.4 SFT:

Sanction for test (SFT) is a safety document specifying the

EHV/HV
equipment
.
• Check the opening of Source of supply
• Discharge the line in his presence
• Put the short Chain / Safety Zone to be created
• Cordon / Barricade the area with Rope / Tape.
• Safety Belt must be used by L/M or authorized person who has to work
on line.
• An helpers in the team must wear safety helmet.
• Supervisor must also wear Helmet.

DANGER SIGN Must be placed surrounding FANCING

5.5 ADVISE:

KEEP YOUR EQUIPMENT HEALTY

DIGNOSE THE PROBLEMS

KEEP DISCUSSING AND FIND SOLUTION

58
 IMPLEMENT AS SOON AS POSSIBLE

BE HEALTHY

BE HAPPY

SUMMARY
This paper describes the operation & maintenance of 33kv substation used
by BSES Rajdhani power limited.

The maintenance and the inspection are a dangerous work; from there,
beforehand a detailed program must be developed, placing special attention
on the safety of the workers and of the equipment. When working with bus
bar, lines, terminal, etc., the work can only begin after confirming that these
parts are not receiving any power, verifying for this that the switches are in
the open position, something which can be checked with a detector for
circuits. The omission of these revisions, thinking erroneously that the
circuits do not have voltage can cause serious accidents. To maintain the
transformer in perfect operating conditions, keep in mind the previous items,
also about the routine operation and not forgetting to give the proper
treatment when some change in the service conditions is noted. It is
necessary also to de-energize the transformer regularly and conduct a
meticulous inspection. With this routine and with regular inspection, the
degree of deterioration will be minimized. Since a transformer is made of
many parts, such as the insulating oil, the cooling equipment, etc. must be
checked permanently. Oil in addition to serving as insulating means serves
to transfer the heat generated in the windings and the core toward the walls
of the tank and the radiators. The cooling equipment is the most important
part in the normal daily operation of a transformer. It is necessary a special
care for its maintenance and inspection, since any abnormality can reduce
the useful life of the transformer or cause serious defects. There are short
circuits between the turns, between the phases and between the windings.
Most short circuits failures are caused by abnormal tensions on the surge
arresters and others because of the deterioration of the insulation oil and to
the penetration of rain. Also, some short circuits are caused by the
deterioration because of heat, caused by an electromagnetic mechanical force
or by an abnormal excessive load.

Generally, as secondary effect, internal short circuits cause serious

deformations to windings.Use the different relays that the transformer has

59
to detect and be protected of failures. Next you can find which parts are
used to protect the transformer from internal failures: Those devices that
are attached directly to the transformer, and detect failures
mechanically: Buchholz Relay, pressure rise relay, pressure relief
device. Those devices that are indirectly joined to the control cabinet
which detect failures electrically: Differential Relay, overcurrent relay,
ground current relay.The manufacturing techniques for transformers
and their reliability have been improved to such degree that the internal
inspection is almost unnecessary; currently the maintenance is limited
almost exclusively to the maintenance of the oil to prevent
itsdeterioration.

60