FIELD VISITS

This program also included three field visits. Out of these three, two visits were to substations
and one was to KAVIKA( Karnataka Vidyuth Karkhane Limited).

SUBSTATIONS VISITED:
1) Subramanyapura Receiving Station(220/66 KV)

2) Padmanabh Nagar Substation(66/11 KV)

SUBRAMANYAPURA RECEVING STATION:

Subramanyapura receiving station, also known as NRS(New receiving station),is one of the
oldest substations of KPTCL (Karnataka Power Transmission Corporation) functioning from
1951. 220 KV two lines are coming from Somanahally and Peenya. Presently NRS is one of
the biggest station (But very compact) in Bangalore handling about 3 million units per day,
with a Peak load of the station at about 176 MW’s. Out of this about 100 mega watts are
handled at 66KV side and the balance 70 megawatts are handled at 11KV side. As regards to
equipments of this station, one can see equipments manufactured about 50 years back to
latest. Two 100 MVA transformers are connected to stepped down the 220 KV Voltage to 66
KV Voltage. Transformer 1 made of NGEF and Transformer 2 is of ABB, to match the
impedance of the transformer they are operated within 2 to 7 numbers of the taps. And 5
numbers of 66KV/ 11KV transformers are connected to feed local feeder of 11 KV. Two
numbers are single bus arrangement is available in this substation 220 KV and 66 KV bus.

There are potential transformers in the form of CVT (Capacitor Voltage transformer) to
measure the incoming line voltage. The CVTs also serve as coupling condenser for
connecting PLCC lines in one or two phases of the lines. Wherever PLCC lines are connected
one can see Wave traps to block communication signals reaching the 220 KV bus.

Wave traps are tuned inductors to allow a particular frequency (here it is 50 c\s power) the
first line control is through double break isolators coupled with grounding switch.

CIRCUIT BREAKER:
It is a single pole breaker here. The breaker consist of, three numbers of single phase SF6
circuit breakers inter connected to form a three phase item. The arcing contacts held in a
porcelain bushings containing SF6 gas at pressure of about 6 kgs sq.cm are independent with
separate seals. One male contact movement results in engaging or disengaging with a static
female contact.
But the operating mechanisms (watched by a pole disturbance relay) for all three phases is by
means of compressed air at about 15 kgs sq.cm held in high pressure tanks interconnected
through common piping. An automatic operating air compressor motor pump replenishes air
when there is a fall in air-pressure. The opening of breaker is pneumatically controlled and
closing is by spring mechanism The breaker is so arranged that when high pressure air opens
the male and female contacts, spring loading (for a later charging purpose) action is also
initiated. The spring load actuated by relays manual results in the breaker getting closed. The
breaker (held in three porcelain bushings) is provided with all safety devices and indicating
mechanism like SF6 gas pressure indicator, air pressure indicator etc . The breaker trips on its
own if there is a DC failure. It gets locked in (LOCK IN : The breaker fails to obey any
commands i.e. neither opens or closes) whenever the SF6 gas and air pressure falls below the
set pressures. The SF6 pressure in 66 KV breakers is slightly less than 1 kg. sq. cm as they
were installed about 50 years back when SF6 breakers were in developing stages. 6. Current
Transformer:- Rating Rated Voltage 220 KV Rated Current 1250 A Knee Point Voltage 1050
V Burdon 40 KV Number of cores 5 Insulation Level 220/400/1050 KV Frequency 50 Hz
Class Protection PS Metering 0.5 Ratio Available 300-600-1200/1A.

TRANSFORMERS USED:

The transformers are rated 60MVA, 80 MVA and 100 MVA depending on the cooling
system employed i.e. ONAN, ONAF and OFAF. The switching of the transformers from
ONAN to ONAF and from there on to OFAF is done by mercury switches mounted over
WTI (Winding temperature indicators) WTI’s are provided on all the three windings (HV,
LV &tertiary) of the transformers in the case of ABB make.

In the case of the NGEF make WTI’s are provided in HV and LV windings only. The on
load tap changer (MR type) of the transformers have 17 taps which can deliver a constant 220
KV output even if the incoming voltage varies from over voltage 223.4 kV up to 209 kV. For
the purpose of mounting the OLTC the OLTC operation is either by an electric motor or
manual and remote operable from the control room. The main tank is interconnected to the
conservator through a Buchholtz (Gas operated) relay. The neutral is grounded through a
neutral CT for REFR (Restrict Earth Fault Relay) protection. Apart from HV and LV winding
there is tertiary winding of 11 KV output called as stabilizer winding, and connected in delta.
It mainly to stabilize the transformer output from 3rd harmonics since HV and LV windings
are in star connected. Fire extinguisher :This is a recent measure introduced to protect the
EHV transformers when they catch fire even after power supply is tripped off by concerned
relay, master trip relay etc. This is based on experiences of about four 100 MVA (220 LV
class) and one 400 KV class transformer catching fire and burning up. The aim is to prevent
spread of fire to other equipments and preserve at least the salvage value of the transformer
on fire. The measure speaks up the sorry state of affairs to which our systems are sinking with
regard to quality in construction and maintenance of transformers The fire extinguishing is
Nitrogen perching. (Earlier it used to be water quenching called water-emulsification system)
Now a day the nitrogen perching fire protection system has been made compulsory for all
100 MVA and above capacities transformers.
PADMANABH NAGAR SUBSTATION:
The 66/11 KV padmanabah nagar sub-station is located opposite one of the famous
landmarks of Bengaluru namely Devegowda (India’s former prime minister) petrol
station.The sub-station is one of the several 66/11 KV sub-station in Bengaluru. There are
total 40 nos. 66/11 KV sub-station in Bengaluru catering a load of 2000 MW which is 1/3 rd
of power supply in Bengaluru. There are 10 nos. of 220/66 KV sub-station in Bengaluru.
Bengaluru follows’ a ring structure around the city which is one of its kind in India from
which several 66/11 KV supply is taken, this ring structure terminates at the same point
where it started. All equipment and system is earthed properly through GI strips of 25X6 mm
and 150X6 mm via earth electrode which in turn is connected to earth-mat.

The sub-station is having two 66 KV incoming supply. These two incoming supply is coming
from Subramanyapura- 1 & 2 sub-station through XLPE ( Cross Linked Polyi-Ethylene)
cable’s. These cables are 660sq.mm, 3-phase single core copper cable. These cables are
designed according to required voltage, creapage and rain .At present the station bay (area
under an over head structure) is being extended to provide another 66 KV line to serve as
another alternate 66 KV source since both the present feeders are from the same station. The
present two incoming feeders are used alternatively (one at a time). The station peak load is
24 mega watts and handle about 3,25000 units every day.

Earthing Mat:
The earth mat is designed after the procurement of land area. The land is excavated by 1m
deep. After the excavation the galvanized iron rods are laid in latitudinaly and longitudinally.
In this sub-station the earthing mat design is done by KPTCL using software. During
construction of the earth-mat charcoal and sand with water is added to lower the resistivity of
soil. The dimension of GI material is 25X2 mm and 150X6 mm. The main criterion to design
the earth-mat is to find soil resistivity. The soil resistivity varies widely and depends on the
nature of soil. The main purpose of designing earthing system is to protect both human and
electrical system from electric hazards. Humans are very vulnerable to the effects of electric
currents. Even a current of 0.1 A is lethal at power frequency.

LIGHTNING ARRESTORS:
The lightening or surge arresters (L.A) used in the sub-station is rod gap type. These are used
for the protection of power system equipments. The surge arrester used here is of 45 KV. The
XLPE cable coming from Subramanyapura sub-station terminates here through L&T-type
clamps. The surge arresters are mounted on the platform which is earthed by GI strip and
through the earthed electrode it is connected to earthing-mat.
Isolators

The isolator is 66 KV incoming line Gang Operating Switch (GOS). The main purpose of the
isolator is to carry out maintenance work after line clearance. The isolators are mounted on
the lattice structures and are earthed by GI strips to earth electrode which in turn is connected
to earthing mat. The first line isolators are always provided with the earth or grounding
switch. This grounding switch is provided to carry out maintenance work. Whenever there is
any work required to carry out in the system we put operate the earth switch so that the whole
system will be at ground potential. This earth switch is provided in both of the sub-stations i.e
padmanabah and Subramanyapura. In some isolators there is mechanical interlocking
provided so that the earth switch cannot be operated when the system is in line. If this is done
than the whole system will be at high risk and havoc is created.

Transformer

There are two one of 16\20MVA and another of 31.5 MVA Dyn11 vector group 66/11kv
class transformers.

CTR Fire Protection system

Transformer is also protected from fire during any abnormal fault condition. Well adequate
clearance is maintained between the two transformers in the substation.

Main equipment used for this is the water emulsified fire extinguisher which takes care of the
abnormal conditions. During these fault conditions CTR has equipment which does not allow
the oil passage from the top portion of the conservator tank when it senses any abnormal
temperature difference.
KAVIKA(Karnataka Vidyuth Karkhana Limited)
The Karnataka Vidyuth Karkhane Limited(KAVIKA),a fully owned Government of
Karnataka undertaking, is the successor to the Government Electric Factory, the first ever
manufacturer of electrical transformers in the country , established way back in 1933 by the
erstwhile Maharaja of Mysore.

Today, after a 8 decades of successful production and operations, KAVIKA has emerged as a
renowned name for Distribution Transformers in the range of 25 kVA to 500 kVA upto 11
kV/433V Class as well as for custom built / special type transformers as per specific
requirements.

Products Manufactured:
Energy Efficient 3, 4 & 5 star category Transformers.Fully as per IS Specifications. All
materials used in the manufacture are as per IS Specifications.All the materials are tested to
meet the IS requirements.Sufficient cooling is provided to dissipate the guaranteed losses and
to maintain the guaranteed temperature rises – which gives longer life to Transformer.

Conventional Transformers:
1)3 Phase Aluminium wound Transformers (with or without taps)

2) 3 Phase Copper wound Transformers

3) Four & Five Star rated transformers

Special Transformers:
1)Single Phase Neutral grounding Transformers

2)Booster Transformers

SPECIAL FEATURES OF KAVIKA TRANSFORMERS:

1) Vacuum chamber is used in the process of drying the active parts, which helps to
maintain very high insulation resistance (minimum of 1000 Mohms at 90o C) is
maintained.
2) Good quality lamination of cruciform core from the heart of the transformer.
3) Electrolytic Conductor grade conductors of proper tensile strength are used. Because
of the sufficient tensile strength on the conductors, windings are wound with tension.
4) Multipaper covered copper conductor leads of sufficient cross section are used on the
high voltage side.
5) “S” type jumpers of sufficient cross section are used in Low voltage connection.
6) Solid packing piece made of 100% wood pulp are used for supporting the low voltage
and high voltage coils, which offers sufficient electrical breakdown strength between
 the windings and earth parts. Also solid packing supports the windings better under
short circuit conditions.
7) Proper arrangement for lifting is provided for job as well as tank for proper handling.
8) In addition to the above all the raw materials are conforming to Indian Standards.
9) In all the stage process quality checks are made and in the final testing stage all the
routine tests are conducted as per BIS on each and every transformers before dispatch.
10) Type tests are conducted in CPRI Bangalore From time to time (short circuit, high
voltage and temperature rise test.

The Company has a long list of satisified customers.the major customers are the state
Eletricity Companies such as Bangalore Eletricity Supply Company Ltd.,Hubli Eletricity
supply company Ltd., Mangalore Eletricity Supply Company Ltd.,Gulbarga Eletricity Supply
Company Ltd., and Chamundeshwari Eletricity Supply Corporation, Karnataka Power
Corporation Ltd., etc., The list not only includes the state Eletricity Companies,but also many
Industrial and Commercial Customers such as Bharat Heavy Eletricals Ltd Karnataka State
Womens University,BGS College and other private institutions,etc.,

The Company has Shown an impressive growth since past five years which is evident from
the audited balance sheet.the sales of transfromers has increased from 168 Nos with a
turnover of RS 869lakhs in 2005-06 to 14610 Nos with a turnover of Rs 7623 lakhs in 2010-
11, from loss of Rs 130 lakhs in 2005-06 to a profit of Rs 152 lakhs in 2010-11.However,the
employee strength has reduced from 321 Nos to 210 Nos in corresponding period.

1. Manufacturer of Quality Oil filled Transformers.

2. Product range - 25KVA to 500KVA 11/0.433kV,3 phase Distribution transformers.
3. Major utility Customers-
o Bangalore Electricity Supply Company Ltd.,
o Hubli Electricity Supply Company Ltd.,
o Mangalore Electricity Supply Company Ltd.,
o Gulbarga Electricity Supply Company Ltd.,
o Chamundeshwari Electricity Supply Corporation Ltd.,
o Karnataka Power Corporation Ltd.,Raichur / Shaktinagar.
4. Major Commercial Customers-
o Karnataka Power Transmission Corprn.ltd., Tumkur,Belllary,
o Karnataka State Womens University,Belgaum,
o BGS Institution,and
o Other Private Customers