ESP(22633) 2022

Unit 2

11 kV Substation

Pole Mounted Substation:

1. It is a distribution sub-station placed overhead on a pole. It is the cheapest form of substation as it does not
involve any building work. Fig (i) shows the layout of pole-mounted sub-station
2. Whereas Fig (ii) shows the schematic connections. The transformer and other equipment are mounted on
H-type pole (or 4-pole structure).
3. The 11 kV line is connected to the transformer (11kV / 400 V) through gang isolator and fuses.
4. The lightning arresters are installed on the H.T. side to protect the sub-station from lightning strokes.
5. The transformer steps down the voltage to 400V, 3-phase, 4-wire supply. The voltage between any two
lines is 400V whereas the voltage between any line and neutral is 230 V.
6. The oil circuit breaker (O.C.B.) installed on the L.T. side automatically isolates the transformer from the
consumers in the event of any fault.
7. The pole-mounted sub-stations are generally used for transformer capacity up to *200 kVA.
8. The following points may be noted about pole-mounted sub-stations:

A. There should be periodical check-up of the dielectric strength of oil in the transformer and O.C.B.
B. In case of repair of transformer or O.C.B., both gang isolator and O.C.B. should be shut off.

Plinth mounting:

As per IS 1180, DTs above 500 KVA have necessarily to be mounted on a plinth, however, lower
capacity DTs may also mounted on plinth. The plinth is a low height platform, normally made of
concrete structure. The Plinth should be capable to carry the weight of the DT. The plinth shall be higher
than the surroundings. Plinth mounted distribution sub-stations should be adequately protected by
fencing so as to prevent access to the equipment by unauthorized persons, animals and should be
provided with standard danger boards. The enclosure should also permit free circulation of air on all
sides. This type of DT substations is best suitable for higher load centers areas where adequate land is
available such as in urban areas , housing complex, office complex and other developed areas. This
substation can be indoor type or outdoor type and the rating of Transformer may normally be more than
250KVA to 1000KVA depending on load requirement in the localities and also for economic reasons as
this needs control gears/ switchgears and proper enclosed wall boundary.

Distribution substation consists of:

1. Pin type insulator

2. AB switch
3. Lightning Arrester

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4. Circuit Breaker
5. Distribution Transformer
6. Earthing
7. DO Fuse
8. Stay Wire
9. MV cable
10. LV cable

1. Distribution Transformer
The distribution transformer is a main and largest equipment of distribution substation.

It is basically a static electrical device which steps down the primary voltage of 33kV or 11 kV to
secondary distribution voltage of 415-440 volts between phases and 215 volts between phase and
neutral through delta-star windings by electromagnetic induction without change in frequency.

Distribution transformers normally have ratings less than 500 kVA. Distribution transformers are
energized for 24 hours a day (even when they don't carry any load), reducing iron losses plays an
important role in their design. As they usually don't operate at full load, they are designed to have
maximum efficiency at lower loads. To have a better efficiency, voltage regulation in these transformers
should be kept to a minimum. Hence they are designed to have small leakage reactance.

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Transformer consists of the following parts and components.

 Primary winding
 Transformer tank
 Cooling tubes
 Buchholz Relay
 Tap changer
 Oil outlet valve
 L.T. terminals
 Temperature gauge
 Secondary winding
 Conservator
 Breather
 Explosion vent
 Oil inlet valve
 Oil level indicator
 H.T. terminals

2. Pin Type Insulator

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The pin insulator is used in power distribution for the voltage up to 33kV. It is placed on the
cross arm of the supporting tower. The pin insulator has grooves on the upper end for keeping the
conductor. The conductor is tied to the insulator on the top groove on straight line positions and side
groove in angle positions by annealed binding wire of the same material as that of the conductor. A lead
thimble is cemented into the insulator body to receive the pin.

The pin insulator uses non-conducting material like porcelain, ceramic, silicon rubber, polymer, etc.

3. Lightning arrester

Lightning arrester is a most important protective device of distribution substation to protect

valuable equipment as well as working personnel. It arrests and discharges over voltage to earth during
lightning strokes. These are installed between line and earth near equipment. If the lightning arrester
fails or is not installed, then extremely high voltage is introduced in the line due to lightning. This causes
severe damage to the transformers and other devices on the Pole.

4. Air Break Switch

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The triple pole AB switch is gang operated and designed for outdoor application. The switch is
designed to suit overhead systems used in high density urban situations or high load centers, where the
load is much higher and the need of improved and steady quality supply is much greater. Main function
of this product is to isolate the Transformer, Overhead lines, System or Cables from distribution
network.

The contacts of AB switch open in the air and the arc is quenched by compressed air, therefore it
is called as an air break switch. The air acts as a dielectric medium for the air-break switch. It is more
effective and reliable as compared to another switch. The air break switch is operated manually when
their handle is placed on a ground level.

5. Circuit Breakers

The circuit breaker is the equipment which automatically cut off power supply of the system
when any fault or short circuit occurs in the system. It detect and isolate faults within a fraction of a
second thereby minimizing the damage at the point where the fault has occurred.

The circuit breakers are specially designed to interrupt the very high fault currents, which may be ten or
more times the normal operating currents.

These units are used primarily on overhead feeder lines and are designed to protect distribution transformers
from any current spikes or surges that can overload equipment.

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Body: The frame supports the fuse tube/blade and is mounted to the cross arm or bracket. The insulator
body on this frame is of porcelain material. The live connector parts are also mounted to the ends of this
frame.

Fuse Holder: It is known as the fuse tube or “door” that contains the fuse link. This piece acts as a
simple switch. When the fuse operates, the fuse holder will drop open disengaging the switch from the
line. This ensures any downstream circuits are electrically isolated.

Fuse Link: Also known as an element is the replaceable portion of the product that extinguishes due to
higher than normal current transfers.

How do they work?

A current surge from a customer circuit or a transformer will cause the fuse link inside the tube to
expand and melt. Once the fuse reaches maximum current capacity it breaks and this energy is thrown
out of the bottom of the tube and disconnects the transformer from the line by the tube dropping out of
the upper contact and swinging down on the hinge. The physical indication that the fuse has been
extinguished and needs to be replaced is seen when the tube swings open and remains in a downward
orientation.

Application:

The dropout (swing out) fuse is an expulsion type and its main function is to protect Transformers on
rural distribution network. It is also particularly useful for inaccessible Sub-stations where indication of
fusing is of advantage.

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On blowing of fuse element, the fuse carrier hangs down vertically from the bottom contact. This is
advantageous locating the fault as hanging fuse carrier is noticeable from distance and this save times
which otherwise would be taken in investigation.

Current transformer (C.T.):

A current transformer is essentially a step-down transformer which steps down the current to a known
ratio. The primary of this transformer consists of one or more turns of thick wire connected in series
with the line. The secondary consists of a large number of turns of fine wire and provides for the
measuring instruments and relays a current which is a constant fraction of the current in the line.
Suppose a current transformer rated at 100/5 A is connected in the line to measure current. If the current
in the line is 100 A, then current in the secondary will be 5A.

Similarly, if current in the line is 50A, then secondary of C.T. will have a current of 2·5 A. Thus the
C.T. under consideration will step down the line current by a factor of 20.

Voltage transformer:

It is essentially a step down transformer and steps down the voltage to a known ratio. The primary of
this transformer consists of a large number of turns of fine wire connected across the line. The secondary
winding consists of a few turns and provides for measuring instruments and relays a voltage which is a
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 voltage across the secondary will be 110 V.

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Metering and Indicating Instruments:

There are several metering and indicating instruments (e.g. ammeters, voltmeters, energy meters
etc.) installed in a sub-station to maintain watch over the circuit quantities. The instrument transformers
are invariably used with them for satisfactory operation.

Strain Insulator

At a dead end of a transmission line or at a corner or sharp curve, the transmission line is
subjected to a great tensile load. In order to sustain this great tension, strain insulators are used at dead
ends or sharp corners. For high voltage transmission lines, stain insulator consists of an assembly of
suspension insulators. In this case, the suspension string is arranged horizontally and the insulator discs
are in vertical plane. Two or more suspension strings can be assembled in parallel to sustain greater
tensions. For low voltage lines (less than 11 kV), shackle insulators are used as strain insulators.

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Shackle Insulator

Shackle insulators are used in low voltage distribution lines as strain insulators. A shackle
insulator can be used vertically as well as horizontally and it can be directly fixed to a pole with a bolt or
to the cross arm. However, the use of such insulators is decreasing after increasing the use of
underground cables for distribution purpose.

Some additional types of insulators are: post insulators, glass insulators, polymer insulators, long-rod
insulators, stay insulators etc. .

Distribution Box (Board):

A distribution board (also known as panel board, breaker panel, electric panel, DB board or DB box) is a
component of an electricity supply system that divides an electrical power feed into subsidiary circuits while
providing a protective fuse or circuit breaker for each circuit in a common enclosure.

A typical electrical distribution box will include a bus bar, fuse links, switches, bypass equipment, and
residual current detector (RSD).

Their main functions are to:

- Break up the power supply into sub-circuits depending on the purpose for it.
- Ensure that everyone and everything is safe against short circuits.
- Distribute power to different areas from the main power source.

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Insulation Resistance Test of Transformer

 The measurement of insulation resistance is a common routine test performed on all types of
electrical wires and cables.

 The test consists of measuring the IR by short circuiting the phase and neutral.
 A Mega Ohm Meter is used to measure the ohmic value.

 This test is performed at or above rated voltage to determine if there are low resistance paths to
the ground or between winding to winding as a result of winding insulation deterioration.

 The test measurement values are affected by variables such as temperature, humidity, test
voltage, and size of the transformer.

 This test should be conducted before and after repair or when maintenance is performed.

 The test data should be recorded for future comparative purposes.

 The test values should be normalized to 20°C for comparison purposes.

Procedure of Insulation Resistance Test of Transformer:

i. Shut down the transformer and disconnect the jumpers and lightning arrestors.
ii. Thoroughly clean all bushings.
iii. Short circuit the windings.
iv. Firstly the positive terminal of the megger is connected to primary side and negative terminal
to ground.
v. Then readings are recorded after application of voltage.

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vi. Then again positive terminal of megger is connected to secondary side and negative terminal
side to ground.
vii. Then we again apply the voltage and readings are recorded.
viii. And at last again the positive terminal of megger is connected to primary side and negative
terminal to secondary side.
ix. Then we record the readings after application of voltage.
x. Record the IR. value at 60 seconds after application of the test.

Factors affecting on IR value of Transformer:

The IR value of transformers are influenced by

1. Surface condition of the terminal bushing

2. Quality of oil

3. Quality of winding insulation

4. Temperature of oil

5. Duration of application and value of test voltage

Earthing

Equipment earthing is a connection done through a metal link between the body of any electrical
appliance, or neutral point, as the case may be, to the deeper ground soil. The metal link is normally of
MS flat, CI flat, GI wire which should be penetrated to the ground earth grid.

The grounding system in substation is very important. The functions of grounding systems or earth mat
in include:

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 Ensure safety to personnel in substations against electrical shocks.

 Provide the ground connection for connecting the neutrals of stat connected transformer winding
to earth (neutral earthing).

 Discharge the over voltages from overhead ground wires or the lightning masts to earth. To
provide ground path for surge arresters.

 Provide a path for discharging the charge between phase and ground by means of earthing
switches.

 To provide earth connections to structures and other non-current carrying metallic objects in the
sub-station (equipment earthing).

In addition to such a grid below ground level, earthing spikes (electrodes) are driven into the ground.
They are connected electrically to the earth grid, equipment bodies, structures, neutrals, etc. All these are
connected to the station earthing system by earthing strips.

If the switchyards have a soil of low resistivity, earth resistance of the earthing system would be low. If
the soil resistivity is high, the mesh rods are laid at closer spacing. More electrodes are inserted in the
ground.

The earthing is broadly divided as

1. System earthing (Connection between parts of plant in an operating system like LV neutral of
a power transformer winding) and earth.

2. Equipment earthing (safety grounding) connecting bodies of equipment (like electric

motor body, transformer tank, switchgear box, operating rods of air break switches, LV breaker
body, HV breaker body, feeder breaker bodies etc) to earth.

The points we must earth in an electrical substation include:

1. The neutral point of different voltage levels

2. The metallic enclosure of all current carrying equipment

3. The framework of all current carrying equipment

4. All the metallic structure even not associated with current carrying equipment

Method of Earthing

We connect all the points to be earthed with the earthing grid with corrosion resistance mild still rods.
We bury the connection rods a minimum 600 mm below the ground level. If these horizontally buried

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rods cross a cable trench, road, underground pipe work, or rail track the rods should cross the barriers
through at least 300 mm below the bottom of the barriers.

Reasonable values for earth resistance are:

 Power stations – 0.5 ohms

 EHT stations – 1.0 ohms

 33kV SS – 2 ohms

 DTR structures – 5 ohms

 Tower foot resistance – 10 ohms

Daily Maintenance:

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Monthly:

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Quarterly:

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Half Yearly:

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Yearly:

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5 Yearly:

Safety Precautions:

 We have to switch off, isolate and properly earth the circuit before doing any work with the
circuit.
 We shall only execute the work after getting properly issued work permit from the concerned
operating personal.
 The work permit can only be issued after making the circuit completely dead, isolated and
earthed.
 We must display Danger Board at the place of work.
 We should not allow any unauthorized person to enter in the working place.
 We should not put any new equipment into the service without necessary testing by authority.
 All electrical equipments, bays, circuits, should be identified by properly viewable labels to
avoid any mistake.
 We should not work on electrical circuit during heavy lightning storm.
 We should wear shoes having sewn soles, preferably insulated rubber soles.
 We should not wear suspenders, arm bands, with metal buckets or other metal parts. We also do
not wear metal key chain or metal keepers for key rings or watch rings outside the clothing
during work. We should always, take extra precaution while work in extra damp area.
 When there is a hurry to do the work, the tired and exhausted workers should be avoided to do
so.
 We should not toss the tools or working materials to other person. It is better to deliver the tools
and materials hand to hand.

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 We should not keep any tools at the edge of equipment cabinet or structure from where these
may fall off.
 We should not do anything which may startle the person working in hazardous condition.

Safe isolation procedure for isolation:

The 7 steps for safe isolation are similar for low voltage and for high voltage. The process is as follows:
 identify suitable point(s) for isolation
 carry out the safe isolation process
 secure the point of isolation (place notices)
 prove dead
 apply safety earths
 place danger notices
 issue electrical permit to work

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