CHAPTER 1

INTRODUCTION

A) OVERVIEW OF TMLSD-2ND AMARGARH SOPORE SUB STATION

. TLMD-2nd AMARGARH is located in district Baramulla (Kashmir)

. It is one of the oldest sub stations in Jammu and Kashmir

. It’s nearby areas are Railway Station, J&K Bank

. It is located 22kms towards North from District Head Quarters Baramulla.

B). Introduction:-

It receives its supply from

1. Delina (132KV)

2. Pattan (132KV)

There are four 132/33 kV transformer Banks with capacity

1x20MVA =20MVA

1x12.5MVA=12.5MVA

1x50MVA =50MVA

1x15MVA =15MVA

There is provision for five outgoing feeders of 33KV each.

1) Sopore (33KV)

2) Aram pora (33KV)

3) Baramulla (33KV)

4) Bandipora(33KV)

5) Nowpora (33KV)

Page | 1
1.1 SUBSTATIONS

Substations serve as a source of energy supply for the local areas of distribution in which
these are located. Their main functions are to receive energy transmitted at high voltage
from the generating stations, reduce the voltage to a value appropriate for local distribution
and provide facilities for switching. Some substations are simply switching stations where
different connections between various transmission lines are made; others are converting
substations which convert AC into DC or vice versa or convert frequency from higher to
lower or vice versa. Substations have some additional functions. They provide points where
safety devices may be installed to disconnect equipment or circuit in the event of fault.
Voltage on the outgoing feeder can be regulated at a substation. A substation is convenient
place for purpose of improving power factor and make measurement to check the
operations of the various parts of the power system.

The substations may be defined as the assembly of apparatus, which transforms the
characteristics of electrical energy from one form to another: e.g. - AC power to DC power,
higher voltage level to lower voltage or vice-versa, etc.

1.2 Design of Substations:-

When a substation is to be designed, the following procedure should be adapted:

1. Prepare a single line diagram of main electrical connections showing bus bar
arrangements, circuit breakers and transformers.
2. Decide the layout of switch gear keeping view capacity of substations, method of
control, number of feeders, reliability, safety, flexibility, space needed and construction.
3. The layout should be such that it should be possible to isolate any section during fault,
without affecting the service of the healthy section.
4. It should be possible to have an easy and safe access for maintenance and inspection for
different equipments.
5. An arrangement should be made to extinguish fire.
6. The earth conductor should of sufficient cross-sectional area to carry the fault current in
severe conditions.

Page | 2
1.3 Location of Substations:-
I. The following points should be take mainly into consideration in choosing the
location of substation:

i) Locate substations as close to the load center as possible.

ii) Allow access to the incoming transmission line and outgoing distribution line.

iii) Choose the site where municipal restriction of property laws should permit the
type of building necessary for substation.

iv) Keep load on the substations with in such limits that an undue large area or
number of consumers will not be affected incase the station shut down occurs.

v) Suitable communication facility is desirable at a proposed substation both during

and after its construction. Its better therefore to select site along side on existing
road to facilitate an easier and cheaper transportation

1.4 TYPES OF SUBSTATION

There are several ways of classifying substations. However the two most important ways of
classifying them are according to

1) Service requirement

2) Constructional features

According to service requirement: A substation may be called upon to change voltage

level or convert a.c power into d.c power etc.According to the service requirement
substations may be classified into

1) TRANSFORMER SUB STATIONS: Those sub stations which change the Voltage
level of electric supply are called transformer sub stations.these sub stations receive
power at some voltage and deliver it at some other voltage.

Page | 3
 2) SWITCHING SUB STATIONS: These sub stations do not change the voltage level
i.e. incoming and outgoing lines have same voltage

3) POWER FACTOR CORECTION SUB STATION: Those sub stations which

improve the power factor of the system are called power factor correction sub
stations. such sub stations are generally located at receiving end of transmission
lines.

4) FREQUENCY CHANGER SUB STATION: those sub stations which change the
supply frequency are known as frequency changer sub stations

CONVERTING SUB STATIONS Those sub stations which change a.c power into d.c
power are called converting sub stations.these sub stations receive a.c power and convert it
into d.c power with suitable apparatus e.g. rectifiers

INDUSTRIAL SUB STATIONS: Those sub stations which supply power to individual
industrial concern are known as industrial sub stations.

According to constructional features: The substations are classified as

I. Indoor sub-station
II. Outdoor sub-station
III. Underground sub-station
IV. Pole-mounted sub-station

The substation installed in the Wanpoh grid is outdoor sub-station which is described below:
Out-door substation;
For voltages beyond 66kv equipments is invariably installed outdoor. it is because for such
voltages, the clearances between conductors and the space required for switches, circuit
breakers and other equipments becomes so great that it is not economical to install the
equipment indoor.

Page | 4
 1.5 SINGLE LINE DIAGRAM OF SANAT NAGAR GRID STATION

1.6 EQUIPMENTS AND SWITCH GEAR INSTALLATION IN THE Sanat Nagar GRID
STATION

There are various electrical equipments installed at substations. These are:-

Incoming Lines:-

These lines supply power to substations from source of generations or from transmission
lines at high voltages.

BUS BARS:-

When a number of lines operate at the same voltage have to be directly connected
electrically, bus bars are used as the common electrical component. Bus bars are copper or
aluminum bars (generally rectangular x- section) and operates at constant voltage

The most commonly used bus bars arrangements in substations are:-

Single busbars:-
This arrangement is the simplest and cheapest. However it suffers from two major defects:-
Maintance without interruption of supply is not possible and extension of the substation
without a shutdown is not possible.
a) Single Busbars with Bus Sectionalize:-

Page | 5
Because of cheapness and simplicity single busbar is adopted with sectionalizing
arrangements. Full advantage of the scheme is realized if the incoming and outgoing circuits
are distributed evenly on the sections.
b) Double Busbar:-
The Scheme use two identical bus bars so that:-
c) Each load may be fed from either bus
d) The indeed and load circuits may be divided into two separate groups if needed from
operational considerations.
e) Either bus bar may be taken out for maintenance and cleaning of insulators.
1.7 (132 Kv bus bars)
The bus bar system used in Wanpoh grid station is Double busbar system which is
illustrated below;
I. Main bus.
II. Reserve bus.
 Transformers are charged through main bus
 In case of any fault or maintenance of main bus the continuity of supply is done
through reserve bus
 In Wanpoh grid station the busbars used are made up of Aluminum
1.8 (33 Kv busbars)

There are three 33Kv bus bars

I. Main bus
II. Reserve bus

 Main bus is charged by the transformers

 Voltage on the bus is 33Kv and current is about 1500A
 Feeders are supplied by 33Kv buses
 In case of any fault on main bus reserve bus is used to supply the feeders

1.9 INSULATORS
The overhead line conductors should be supported on the poles or towers in such a way
that currents from conductors do not flow to earth through supports I.e. line conductors
must be properly insulated from supports this is achieved by securing line conductors to
supports with the help of insulators.
Thus insulators provide necessary insulation between line conductors
and supports and thus prevent any leakage current from conductors to earth.

Types of Insulators:-

Page | 6
There are several types of insulators and there use in the substations will depend on the
service requirements:-
I. Pin Type
II. Suspension Type
III. Post Insulator type
The insulators used in the Wanpoh grid station are Pin Type and Suspension Type
insulators which are discussed below:

I. Pin Type Insulators:-

This type of insulator was amongst the earliest designes, and used for supporting line
conductors. The pin type insulator is secured to the cross arm on the pole there groove on
the upper end of the insulator for housing.The conductor passes through this groove and is
bound by the annealed where of the same material as the conductor.
Pin Type insulators are used for transmission and distribution of electric power at voltages
up to 33Kv.Beyond operating voltage of 33Kv the pin type insulators become too bulky and
hence uneconomical.

Fig 1.2
II. Suspension Type Insulator:-
For high voltage rating these insulators are used. These insulators consist of one or more
insulators units flexible connected together and adopted to be hung for the cross on of the
supporting structure and to carry a power conductors at its lowest extremity. Such
composite units are known as string insulators. Each insulator is a single disc shade piece of
porcelain grooved on the under surface leakage path between the metal cap at the top and
the metal pin at the bottom of the insulator. Suspension insulators. Each insulator is design
for 11KV and hence for any operating voltage a string of insulators can be used.

Page | 7
 Fig:1.3 suspension insulators
1.10 Isolating Switches
In Sub Stations, it is often desired to disconnect part of the system for general maintenance
and repairs. This is accomplished by the isolating switch or isolator. An isolator is essentially
a knife switch and is designed to open a circuit under no load. In other words, isolator
switches are operated only when the lines in which they are connected carry low current.
Isolators are not fitted with arc control devices and function only for instaneous changes of
switching circuits arrangements and for providing a visible break in a circuit. So as to make
certain operation that can be performed on an isolated section without running a risk.
Isolators are handled mannaually as well as automatically.

Fig 1.4 Isolating Switches

CIRCUIT BREAKER
A circuit breaker is a piece of equipment which can
i) Make or break a circuit either manually or by remote control under normal
conditions
ii) Break a circuit automatically under fault conditions
iii) Make a circuit either manually or by remote control under fault conditions

1.11 Operating principle

Page | 8
A circuit breaker essentially consists of fixed and moving contacts called electrodes. Under
normal operating conditions, these contacts remain closed and will not open automatically
until and unless the system becomes faulty. Of course, the contacts can be opened manually
or by remote control whenever desired. When a fault occurs on any part of the system, the
trip coils of the circuit breaker get energized ant the moving contacts are pulled apart by
some mechanism, thus opening the circuit.
The interrupting capacity of a circuit breaker is the
maximum value of current which can be interrupted by it without any damage. The
circuit breakers are also rated in MVA which is the product of interrupting current,
rated voltage and 10 raise to power minus six
TYPES OF CIRCUIT BREAKERS
1. Oil circuit breakers
2. Air blast circuit breakers
3. Sulphur hexa fluoride circuit breakers (SF6)
4. Vaccum circuit breakers
The circuit breaker used in the Wanpoh grid station is Sulphur hexa fluoride (SF6) which is
described below:-

Page | 9
 Fig 1.5
SF6 Circuit breaker: - In such circuit breaker sulphur hexafluoride gas is used as arc
quenching medium. The SF6 is electronegative gas and has a strong tendency to absurd free
electrons. The contacts of the breaker an opened in a high pressure flow of SF6 gas to form
relatively immobile negative ions. This loss of conduction electrons in the arc quickly builds
up enough insulating strength. The SF6 circuit breaker has been found to be very effect able
for high power and high voltage services. SF6 has excellent insulating strength because of its
affinity for electrons i.e. whenever a free electrons collides with the neutral gas molecule to
form negative ions, the electrons is absorbed by the neutral gas molecule may occur in two
ways.
SF6 + e = SF6
SF6 + e = SF5 + F
1. The negative ion formed is relatively heavier as compared to free electrons and
therefore under a given electric field the ions do not attain sufficient energy to
lead cumulative ionization in the gas.

Name plate details of 132kv SF6 CB

TYPE 200-SFM-40A
Rated voltage 145Kv
Lightning impulse with stand 60KV(peak)
Rated frequency 50HZ
Normal current 1600A
Rated short circuit making current 80KA(peak)
Out-of-phase Breaking current 7.9K
Rated break time 60ms(3 cycles)

Rated short time current 40K for 3sec

Total mass of SF6 gas 8.7Kg
SF6 gas pressure 6.3bar
Total mass of the CB 1300Kg
Reference standard IEC-56
Operating sequence 0-0.03s-CO-3min-C0

1.12 PROTECTIVE RELAYS:-

It is a device that detects the faults and initiates the operation of the circuit breaker to
isolate the defective element from the rest of the system. The relay ensures the safety of
the circuit equipment from any damage which might be otherwise caused by the fault. Basic
requirements of protective relaying should have:
a) Selectivity:-The protective system must select correctly the faulty part of the power
system.
b) Sensitivity:-The protective system must be as possible, should operate for low values
of fault current.

Page | 10
 c) Reliability:-The protective system must operate definitely under predetermined
condition.
d) Speed:-The protective system should respond as quickly as possible.
e) Non Interference with Future Extension:-The initial installation is carried out in such
a way has future extension should be possible without interfering with the original
one.
THE TYPES OF RELAYS INSTALLED AT SANAT NAGAR ARE:-
(I) IDMTL type relay (Directional & non directional)
(II) Primary relays such as buchol’z, Restricted earth fault etc.

Fig 1.6

(I) IDMTL (Inverse definite minimum time over current relay):-

IDMTL is one in which the operating time approx inversely proportional to the fault
current near pick up value and becomes substantially constant slightly above the
pickup value of the relay. This is achieved by using a core of the electromagnet which
gets saturated for currents slightly greater than pick up current. It has two types:-
(a) Non directional relay
(b) Directional relay
(a) Non directional(Over current or earth leakage) relay:- This type of relay will not be able
to discriminate when used on transmission lines, whether the fault has been taken place
in the section where the relay is located or it has taken place in the adjoining section.
Under the condition of high power factor or leading power factor, the impedance seen
by the relay is a very low or even negative.

Page | 11
(b) Directional (Over current or earth fault) relay:- The non directional relay can operate
for fault flow in either direction. In order to achieve operation for the fault flowing in a
specific direction, it is necessary to add a directional element to the non directional
element. Such a relay which responds to fault flow in a particular directional is called a
directional relay.
(II) Buchol’z relay:-
Buchol’z relay is a gas actuated relay used for protecting oil immersed transformers
against all types of internal faults and makes use of the fact that faults decompose
oil thus generating gases. The device relies on the fact that an electrical fault inside
the transformer tank is accompanied by generation of gas, and if the fault current is
high enough by a surge of oil from the tank to the conservator.

Fig:1.5 Buchholz relay

1.13 Lightning Arrestors:-
The earthing screen and ground wires can well protect the electrical system against direct
lightning strokes but they fail to provide protection against travelling waves which may
reach the terminal apparatus. The lightning arresters or surge diverters provide protection
against such surges.
Thus a lightning arrester or a surge diverter is a protective device which
conducts the high voltage surges on the power system to the ground. It is good practice to
connect the lightening arrestors through isolators so as to facilitate their maintenance, tests
and disconnection in cold season. Lightening arrestors must be earthed with rigid buses
routed over the shortest possible distances. Metal surfaces of the arrestors are coated with
moisture resistance paint.

Page | 12
 Fig:1.5 Lightining Arrester
Types of Lightning Arresters:-
There are several types of lightning arresters in general use. They differ only in
constructional details but operate on the same principle providing low resistance path for
the surges to the ground. The various types of lightning Arresters are given below.
(a) Rod gap arrester
(b) Horn gap arrester
(c) Multigap arrester
(d) Expulsion type lightning arrester
(e) Valve type lightning arrester
The lightning arresters used at Wanpoh grid were Rod gap arrester

Rod gap arrester:-

Line on the bushing of transformer has frequently a rod gap across it. It is a very simple type
of diverter and consists of two 1.5cm rods which are bent at right angles with a gap in
between as shown in figure. One rod is connected to the line circuit and the other rod is
connected to the earth. The distance between gap and insulator must not be less than one
third of the gap length so that the arc may not reach the insulator and damage it. Generally
the gap length is so adjusted that break down should occur at 80% of spark space over
voltage in order to avoid cascading of very steep wave fronts across the insulators. The
string of insulators for an overhead

Page | 13
 Under normal operating conditions, the gap remains non-conducting. On the
occurrence of a high voltage surge on the line, the gap sparks over and the surge conductor
is conducted to earth. In this way, excess charge on the line is due to the surge is harmlessly
conducted to earth.

Fig:1.6 Rod gap arrester

The lightning arrester voltage rating corresponding to the system voltages are indicated
below:

Rated system voltage(Kv) Highest system voltage(Kv) Arrester ratting in (Kv)

11 12 9
33 36 30
66 72.5 60
132 145 120/132(latex)
220 245 198/216(latex)
400 420 336

Specification of lightning arrestors in 132Kv system:

Style= SMX
Type= ZOBIVER
Rated voltage= 102Kv (r.m.s)
Long duration Discharge= 3
Frequency= 50Hz
Pressure Relief current (r.m.s)= 40KA
Normal Discharge current= 10KA

Page | 14
1.14 Power Line Carrier Communication System (PLCC):-
Whenever some breakdown occurs in the transmission network at any place, the message
to rectify the fault must be sent to all substations.
Quickness is the first priority. The ordinary telephone network cannot be used as it already
overloaded and remains engaged. Therefore, the same power lines, which carry energy, are
used for this purpose. The signal is modulated by HF carrier and is send as radio waves
through the power lines. This system is known as power line carrier communication system.
Miscellaneous equipments:-
In addition to above, there following equipments in a substation:-
(a) Fuses
(b) Carrier-current equipment
(c) Substation auxiliary supplies

Fig 1.7
a) Fuses:- Fuse is a essentially a short piece of metal (or a fusible material) inserted in a
circuit which melts when a predetermined value of current flows through it and thus
breaks the circuit. The protective element of the fuse is a fuse-link inserted in series
with the circuit being protected. The most generally material used for fuse element
is a low melting point material such as tin, lead or zinc. Fuses may be low voltage
type or high voltage type: Low voltage can be further divided into classes’ namely
semi-enclosed reliable fuse and the cartridge type fuse.
b) Substation Auxiliary Supply:- In small unattended substations only small amount of
power for electric lightening during regular periods of inspection, maintenance and
repair is required. In regional substations the electric power is required for the
auxiliaries- the lightening circuits, air blast fans of power transformers, battery
changing sets, compressor units in case of air blast circuit breakers, ventilating fans
of the substation building etc. in large substations it is wide practice to connect two
transformers to the main bus bars supply of the auxiliaries.
Page | 15
 c) Earthing:-
Connecting of an electrical equipment or apparatus to the earth with the help of a
connecting wire of negligible resistance is known as “earthing” or “grounding”.
In an electrical installation, if a metallic part of an electrical appliance comes in direct
contact with a bare or livewire, the neutral being a good conductor of electricity is charged
and static charge on it will accumulate. Now if any person comes in contact with this
charged metal part, he will get a severe shock. But if the metallic parts of the equipment or
apparatus are earthed, the charge will be given to earth immediately as the metallic part
comes in direct contact with a bare or live wire or breakdown occurs. And as the discharge
takes place to the earth, the impedance of the path of the current is low, heavy current
flows to earth, the instant the current exceeds the limiting value the protective device
(usually a fuse) operates and isolates the appliance or equipment from the supply. Thus to
provide safety to the users as well as for the operating and maintenance personals it is
essential to provide earthing.
The earthing can be divided into two parts:-
(i) System Earthing: It is required to provide low fault impedance to the ground fault
currents for proper operation of the protective relays and for meeting the system
requirement by effectively earthed system.
(j) Safety Earthing: It is required to provide protection to the operating staff working in
the yard and substation from any injury during fault conditions by keeping the voltage
gradient with in safe limits.
The above two parts have common earth mat from which flat iron risers are taken out to
connect all the non-current carrying metal parts of the equipment. At the same time the
earth mat conductors rise to voltage, which is equal to the resistance of the earth mat
multiplied by ground fault current. This difference of potentials results in voltage gradients.

In electrical installation the following components must be earthed:-

 The frames, tanks and enclosures of electric machines, transformers and apparatus,
lightening fittings and other items of equipment;
 The operating mechanism of the switchgear;
 The framework of the switchgear;
 The structural steel work of indoor and outdoor substations, metal cable jointing
boxes, the metals sheaths of the cable, and similar metal work.
Neutral grounding:-
In practice, the neutral of a three phase system is earthed at substations. This is known as
neutral earthing or grounding. An earthed neutral system has the following advantages:
a) It provides a better protection against earth faults.
b) It ensures nearly constant voltage of healthy phases because neutral point is not
shifted.

Page | 16
c) This system provides a better reliability of service.
d) It is safer for personnel and equipment.
e) It requires lesser maintenance expense as compared to the unearthed neutral
(isolated) system.
f) In the system, transient voltages produced are very small.
g) Ground fault relaying is simple. The earth may be utilized to operate protective
relays to isolate the fault.
h) Persistent arcing grounds can be eliminated by employing protective gears.

Page | 17
CHAPTER 2
2.1 POWER TRANSFORMERS
A power transformer is used in a sub-station for step up or step down the voltage. Except at
the power station, all the subsequent sub-station used step down transformers to gradually
reduce the voltage of electrical supply and finally delivered it at the utilization voltage. The
modern practice is to use 3 phase transformer in the sub-station, although 3 single phase
bank of transformer can also be used. The use of three phase transformer (instead of 3
single phase bank of transformer) permits two advantages. Firstly, only one 3 phase load
tap changing mechanism can be used. Secondly its installation is much similar then single
phase transformers. The power transformers are generally installed upon length of rails
fixed on concrete slabs having foundations 1 to 1.5 mtr deep. In Wanpoh grid station there
are five transformers out of which four are 20MVA and one is 50MVA.

Fig: 2.1 Power Transformers

Transformer Oil:-One of the most important factors which determine the life and
satisfactory operations of a transformer is the oil in which it is immersed. The transformer
oil has two prime functions:-
a). To create and acceptable level of insulation in conjunction with insulated conductors
and coils.
b).To provide a cooling medium capable of extracting quantities of heat without
deterioration as an insulating medium.
Transformers oil is a mineral oil obtained by fractional distillations of crude petroleum.
Vegetable and animal oils are not used in transformers. Some of the important
characteristics necessary in transformer oil are its dielectric strength, resistance to
emulsion, viscosity, purity, flash point and sludge formations.

Page | 18
2.2 Transformer cooling:- The transformer is a static device that converts energy at one
voltage level to another voltage level. During this process of energy transfer, losses occur in
the bindings and core of the transformer. These losses appeared as heat. This heat is
dissipated to the surroundings. The coolants used in the transformers are:-
(1) AIR
(2) OIL
The transformer using air as a coolant are called dry type transformers while transformers
which uses oil as the coolant are called oil immersed transformers. In dry transformers the
heat generated is conducted across the core and windings to be dissipated from the outer
surface of the windings to the surrounding air through convection.
In the case of oil immersed transformers, the heat produced inside the core and the
windings is conducted across them to their surfaces. The heat is transferred oil to the walls
of the tank through convection. Finally, the heat is transferred from the tank walls of the
surrounding air by radiations and convection.
Methods of Cooling:-There are number of methods used for cooling of transformers.
The cooling methods used for used for dry type transformers are:
i. Air Natural (AN): The natural circulation of surrounding air is utilized to carry
away the heat generated by natural convection
ii. Air Blast (AB): Air blast is employed in order to keep the temperature rise
within the limits. The forced air circulation improves the heat dissipation.
The cooling methods used for oil immersed transformers are:
a) Oil Natural (ON): The cooling by air is not so effective and proves insufficient for
transformers of medium sizes. Oil as coolant has two advantages:
~ it is better conductor of heat than air, and
~ it has high coefficient of volume expansion with temperature
b) Oil Natural Air Forced (ONAF): In this method, the oil circulating under natural head
transfer heat to the tank walls. The transformer tank is made hollow and air is blown
through the hollow space to cool the transformer.
c) Oil natural Water forced (ONWF): In this method, copper cooling coils are mounted
on the transformers core but below the surface of oil. Water is circulated through
the cooling coils to cool the transformer.
d) Forced Circulation of Oil (OF): Oil is circulated by a motor driven pump from the top
of a transformer tank to an external cooling plant where oil is cooled. The cold oil
enters the transformer at the bottom of the tank
i) Oil forced air natural (OFAN)
ii) Oil forced air forced (OFAF)
iii) Oil forced water forced (OFWF)
2.3 Transformer Protection:-

Page | 19
 The voltage of power networks supplied by the transformers can be controlled by changing
the ratio of transformation can be affected by providing tapping on the transformer
windings. The tapings are connections provided at different places in windings and
therefore, the number of turns at another tap. Hence the turn’s ratio is different at different
tapings and as different voltages is obtained at different tapings.
There is always a tapping on high voltage winding which when connected to rated voltage
gives rated voltage on the low voltage side. This taping is called the principal taping.
The number of turns included at other taps may be either greater or lesser than the number
of turns used at principal tapping. The tapping at which the turns included are more than
that of principal tapping is called positive tapping, while a tapping at which the number of
turns included is less than the number of turns included at principal tapping is called
negative tapping. The tapping may be changes when the transformer is disconnected from
the supply. This is called off circuit tap changing. The off circuit tap changing is used for
occasional adjustments, as in distribution transformers.
The tapings may also be changed while the transformer is energized or no load. This is called
on load tap changing.

2.3 Conservative and Breather:

Fig:2.2 Breather
The oil level of a transformer changes with changes with changes in the temperature rise of
oil which in turn depends upon the load on the transformer. The oil expands if load
increases and contracts if load decreases. Therefore, provision must be made to take cover.
Page | 20
This space is taken by air. When the oil expands, air is expelled out while if it contracts air is
drawn in from the atmosphere. This is called breathing of the transformer. The air entering
the transformer is passed through an apparatus called breather for purpose of extracting
moisture from it. A breather consists of a small container connected to the vent pipe and
contains a dehydrating material like silica dry and a whitish pink when damp.

Oil is prevented from having direct contact with air as well as moisture. Conservators are
used for this purpose. The function of the conservators is used for this purpose. The
function of the conservator is half full. The interior of the conservator above the oil level is
connected to the atmosphere through breather having dehydrating material.

2.4 Explosion vent:

In order to guard against the possibility of sudden high pressure caused by a breakdown or a
short circuit in the transformer winding, a diaphragm. Relief device is used. This device
consists of a large opening to the atmosphere covered by a thin non metallic diaphragm.
The diaphragm bursts if the pressure inside the tank becomes excessive. The relief device
must be above the level of oil in the conservator in order to prevent an overflow of the oil in
case the device operates.

2.5 Temperature Indicators:

The oil temperature is measured by a dial type thermometer. The bulb of the thermometer
is mounted in the oil and the dial is mounted outside the tank. However, oil temperature is
not a reliable measure of the winding temperature especially under sudden overloads which
cause the winding temperature to rise more than the oil temperature. Therefore it is
desirable to use an indicator which will show the actual temperature of hot spot in the
winding.

Winding temperature indicator is a thermometer with a bulb. The thermometer is immersed

in oil and the bulb is heated which carry a current proportional to the winding current.

2.6 Instrument Transformers:

The lines I sub stations operate at high voltage and carry current of 1000 of amperes. The
measuring instruments and protective devices are designed for low voltages (for generally
110 volts) and currents (about 5A). Therefore, they not work satisfactory if mounted directly

Page | 21
on the power lines this difficulty is overcomes by installing instrument transformers on the
power lines. The function of his instrument transformers is to transfer voltages or currents
in the power lines to values which are convenient for the operation of measuring
instruments and relays. There are two types of instrument transformers.

1) Current Transformers (C.T)

2) Potential Transformer (P.T)

i) Current Transformers:-C.T is essentially a transformer which step down current to a

known ratio. The primary winding of this transformer consists of one or more turns
of thick wire connected in series with the line. The secondary consists of large
number of turns of fine wire and provides for the measuring instruments & relays a
current which is a constant fraction of the current in the line. Suppose current
transformer rated at 100/5 A is connected in the line to measure current in primary
the current in primary the current in the line 100A, then secondary of C.T will be 5A.
Similarly, if current in the line is 50A, then secondary of C.T will have current of 2.3A
Thus C.T under consideration will step down the line current by a factor of 20.

Fig:2.3 current transformer(CT)

ii) Potential Transformer; It is essentially a step down transformer & step downs the
voltage to a known ratio. The primary of these transformers consists of large number

Page | 22
 of turns of fine wire connected across the line. The secondary winding consist of a
few turns provides for measuring instruments and relays a voltage is known fraction
of the line voltage. Suppose a potential transformer rated at 66kv/110v is connected
to a power line. If line voltage is 66kv, then the voltage across secondary will be
110KV

Fig: 2.4 Potential transformer (PT)

II. Specification of 132/33Kv potential Transformer

Line voltages=132kv
VA/phase=750
Phase=1
Class=B
Frequency=50 Hz*
Neutrally Earthed voltage
Primary-73200V
Secondary-63.5V
Metering & Indicating Instruments:There are several metering & indicating (e.g. ammeter,
voltmeter, energy meter etc) installed in a substation to maintain watch over the circuit
quantities. The instrument transformers are invariably used with them for satisfactory
operation.

Page | 23
CHAPTER. 3

DESIGN. MANUFACTURING AND TESTING PROCESS OF

TRANSFORMER

3.1 SPECIFICATION OF 20 MVA POWER TRANSFORMER

Type : 3-Phase, core type step down distribution
Transformer
Connection : Delta/Star
Cooling : ONAN/0NAF
Rated Power : 16000/20000 KVA
Rated voltage at no Load : HV 132000
LV 33000
Amperes : Hv 69.98/87.48
LV 279.93/349.91
No of phases : 3
Primary Turns (H.V) : 2772 turns of 1.62mm Aluminum wire

Secondary Turns (L.V) : 63 turns of 10.4x4.25mm Al. strip

Quantity of Transformer : 12500 Liters Oil

Core used : Stampings of transformer sheet steel of

Thickness 0.30mm

Frequency : 50Hz

Manufactured by : Indo tech transformers Ltd

Page | 24
3.2 DESIGN AND MANUFACTURING;-

The whole process of design and manufacturing of a 100KVA distribution transformer is

divided in to several steps for ease. The various steps under which manufacturing process is

completed are:-

a). fabrication of transformer tank

b). fabrication of core.

c). Winding of coils (Primary & Secondary)

d). Assembling of core & coil.

e). Blowing hot air on core & assembly by placing it into the oven.

f). Assembling of transformer tank.

3.3 FABRICATION OF TRANSFORMER TANK

Transformer tank is the outer covering in which the core and coil assembly of the
transformer are placed. The transformer tank is fabricated of 10mm thick mild steel sheets.
First the 10mm thick mild steel sheet is taken and various dimensions are marked
dimensions using a power hacksaw. The various parts are then welded using mild steel are
welding to form the desire tank. The top cover of the tank is fabricated separately and it
carries various other parts such as conservator, L.V and H.V bushings. The top cover is then
fitted with the tank using nuts and bolts.
Other accessories provided with the transformer tank are:-

Conservator

Conservator is a cylindrical enclosure at the top of the transformer connected to the main

tank by a pipe. The conservator contains the excess transformer oil to cope with loss of

Page | 25
transformer oil in the tank due to oxidation of oil so that transformer tank always remains

filled with the oil.

I. Bushings

The bushing of distribution transformer consists of a current carrying conductor in the form

of conducting rod fixed rigidly in the center of a porcelain cylinder carrying part. For a 100

KVA, 11000/433V Distribution transformer, three H.V bushings (11KV), and four L.V

bushings (433) are needed for primary and secondary sides respectively.

II. Radiators

Radiators are provided on the sides if transformer for the purpose of cooling. The oil which

gets heated up due to losses in the transformers circulates through the radiators and the

heat gets dissipated to the atmosphere. Thus radiator helps in cooling of the transformer.

3.4 Testing of Transformer Tank against Leakage

After fabrication of the transformer tank, the transformer tank is tested against leakage. For

this purpose the top cover if fixed on the transformer body, and compressed air is filled in

the tank using a compressor. The transformer is then dipped in the soap water and is

carefully examined. If there is any leakage in the tank, the bubbles come out of the water

which indicates the leakage.

3.5 FABRICATION OF CORE

In a core type distribution transformer, the coil surrounds the considerable portion of the

core. The material used for the core should be such that it provides low reluctance path for

the flux and it should also have low hysteresis loses. The transformer sheet steel, also

known as Silicon steel is the material used for construction of core. The presence of high
Page | 26
silicon content reduces the hysteresis losses in transformer. The core is made into thin

stampings called laminations, which are then minimizing the eddy current losses. The eddy

current losses are directly proportional to the thickness of the laminations, so fine

laminations of 0.30mm thick sheet are made are insulated from each other by thin layer of

core plate varnish.

The various designed dimensions are marked on 0.30mm thick transformer sheet steel and

the sheet is cut to the marked dimensions using mechanical shearing machine. A rectangular

core cannot be used for a 100KVA transformer due to its wastefulness and low space factor.

The core is made in cruciform shape with five core steps. This core steeping gives high space

factor and also reduces the mean turn length and consequent copper losses. The core

steeping makes core-section shape nearly circular.

Mitered (beveled) joints are used for cores and yokes. This is employed in order to increase

the mechanical strength of the core and to reduce the air gap between yoke and middle

limb. In this process, the top and bottom edges of adjacent pair of laminations are displaced

from the axes.

The first two laminations exhibit the pattern and the next pair. This process continues till
the assembly of yoke is completed. When the core is completed, the top yoke and bottom
yokes are tightened between channels. The top and bottom channels are tightened with the
help of tie rods securely tightened. The core is then raised to vertical position.

The core limbs are tightly braced using cotton insulating tape around the limbs. The top
yoke is then removed to enable L.V and H.V coil to be placed.

Core bolts are not used for tightly of core limbs. The limbs are braced with cotton insulating
tape and the L.T winding act as tightening agent.

Page | 27
3.6 WINDING OF COILS

100KV transformer has two coils namely low voltage coil (L.V) and high voltage coil (H.V)
both these coils are wounded independently. Both coils are formed wounded and of
cylindrical type. The circular cylindrical coils are used because of high mechanical strength.
The low voltage coil is placed near the core because it is easy to insulate L.V coil.

i. L.V Coil

A cylindrical form of 10mm pressboard insulating paper is pleased in a drum. Two aluminum
rectangular paper strips of 10.4x4.25mm cross-section are both insulted using 3mm
insulating brown paper on each strip through the length. The starting terminals of these two
strips are taken out of former then the strips are wound helically on the former. Two
parallel strips are used because it is difficult to wind one strip of equivalent cross-section
due to its high mechanical strength. 63 turns of these strips are wounded and finished
terminal is also taken out of the former. The coil is then covered with another insulating
cover and tightly braced to prevent any insulation damage. Three such coils are wounded
three limbs to act as three phases.

ii. H.V Coil

Aluminum conductor of 1.62mm gauge is wound on an insulating cylinder of 10mm

pressboard. 2772 turns of conductor are wound on H.V. coils. The conductor is concentric
helical layers. Each helical is insulated from surrounding layers by insulating paper.

For ease in winding, the H.V. coil is 12 bundles each of 693 turns, 4 bundles in series acting
as one phase.

3.7 ASSEMBLING OF CORE AND COIL

After completion of core, it is raised to vertical position and top yoke is removed. First the
L.V coil is placed on each limb with their terminals facing upwards. L.V coil is placed near to
the core because it is easy to insulate L.V coil. Utmost care is required to be taken while
placing L.V coil on core limbs so that the insulations of coil does not damage. After placing
L.V coil on the core limb and the coil. These are called the vertical spacers and keep the L.V
coil equally spaced from core at all parts. They keep the core limb laminations tight.
Page | 28
After placing L.V coil on each limb, four bundles of 693 turns of H.V coil are placed on each
limb. Radials spacers of 10mm press-board are provided between these bundles and vertical
spacers of wooden batten provided between H.V and L.V coils. The vertical and radial
spacers ensure oil circulation between L.V and H.V coil and thus help in cooling. Layer of
insulation is provided on either side of the coils as protection against flash over due to over
voltage.

The core and windings should be rigidly braced so as to prevent possible insulation damage
during movement and to reduce vibrations and the noise.

After placing coils on the core, the top yoke of core is placed on the core limbs and the core
is tightened by nuts and bolts.

3.7 ASSEMBLING OF TRANSFORMER TANK

The prepared transformer is washed, cleaned and dried so that there is no dust or moisture
in the tank. The heated core and winding is taken out of oven and placed immediately into
the tank. The core base channels are tightly fitted to the base of the transformers. The
various connections are made L.V coil is connected in star and various terminals are
connected to four L.V bushings. H.V coil is connected in delta and three terminals are
connected to the three H.V bushings.

After putting assembled core and winding at its proper place, the tank is filled with heated,
purified and filtered high quality insulating transformer oil. The transformer oil performs
two functions:-

a) It keeps the transformer reasonably cool by circulation.

b) It provides excellent insulating properties.

The transformer oil, before filling its tank is tested for its dielectric strength.

The transformer top cover is placed in position and fitted air tight using nuts and bolts. The
core and coil shell always be completely immersed in oil. The transformer is now put to
certain tests.

Page | 29
CHAPTER 4

4 TESTING OF TRANSFORMERS

In a transformer testing there are two types of tests, i.e. preliminary tests and final tests.
Preliminary tests are carried out on transformer before it is put into the tank. Final test are
carried out on complete assembled transformer.

4(a) PRILIMINARY TESTS:-

Following preliminary tests are carried out on transformers:

4.1 MEGGER TEST (INSULATION TEST)

In this test:

# Equipment used:- Megger (usually of 1000v or 2500v)

# measured insulation resistance between

(i) H.T-E i.e., H.T coil to core

(ii) L.T-E i.e., L.T coil to core

(iii) H.T-L.T i.e., H.T to L.T coil

The insulation resistance value as indicated by megger in all the cases
should be more than 500Mohm.
4.2 OIL TEST (VOLTAGE BREAKDOWN TEST / DIELECTRIC STRENGTH OF TEST OF OIL)
Good transformer oil should be absolutely free from impurities like alkalies and particularly
from moisture, which reduce the dielectric strength of oil. Therefore the transformer oil
should be filtered and heated and then tested for the dielectric strength.
In this test:
# Instrument used: Basically a potential transformer.
# 230V 1-0 supply is raised 240KV for gap of 2.5mm.
# Duration of test: 60 sec
Make sure no air bubbles are there in sample of oil and it should withstand 30KV (average)
for 60 sec for untreated oil and 50KV for filtered and treated oil. In case of contamination,
i.e., moisture, there will be spark and the potential transformer will trip.

Page | 30
4(b) FINAL TESTS:-
Following final tests are carried out on completely assembled transformer:
4.3 OPEN CIRCUIT/ NO LOAD TEST (FOR MEASUREMENT OF CORE / IRON LOSSES)
The main purpose of this test is to determine the no load losses / core losses and no load
current of the transformer.
In this test:
(i) Core not properly clamped/ loosely clamped.
(ii) High supply frequency.
(iii) Rusted/ rough cutting of core laminations edge.
4.4 SHORT CIRCUIT TEST/ FULL LOAD TEST
The main purpose of this test is to determine the total cu losses and impedance voltage of
the transformer.
In this test:
# Feed full load amperes on H.T side.
# L.T side solidly short circuited with a thick lead.
# Some of the wattmeter readings gives total cu losses i.e.
W1 + W2 = total cu losses
Since in this test, the applied voltage is small percentage of the voltage, the mutual flux,
produced in the core is also small; hence the core losses are very small. So the wattmeter
reading represents the total full load i.e., cu losses. The voltmeter on H.T side gives that
circuit voltage or impedance voltage which is the voltage required to produce the rated
current on H.T side. Impedance voltage is about 4.5% of rated voltage on H.T side. The value
of impedance voltage is approx. equal to 480V.
Total equivalent impedance of transformer = Zph = Vsc/Isc =480/3.03 = 158.4 ohm.
%impedance voltage = voltage to produce rated current/rated voltage at H.T side.

Page | 31
CONCLUSION
Now from this report one can conclude that electricity plays an important role in our life. At
the end of the training. I came to know about the various parts of substations and how they
are operated. Also I learnt about how transmission is done in various parts of
Jammu&Kashmir.

Page | 32
BIBLIOGRAPHY

1. www.scribd.com

2. en.wikipedia.org/wiki/Optical isolator

3. en.wikipedia.org/wiki/Circuit breaker

4. en.wikipedia.org/wiki/Transformer

5. en.wikipedia.org/wiki/Lightning rod

6. library.thinkquest.org/C0121286/earthing.htm

Page | 33