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CHAPTERII

SUBSTATIONSANDSWITCHINGSTATIONS

20200Introduction

1.Thischapterisdividedinto4sectionsasunder

SectionIOrganization:AbroadsetupoftheorganizationanddutiesofChiefTractionForeman(Power
SupplyInstallations)arecovered.

SectionIIOperationofSubstations:Theimportantpointsrelatingtooperationoftransformersand
protectivedevicesarecovered.

SectionIIIGuidingNotesonMaintenance:Theimportantpointstobeborneinmindinthemaintenanceof
chiefpowersupplyequipmentsarecovered.

SectionIVArecommendedscheduleofmaintenanceforpowersupplyequipmentsisgiven.

2.ThefollowingdocumentshavebeenincorporatedasAppendicestothisVolume:

2.1"CodeofPracticeforEarthingofPowerSupplyInstallationsfor25kV.ac,50HzSinglePhaseTraction
System"issuedbyRDSO(AppendixIII).

2.2"GuidelinesforRelaySettingatTractionSubstationsandSwitchingPosts"issuedbyRDSO(AppendixV)

2.3"GuidelinesforProvisionofMaintenanceDepots,ToolsandPlantsandTransportFacilities(AppendixVI).

2.4"ListofSpecificationsandDrawingsforEquipmentsandMaterialsforRailwayElectricTraction"issuedby
RDSO(AppendixIX).

I.ORGANIZATION

20201OrganizationalSetup

TheDivisionalsetupofseniorsubordinatesworkingunderSr.DEE/DEETrDhasbeenarrangedontwotypes
ofpatterns:

(a)Territorialbasis

(b)Functionalbasis

IntheterritorialsetuponeSr.Subordinateisresponsibleforalltheactivitiesofmaintenanceandoperation
overapredeterminedsectionofelectrifiedterritoryorasubdivision.Thefunctionalsetupenvisagesseparate
Sr.Subordinatetobeinchargeofeachactivityviz.substation,OHE,Workshop.PSIetc.inadivisionorsub
division.Duties,however,havebeenspecifiedhereinrelationtoparticularfunction.Forterritorialsetup,the
CTFOinchargewillperformhisdutieskeepingallfunctionsinview,thenextincommandviz.TFObeingthe
functionalinchargeofthespecificactivity.

Remotecontrolsystemorprotectiverelaytestingbeingaspecializedactivity,CTFO(RC)andCTFO/TestRoom
usuallyhaveafunctionaljurisdictionovertheentiredivision,withHeadQuartersattheRemoteControlCentre
andDivisionalRepairShoprespectively.TheCTFOsinterritorialcharge,shouldkeepaconstantliaison
betweenthemselvessincetheseaspectswillhaveanelementofdualcontrol.

20202DutiesofChiefTractionForeman,PowerSupplyInstallations

HeistheseniorsupervisorworkingunderthecontrolofDEE/AEE(TrD)anddirectlyresponsibleforthesafe
andefficientoperationandmaintenanceoftractionpowersupplyinstallationsincludingsubstations(when
ownedbytherailway),switchingstations,boostertransformersandauxiliarytransformersinhisjurisdiction.
Heshallbethoroughlyconversantwithalltechnicaldetailsoftheequipmentunderhischargeincludingtheir
rating,trendofpowerdemandasalsocorrectmethodsoftheiroperationandmaintenance.Inparticular,he

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shall

1.supervisethemaintenanceofinstallationsunderhischargeinaccordancewiththeprescribedschedulesto
keepthemfullyserviceableatalltimesandinastateofgoodrepair

2.maintainpropercoordinationwiththeTractionPowerController.ChiefTractionForeman(OHE).Supply
Authoritiesandrenderassistancewhenrequiredtoensurereliabilityofpowersupply

3.keephisorganisationinconstantreadinesstodealpromptlywithanybreakdownsandfailuresof
equipment

4.ensurethattheprogrammeoftestingandmaintenanceofprotectiverelaysisadheredtoandensurethat
othersafetyequipmentincludingbondingandearthingarefunctioningeffectively

5.instruct,trainandsupervisestaffunderhiscontrolandensurethattheydooperateandmaintainthe
equipmentproperlyandinparticulardoactuallyobserveallrulesandregulationsandsafetyprecautionslaid
down

6.deputestaffforrefreshercoursesasprescribed,particularlyforsuchstaffasarefounddeficientintheir
working

7.ensurethatspecialinstrumentsandtoolsprovidedformaintenanceoperationandtestingofallinstallations
areproperlycaredfor

8.keepaclosewatchonavailabilityofsparepartsandotherstoresrequiredformaintenanceandoperationof
theinstallationsandinitiatetimelyactiontorecoupstocks

9.ensureproperaccountalandperiodicalverificationofstoresandtoolsinhischarge.

10.deputestaffwhenrequiredtomansubstationsandswitchingstationsintheeventoffailureofremote
controlequipment

11.inspectallinstallationsunderhischargeatleastonceamonth,withparticularattentiontosafetyaspects

12.submitprescribedperiodicalreturnsaftercarefulscrutinytoAEE(TrD)andSr.DEE/DEE(TrD)

13.keephissuperiorofficersfullyinformedofallimportantdevelopmentandseektheirguidancewhen
required

14.carryoutsuchotherdutiesasmaybeallottedbysuperiorofficersfromtimetotime.

15.carryoutinspectionsasindicatedatAnnexure2.01.

II.OPERATIONOFSUBSTATIONS

20203Introduction

Sincetheelectrictractionsystemdependsuponcontinuousavailabilityofpowersupply,substationsand
switchingstationshavetobekeptinproperworkingconditionatallthetime.Toensurethis,thetransmission
lines,the25kVfeederlinesandtractiontransformerswithassociatedswitchgearandcontrolandrelay
panelsareduplicatedsothatifoneunitfails,thestandbyunitcanbebroughtintoservicetocontinuepower
supply.Allswitchingoperationsarealsocentralizedandcontrolledbyremoteoperationbyasingleauthority,
namelyTractionPowerController.

20204InspectionBookandLogBookatSubstations

An"InspectionBook"shallbemaintainedateverysubstationinwhichobservationsmadebysupervisory
officialsvisitingthesubstationforperiodicalinspectionsshallberecorded.Inadditionalogbookshouldalso
bemaintainedtokeeparecordofthetractiontransformeroiltemperature,ambienttemperatureaswellas
thecurrentsandvoltagesasindicatedonthecontrolpanelatafixedtimeeverymorning.Ifthereisanything
abnormalorunusual,CTFO(PSI)willinvestigatethecausethoroughlyandtakenecessaryremedialaction.

20205OverloadCapacityofTractionTransformers

Tractiontransformersusuallyhavethefollowingoverloadcapacity:

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1.Overloadrating:(a)50%overloadfor15min.,and(b)100%overloadforaperiodof5min.afterthe
transformerhasattainedsteadytemperatureoncontinuousoperationatfullload.

2.Overanambienttemperatureof45"Cthemaximumpermissibletemperatureriseshallbeasunder:

(a)Winding=50C(byresistancemethod)

(b)Oil=40C(bythermometer)

(c)Currentcarrying=35C(bythermometer)parts

3.Thehotspottemperatureafter50%overloadfor15min.or100%overloadfor5min.shallnotexceed
100Cforanambienttemperatureof45C.

4.Intervaloftimepermissiblebetweentwosuccessiveoverloads(aftercontinuousworkingatmaximum
ambienttemperatureof45C)is3hoursforboth50%overloadfor15min.and100%overloadfor5min.

20206TapSettingonTractionTransformers

TractionTransformersareusuallyprovidedwithoffloadtapchangers(operatedlocallyorbyremotecontrol)
withtapsfrom+10%to()15%instepsof5%.Todecidethecorrecttapsettingarecordingvoltmeter
shouldbeconnectedatthetractionsubstationtothesecondarysideofapotentialtransformertoascertain
thepatternofvoltagevariationthroughoutthe24hoursforatleast3typicaldays.Basedonthereadingsfrom
therecordingthetappositionshouldbefixedsothatthedailyOHEvoltagepeaksatthetractionsubstationlie
justbelow27.5kVbutdoesnottouch27.5kV.ThiswillensurethattheOHEvoltageiswellabovethe
minimumof19kVatthefarthestpointonthesystemevenwhenheavilyloaded.Onceayeara24hour
recordofvoltagesavailableonthetwosidesofeveryneutralsectionshouldbetakentomakesurethatthe
voltagedoesnotfallbelow19kVatanytime.

Sinceanychangeintheinterconnectionsofthegridsystemwouldhaverepercussionsonthevoltageatthe
tractionsubstation,theCTFO(PSI)shouldkeepintouchwiththesupplyauthoritiesinregardtosystem
changes

sothathemayarrangetotakeanothersetof24hourvoltagereadingsifanychangehastakenplaceandto
changethetapsettingifrequired.

20207TestsonTransformerOil

Inordertoimprovetheperformanceandtoprolongthelifeofthetransformers,EHVgradeoilisused.The
followingtwospecificationsthefirstonefornewoilandthesecondforoilinservice,areadopted:

(a)IS335SpecificationforNewInsulatingOils.

(b)IS1866CodeofPracticeforMaintenanceandSupervisionofInsulatingOilinService.

Asummaryoftestsforvariouscharacteristics,therequirementstobecompliedwithandmethodsoftestsas
containedinthetwospecificationsisatAnnexure2.03(A&B).Thetestsarewiderangingandshouldbedone
onceayear.However,someofthetestslikeBreakdownvoltage(BDV)test,aciditytests,crackletestfor
moisture,maybecarriedoutinPSIdepotsorsubstationsonceinsixmonthswhensamplesaredrawnfor
conditionmonitoringasperPara20216.ProceduresforthesetestsareindicatedinIS1866.

20208PurificationofTransformerOil

Theobjectofoilpurificationistoremoveallcontaminantssuchaswater,carbondeposits,dirt,sludge,
dissolvedmoistureandgases.Themostimportantqualitytobepreservedisthedielectricstrength,whichis
affectedbythepresenceofmoisture.

Theinsulatingmaterialsusedinthewindingarehygroscopicbynatureandthereforemoistureisabsorbed
throughdefectivebreathers,gasketsandadditionofuntreatedmakeupoil.Itisessentialtoremovethese
impuritiesbypurifyingtheoilwhenthedielectricstrengthgoesbelowthepermissiblelimits.

20209OilPurificationPlant

Forpurifyingthetransformeroil,machinesconformingtoRDSO'sSpecificationNo.ETI/PSI/103maybeused.
Thesearenormallyoperatedfrom240Vsinglephasesupplytakenfromthe100kVAStationtransformer
providedatthesubstation.Supervisoryofficialsinchargeofmaintenanceoftransformersshouldmake
themselvesfamiliarwiththesupplier'sinstructionsinregardtotheoperationandmaintenanceoftheoil
purifyingequipment.

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20210InsulationResistanceDuringDryingOut

Readingsoftemperatureandinsulationresistanceshouldberecordedeverytwohours,fromcommencement
untilthefulloperationiscompleted.Ifthereadingsareplottedonagraph,theappearancewillbeas3hcwnin
Fig,2.01.

Itwillbeobservedthattherearefourdistinctstages:

A.Initiallytheinsulationresistancedropsdowntoalowvaluebecauseofriseintemperatureoftheoilupto
about75C.

B.Insulationresistancewillcontinuetoremainatalowleveldespitetemperaturebeingmaintainedatahigh
leveluntilmostofthemoisturefromthewindingsandoilhasbeendrivenout.

C.Theinsulationresistancewillthereafterrisegraduallyandleveloff,indicatingthatallmoisturehasbeen
drivenoutandthedryingoutoperationhasbeencompleted.Atthispointoilcirculationshouldbe
discontinued.

D.Astheoilcoolsoff,theinsulationresistancewillrisemuchabovethelevellingoffpointattheendofstage
(C).Thisisbecausetheinsulationresistancevaluedoublesforafallintemperatureofabout10Cto15C.

20211ProtectiveDevices

Anumberofprotectivedevicesareprovidedtoensuresafeoperationoftractiontransformersandother
equipment(undernormalandextendedfeedconditionwithappropriateadjustmentofsettings).Alarmandtrip
circuitoperationsaretelesignalledandindicatedattheRCC.TheTPCshallineverysuchcaseadviseCTFO,so
thathecouldarrangefortheinspectionofthesubstationtoinvestigatethecauseandtakenecessary
correctiveactionandsubmitadetailedreporttoSr.DEE/DEE(TrD).

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20212OperationofTemperatureAlarmorTrip

Alarmandtripcontactsareprovidedtooperateshouldthetemperatureoftransformerwindingsor
transformeroilexceedpresetlimits.Ifalarmorthetripcontactshaveoperated,bothofwhichareindicated
attheRCC,CTFOshouldpersonallyinspecttheinstallation.Ifthedialsettingsarecorrect,thereasonfor
excessivetemperatureriseshouldbeinvestigated.Normallyinstantaneousoverloadsofover150%offullload
aretakencareofbyoverloadrelays,whilesustainedoverloadbelow150%areclearedbythermalprotection.
Itisadvisabletoconnectarecordingammeterandgeta24hourchartshowingthecurrentloadingofthe
transformerinservices.Theshapeoftheloadcurvewouldgivevaluablecluesastocorrectiveactiontobe
taken.

Ifthealarmandtripcircuitsoperatefrequentlyduringpeakperiods,attemptshouldbemadewithOperating
Departmenttospaceoutthetrainsmoreuniformlythroughoutthedaysoastoreducethepeakload.If,on
theotherhand,itisasuburbansectionandthepeakloadcannotobviouslybebroughtdown,thesecond
standby

transformermayhavetobepressedintoserviceforthedurationofthepeakload.Suchparalleloperationof
tractiontransformersmaysometimesalsoincidentallyresultinreductionofthetotallossestherebyeffecting
economy.Secondly,itwillalsoresultinhigherOHEvoltage,sincetractiontransformerimpedanceisnow
halvedasthetransformersareidentical.

Ifasubstationispersistentlyoverloadedandanadjacentsubstationisappreciablyunderloaded,the
possibilityofshiftingtheneutralsectionmaybeconsidered.

20213OperationofDifferentialProtection

Apartfromoperationonaccountofinternalfaultsinthetransformer,thedifferentialrelaycouldalsooperate
eitherbecauseofcurrentinrushonaccountofmagnetizationofthecoreatthetimeofswitchingonor
becauseofspillcurrentcausedbylackofperfectbalancebetweensecondariesofEHVand25kVcurrent
transformers.ThecausesforsuchmaloperationmaybedefectiveharmonicrestraintfiltersorwrongCT
ratiosandshouldbeeliminated.

20214BuchholzRelay

TheBuchholzrelayassemblyisprovidedontransformerstodetectevolutionofgascausedduetointernal
faults.Afterfirstcommissioning,theupperassemblyoftherelaymaysometimesbefoundtooperatecausing
therelaytotrip.Analysisofthecompositionofgascollectedwillindicatethenatureoffault.Ifitismereair
bubblesthetransformerissound.Fordetailsoftestsmanufacturerswriteupmaybereferredto.Itisalways
awisepolicytogetthedielectricstrengthoftheoiltested,measuretheinsulationresistanceandcarryout
ratiotest.

IIIGUIDINGNOTESONMAINTENANCE

20215Introduction

1.Forbetterutilizationoftractionassets,outageofanytractionequipmentfromserviceshouldbeminimum
withoutcompromisingonsafetyoftheequipmentandpersonnel.Monitoringofconditionoftheequipmentby
reliablemeansisessentialforfollowingsystemofneedbasedmaintenancei.e.directedmaintenance.
However,tillsuchtimereliableconditionmonitoringtechniquesareintroduced,thepresentsystemof
preventivemaintenancehastocontinue.

2.RecommendationsofOriginalEquipmentManufacturer(OEM)andguidelinesissuedbyRDSO,timetotime,
shallbekeptinviewwhiledefiningthescopeandperiodicityoftheschedules.

3.ThetighteningtorqueforfastenersofvarioussizesisgiveninAnnexure2.08.

20216Transformers

1.ConditionMonitoring

Inoilfilledequipmentliketransformers,normaldeteriorationorageingofinsulationiscausedbythermo
chemicalreactionwithparticipationofheat,moistureandoxygen.Thisresultsinformationofsolubleand
insolubleproductswhichaccumulateanddeterioratethepropertiesofoilandcellulosicinsulation.Whereasthe
oilca"bereconditionedtorestorefunctionalproperties,nosuchtreatmentispossibleforthecellulosic
insulation,whichsuffersfromreductionofmechanicalanddielectricstrength.Theconditionoftheinsulation,
therefore,needstobecheckedbysuitablemethod.

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Thethermalandelectricalstressescausedduringshortcircuits,overloadsandovervoltagesinthesystem
resultingasformationinappreciableamountanddeteriorationofdielectricpropertiesandloweringofflash
pointofoilfrom145Ctosomewherebetween50to80Cinextremecases.Inthecaseofincipient
faults,thegasesbeingsoluble,areabsorbedinoil.TheBuchholzrelaycannotrespondduringearlystagesof
troubleandbythetimethesedevicesoperatethedamageisdone.Dissolvedgasanalysis(DGA)providesan
importantmeansintheartofconditionmonitoringofpowertransformersandotheroilfilledequipment.Of
thevariousmethodsofgas

analysisGasChromatography(GC)isoneofthemostsensitive,efficientandrapidmethod,eminentlysuited
fordetectionofincipientfaultsandformonitoringofgrowingfaultswhicharenotalwaysrevealedby
establishedroutinetestsetc.Inordertotimelydetectthedeteriorationofinsulation,oilsampleshallbedrawn
annuallyandsubjectedtogaschromatography.

GuidelinesforconditionmonitoringoftractiontransformersbyDissolvedGasAnalysistechniqueareappended
atAnnexure2.04.

2.OverhaulOfTransformers

a)Overhaulofatransformerisnormallyundertakeneitherifitisfaultyorattheendof710yearsbywayof
periodicmaintenance.ThiscanbedoneintheCentralRepairShopwhichisacoveredshophavingfullfacilities
includingacoreliftingbaywithacrane.Beforecommencingtheworkensurethatsparegasketsofproper
qualityareavailable.Drainouttheoil,disconnectallleads,removemanholecoverswhererequired.TheEHV
and25kVbushingsarethencarefullyremovedoutandstoredwellprotectedinasafeplace.Thenremovethe
corebymeansoftheliftinghooksandplaceonshopflooroveratrestleinalargereceptacleintowhichoil
candrainout.

b)Ifthetransformerhasbeenopenedupbecauseofanyinternalfault,makeacarefulnoteofcolourof
transformeroil,arcmarks,carbondeposits,charringofinsulation,conditionofthewindings,unusualodour
andotherabnormalitieswhichwouldallhelpinascertainingthecauseofthefailure.Ifacoilhasbeenburnt
out,thewholetransformerwillhavetobecompletelydismantledandthenthedamagedcoilreplacedwitha
newcoil.Inthecaseofthetractiontransformers,thereplacementofthedamagedcoilisbestdoneinthe
Manufacture'sworkswherenecessaryfacilitiesandstaffwiththerequisiteskillareavailable.

c)Arrangefortheinteriorofthetransformertanktobethoroughlycleanedofallaccumulateddebris,sludge,
etc.andwashwithfreshoil.Removethedrainplug,lightlypolishthevalveseatandrenewtheoiltightgasket
roundthespindlesothatwhenassembledtheplugisfullyoiltightthesameremarksapplytotheoil
samplingvalve,ifprovided.Opportunityshouldalsobetakentoplugorweldupanysmallblowholesthrough
whichoilseepagewasobservedearlier.Finallypainttheexteriorofthetankifnecessaryafterthoroughly
cleaningitupofallpaintwork,rustandtracesofoilanddirt.

d)Ifthecoilassemblyisliftedupafter5,10ormoreyearsofservice,considerableamountofsludge
formationwouldhaveoccurredonallpartsofthetransformer,i.e.,atthebottomofthetanks,metalworkof
thetransformers,windingsandinterspacesbetweenwindings.Alltheseshouldbescrappedoffcarefullywith
awoodenorfibrewedgewithout.causinganydamagetothewindings.Tracesofthesludgeleftoverin
inaccessibleplacesarebestremovedbydirectingathinjetoftransformeroilunderpressureusingsmalloil
purifier.Atthesametimetheoldsurfacecontaminationshouldbebrushedandwasheddown,untiltheclear
surfaceofthewindingisexposed.

e)Careshouldbetakentoprotectthewindingsagainstingressofmoistureparticularlyduringinclement
weather.Careshouldalsobetakenbywipingoffbodysweatwithatowel.Thewindingsshouldalsobekept
warmbysurroundingtheopenwindingsbyanumberofinfraredlampsorbyothermeans.

f)Fullypushhomethewedgesbetweenthecoilsandtakeuptheslacknessofendplatesbytighteningupthe
boltsandlockingthem.Theseareprovidedontractiontransformerstoholdthewindingstightlytogetherto
withstandthehighmechanicalforcesgeneratedatthetimeofshortcircuits.Shrinkageandsettlementusually
takeplacewithinthefirstsixmonthsofthecommissioningofatransformer.Thecoilsarealsoliabletosuffer
displacementduetoshortcircuitforces.Ifthecoilsarenotheldtightlyinposition,itwillleadtorepeated
movementofthecoilsaswellaslayersandturnswhichwillinturncauseabrasionandwearofinsulationand
ultimatelyfailure.Itis,therefore,sometimesrecommendedthatthefirstavailableopportunityshouldbe
takentohavethewedgesfullyhomeandtightenupthepressurescrewswheretheyareprovided.

g)Finallyputbackthecoreassemblyinsidethetank,assemblethebushingchecktightnessofallinternal
connections,fitthetop,providenewgaskets,fillpureoilanddryoutasdetailedinpara20208to20210.
Experiencehasshownthattoolslikespannersandforeignobjectslikewashers,piecesofcloth,etc.are
sometimesinadvertentlyleftbehindinthetransformers,whichpresenthazardofshortcircuits.Itis,
therefore,importantthatalltools,etc.usedintheoverhaulworkshouldbelistedoutatthebeginningand
accountedforattheendofthework.

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WhenoverhauledtransformersaretobecommissionedthesameprocedureasdetailedinChapterIXfornew
transformersshouldbefollowed.

Eachrailwayshouldplan,takingintoconsiderationtheresourcesavailablewiththemtocarryoutthePOHand
repairsofthetransformeranddecidetheagencytoexecutethework.

3.InvestigationintoCausesofFailuresofTransformers

Inmostcasesthecausesofthefaultcanbesurmisedbycarefulobservationoftheconditionthewindings,
e.g.displacementoftheturnsorcoils,coilinsulation(brittleorhealthy),evidenceofoverheating,carbon
depositorflashmarksonthecore,supports,theinnersurfaceofthetankorcover.Thefollowingnotesmay
beofhelpinidentifyingthecause:

(a)FailureduetolightningdischargeorovervoltagesThisischaracterizedbybreakdownoftheendturns
closetothelineterminal.Theremaybeabreakintheturnsorendlead,andalsoflashmarksontheendcoil
andearthedpartsclosetoit,buttherestofthecoilswillbefoundtobehealthy,

(b)Sustainedoverloads.Thewindingsinoneorallphaseswouldshowsignsofoverheatingandcharring
theinsulationwouldbeverybrittleandwouldhavelostallitselasticity.

(c)Interturnshort,interlayershort,orintercoilsshortThesamesignsasforindicatedforsustainedover
loadwouldbenoticed,butonlyonaffectedcoils,therestofthecoilsbeingintact.ThisIslikelyifthe
differentialrelayortheBuchholzrelayhasoperated.

(d)Deadshortcircuit.Thiscanbeidentifiedbytheunmistakable,lateraloraxialdisplacementofthecoils.
Thecoilsmaybelooseonthecore,someturnsontheoutermostlayermayhaveburstoutwardsandbroken
asifundertension.If,inadditiontothesesigns,thewindingsarealsocompletelycharred,itisconclusive
evidencethattheshortcircuithascontinuedforanappreciableperiod,nothavingbeenclearedquicklybythe
protectiverelays.

(e)IftheupperchamberoftheBuchholzrelayalonehastripped,checktheinsulationofcorebolts,by
applyingavoltageof230Vto1000Vbetweenthecoreandeachbolt.Ifitfails,renewtheinsulatingbush.
Observealsoallthejoints,andtapchangercontacts,foroverheatingandarcing.

(f)IftheoilshowsalowBDV,itdoesnotnecessarilymeanthatithascausedthebreakdown.Athighvoltage
ratings,excessivemoisturecontentintheoilmayresultaninternalflashoverbetweenthelivepartsand
earth,whichwillleavecorrespondingtelltalemarks.

20217CircuitBreakersandInterrupters

Thefollowingtypesofcircuitbreakersandinterruptorsarenowinuse:CircuitBreakers:

(a)220/132/110/66kV,Doublepole:

Minimumoiltype

SF6type

(b)25kV,SinglePole

Minimumoiltype

SF6type

Vacuumtype

(c)Interruptors

Bulkoiltype

Minimumoiltype

SF6

Vacuumtype

Oiltypecircuitbreakers/interruptorsrequireconsiderableattentionformaintainingsatisfactoryconditionof

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theoil.Incaseofminimumoiltypeequipmentsfrequentreplacementofoilisnecessaryonaccountofservice
conditions.Toovercometheselimitations,SF6typeandvacuumtypecircuitbreakersandinterruptorsare
nowstandardized.

Manufacturer'sdetailedinstructionsmaybereferredtoforinstallation,commissioning,operationand
maintenanceforalltypesofbreakers/interruptors.RDSO'sadditionalinstructionsonmaintenanceand
modificationstothecircuitbreakers/interruptorsshouldalsobefollowed.Sometipsforthemaintenanceof
circuitbreakersandinterruptors,ingeneral,aregiveninthesucceedingparagraphs.

20218GuidelinesforMaintenanceofCircuitBreakersandInterruptors

A.MinimumOilCircuitBreakers:

1.Oil

Whenacircuitbreakertripsthearcisextinguishedbytheoiland,therefore,theoilgetscarbonizedand
contaminated.Although25kVtractioncircuitbreakersaredesignedfor100successivetrippingsorforshort
circuitcurrentsupto4000A,withoutrequiringreplacementofoil,experiencehasshownthatbecauseofheavy
contaminationofoil,insulationlevelcomesdownrapidlyevenwith40or50trippings.Arecordshould,
therefore,bemaintainedbytheATFO,basedonTPC'sregister/Computerprintoutofthenumberoftrippings
ofeachcircuitbreakersincelastattention.TheCTFO(PSI)shouldkeepawatchoverthesefiguresand
arrangetomeasuretheBDVofoilsamplesatintervalstobedecidedinthelightofexperience.Oilshallbe
purifiedorreplacedifthedielectricstrengthfallsbelowtheprescribedvalue.

2Caskets

Duringinspections,lookforevidenceofoilleakingoutofbushings,tankbody,etc.Slightoilleakagecould
occurdueto(a)thematingsurfacesarenotperfectlyflat(b)thegasketisnotbeingquitefreefromdirtor
extraneousmatter(c)thegasketisnotbeingproperlycompressed(d)gaskethaslostitselasticity.

Leakygasketsshallbeattendedtoorreplacedwithoutdelay,astheymayallowmoisturetogetinand
contaminatetheoil.

3.Bushings

Theporcelainexteriorsurfacesshouldbemaintainedinaperfectlycleanandbrightcondition.Depositsofsalt
andindustrialdustshouldberemovedperiodicallysothattheremaybenopossibilityofflashover.Wherethe

depositsareheavyawetclothmaybeusedforwipingitoff,failingwhichcarbontetrachloridemaybeused.
Afterremovingthecontaminationthesurfacesshouldbewipedoutwithadryclothsothattheglossonthe
surfaceisrestored.

Duringinspectiontheinsulatorsurfaceshallbeverycarefullyexaminedallroundforanyfinesurfacecracks
sothatthedamagedinsulatorsmaybereplaced.Ifthechippingonbushingshedsisonlyveryslight,
replacementmaynotbenecessary.

4.InternalInsulatingParts

Everytimeanoilcircuitbreakerisopenedandoilhasbeendrainedout,alltheinteriorpartsincludingthe
bushingintheminimumoiltypeunitsortankinthebulkoilunitsshouldbethoroughlycleanedtoremoveall
tracesofcarbonorsludgethatmayhaveadheredthereto.Thereafter,thepartsshouldbefirstcleanedwith
drynonfluffycloth(neverwithcottonwaste),thenthoroughlyflushedoutwithgoodoilandareassembled.

5.Contacts

Itisessentialforthecontactsurfacestobeproperlyalignedwithsufficientareaofcontactandpressure
betweenthecontactstoensurethatwhencarryingfullloadcurrents,thecontactsremainquitecool.Badly
pittedorburntoutcontactsshouldbereplacedbeforetheycausedamagetootherparts.Iftheyareonly
rough,thesurfaceirregularitiesshouldbesmoothedoutbytouchinguplightlywithacleanfinefiletakingcare
nottooverdoit.Wherethecontactmechanismconsistsofmainandsecondarycontacts,themaincontactsdo
notnormallyrequireanymaintenance,becausethecurrentismadeorbrokenonlyatthesecondarycontacts.
TheMaincontactsshould,however,beinspectedforgoodconditionandkeptsmoothandclean.The
adjustmentofcontactsshouldbemadeinaccordancewithMaker'sinstructions.

6.OperatingMechanism

Checkwhethertheelasticmountingpadsareingoodconditionandcapableofabsorbingthemechanical
shocksduringoperation.Thelengthofthebreakerstrokeshouldbemeasuredandadjustedifnecessaryin
accordancewiththeMaker'sinstructionbook.Ensurethattheoperatingmechanismfunctionssmoothlyand

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freelythroughtheentirestrokeandwithoutbinding.Lubricateallpinsandbearingsurfaceswithlightoiland
wipeofftheexcess.Ensurethatallcotterpinsareopenandlockingplateandnutsareinplaceandproperly
tightened.

Theoperatingspringsarequitepowerfulandwhentheyareinthechargedconditionconsiderableenergyis
stored.Seriousdamageandinjurytopersonnelmaybecausediftheyarereleasedinadvertently.

Partswhicharescoredorwhichshowexcessivewearshouldbereplacedandadjustmentshouldbemade
withinthetolerancesasindicatedintheMaker'sinstructionbook.

Thecircuitbreakerorinterruptorisguaranteedtoworksatisfactorilybetweenthespecifiedvoltagelimits.
Duringannualinspectioncheckperformanceofinterruptorsandcircuitbreakerstoensurethattheyfunction
properlyatthelowestspecifiedvoltagefortheoperatingcoil.Measureandrecordtheopeningandclosing
timesbothatnormalandminimumvoltage.

7.Interlocks

Payattentiontotheproperfunctioningofinterlocks,bothmechanicalandelectrical,andparticularlyto
auxiliarycontacts,springtensionandscrews,bolts,pins,etc.securingthecontacts.Checkthatthewiring
connectionsatterminalboardsareproperlysecured.

B.SF6CircuitBreakers:

1.GasSystem.

TheSF6gasinapurestateisinert,exhibitsexceptionalthermalstabilityandhasexcellentarcquenching
propertiesaswellasexceptionalhighinsulatingproperties.PhysicalpropertiesofSF6gasareindicatedinthe
Annexure2.05.Thereisverylittledecompositionofthegasafterlongperiodsofarcing.Suchdecomposition
hasvirtuallynoeffectupondielectricstrengthandinterruptingcapability.Thesolidarcproductformedby
arcingismetallicfluoridewhichappearsintheformofafinegreypowderwhichhashighdielectricstrength
underdryconditionsasexistinginthebreaker.Agoodqualityabsorbentisusedintheapparatustoremove
decomposedgaseousbyproduct.Duringthemaintenancerecordgaspressureandtemperature.Supplythe
gasifpressureislessthantheprescribedvalue.Checksettingofgaspressureswitches.

2.InterruptingUnit

Cleanthesurfaceoftheporcelainandotherparts.Contactsshouldbeinspectedandreplacedifnecessary.
Renewtheabsorbenttakingcarethatexposureoftheabsorbenttotheatmosphereisminimal.Thebreaker
shouldbeevacuatedassoonaspossible.

3.OperatingMechanism

Checkstrokefromclosedpositiontocompletelyopenedpositionandoverstrokefromcompletelyopened
positiontostoppedposition.Checkprescribedclearances.Relubricatemovingparts.Checkthatpressure
gaugeisworkingcorrectly.Checkpneumaticsystemforleakage.

Thehousingshouldbecheckedforwaterpenetrationandrust!Ensurethatfastenersarenotloosened.Check
connectionsofcontrolcircuitwiresfortightness.

C.VacuumCircuitBreaker:

Guidelinesasindicatedaboveincaseoftheothertwotypesofcircuitbreakersinrespectofoperating
mechanismanditshousingandothercomponentsaregenerallyapplicableincaseofvacuumcircuitbreakers
alsoexcepttheinterruptingchamberandpneumaticcircuit.Asregardsinterruptingchamber(vacuumbottle)
nomaintenanceassuchisrequiredtofeecarriedout.

20219LeadAcidBatteries

Abatteryisconsideredtobeveryvitalequipmentinthepowersupplyinstallationsandthereforeitsproper
maintenanceisimperative.

Onelectrifiedsectionsbatteriesandbatterychargersareinstalledatthefollowinglocations.

1.TractionSubstations

110V,200Ah.leadacidcellsforcontrol,protectionandindicationcircuits.

2.SwitchingStations

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110Vor72V,40Ahleadacidbatteriesforoperationofcircuitbreakersandinterruptorsandmotoroperated
isolators.

3.RemoteControlEquipment

Batteriesofsuitablevoltageandcapacityatremotecontrolcentre,tractionsubstationandswitchingstations.

ToreducenumberofbatteriesatTSS/SStheremotecontrolequipmentisnowbeingconnectedtothebattery
ofTSS/SS.

Inallcases,mainsoperatedbatterychargersareprovidedwithfacilitiesforeithertricklechargeorboost
charging.Theratingofthebatterychargershouldrelatedtothecapacityofthebattery.

20220GuidelinesforMaintenanceofBatteries

1.Astheentiresystemofprotectionatasubstationdependsuponasoundbatteryitshouldalwaysbein
propercondition.Itshouldundernocircumstancesbedisconnectedwhenthesubstationisinoperation.

Batteriesshouldbemaintainedkeepinginviewinstructionsofthemanufacturerbyatrainedstaff.Thepoints
tobeobservedduringtheinspectionsaresummarizedbelow

a.Generalconditionofthebatteryroomandcells

b.Specificgravityofelectrolyteinthecells

c.Chargingcurrent

d.Cellvoltage

e.Conditionoftheplatesandextentofdeposits

f.Intercellconnectorsandmainbatteryterminals

Adetailedhistoryofeverybatteryshouldbeseparatelymaintainedinwhichallrelevantinformationis
periodicallyentered.Fortnightlyspecificgravityreadingsshouldbetakenandrecordedinappropriateforms.

Smokingortheuseofopenflamesortoolswhichmaygeneratesparksisstrictlyforbiddeninthebattery
room.Thebatteryroomshouldbewellventilatedanddustfreeandshouldhaveacidproofingdoneonthe
wallsandflooring.Itshouldbekeptisolatedfromotherelectricalequipment.Appropriatefuseprotectionfor
shortcircuitinthewiringbetweenthebatteryanddistributionswitchboardshouldbeprovided.

2.SpecificGravity

Thespecificgravityoftheelectrolyteshouldbemaintainedatabout1.210at27Candwhenitdropsto
1.150thecellmaybeconsidereddischarged.Thesevaluesvarywiththetypeofbattery,temperature,age
andworkingconditions.

Specificgravityisrelatedtoelectrolytetemperature.Forthepurposeoftestrequirements,thefullycharged
specificgravityshallbel,200.005correctedto27C.Temperaturecorrectionhydrometerreadingsof
specificgravityshallbemadeasfollows(Ref.IS1652):

a)Foreach1Cabove27C,add0.0007totheobservedreadingand

b)For1Cbelow27Cdeduct0.0007fromtheobservedreading.

Whenthebatteryisfirstcommissionedthespecificgravityoftheallcellswouldbealmostequal.
Subsequentlyduringperiodicalinspections,variationsinspecificgravitymaybeobservedduetounequalrate
ofevaporation.Thisshouldbecorrectedbyaddingdistilledwater.Innocircumstancesshouldconcentratedor
dilutedsulphuricacidbeaddedtoanycellexceptwhenacidisknowntohavespilledout.Distilledwateralone
shouldbeusedfortoppingupthelevel.

Hydrometerreadingstakenwhenacellisgassingfreelygivesthespecificgravityofamixtureofgasbubbles
and

electrolyteandnotthetruespecificgravityoftheelectrolyte.Thereadingsshouldthereforebetakenafter
allowingallbubblestosubside.Hydrometersofreputedmakeshouldonlybeused.Hydrometersof300mm
lengtharenecessarytogiverequiredaccuracy.Twohydrometersshouldalwaysbemaintainedinastation
andtheyshouldbeperiodicallycheckedtoseethattheyreadalike.

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3.PilotCells

Oneofthecellsineachrowofthebatterysetshouldbeselectedandkeptasthepilotcell.Readingsshouldbe
takenonthesecellswithsufficientfrequencytoindicateitsstateofdischargeandchargeandserveasaguide
totheconditionoftheothercells.Thepilotcellwhenonceselectedshouldnotbechangedunlessthecellhas
toundergospecialtreatmentorrepairsinwhichcaseanoteshouldbemadeimmediatelyonrecordsheets.
Theheightoftheelectrolyteinthepilotcellshouldinvariablybekeptatafixedpoint(say12mm)abovethe
topofplatesbyaddingdistilledwatereveryfortnight,ifnecessary.

4.TrickleCharging

Leadacidbatteriesareverysensitivetooverchargingaswellasoverdischarging.Ifovercharged,the
positiveplateswillshedtheiractivematerialquickly.Ifkeptindischargedconditionforlong,theplateswill
suffer'sulphation'evidencedbyappearanceofwhitishdepositsontheplates.Prolongedchargingataverylow
rateafteremptyingtheelectrolyteandfillingthecellwithdistilledwaterissometimesusefulifthesulphation
isverylight.However,thereshouldbenooccasionatallforanybatterysetusedinstationerytraction
installationstobesulphated,astheyarecontinuouslyontricklecharge.Alonglifeforthebatteryis
achievableifthebatteryiskeptfloatingonabatterychargersothattheterminalvoltageofeachcellis
maintainedcloseto2.15V.

Thiscanbeachievedifthebatteryiskeptonaverylowrateofcharge,say,1milliampereperAhcapacityof
thebattery.Theexactrateofchargeshouldbefixedhavingregardtothenormalandintermittentratesof
dischargeoveraperiodof24hours,sothatthebatteryisalwayskeptinfullychargedconditionandnever
overchargedoroverdischarged.

Whenabatteryisbeingproperlyfloatchargedverysmallgasbubbles(aboutthesizeofapinhead)rise
slowlyfromtheplatetothesurfaceoftheelectrolyte.Inbatteries,thatarebeingoverchargedthebubblesare
muchlargerandreachthesurfaceatahigherrate.

5.CellVoltage

Thevoltageofcellattheendofachargeisnotafixedvaluebutwillvarydependingontheageofthe
battery,thetemperature,specificgravityoftheelectrolyteandchargingrate.Thevoltageofnewcellsatthe
endofafullchargewillbeabout2.5to2.75Vwhenitisreceivingchargeatthe10hourrate.Thisgradually
decreasesastheageofthebatteryincreasesuntilitcomesdownto2.4Vwithnormaltemperatureand
chargingrate.

Nocellshouldeverbedischargedbelowthepointwherethecellvoltagereaches1.85Vasmeasuredwhen
thecellisdischargingatthenormal10hourrate.

Itshouldbenotedthatthevoltageofacellgivesanapproximateindicationofitsstateofcharge(or
discharge)onlywhenitisbeingdischarged,sayatthe10hourrate,andnotwhenthecellisanopencircuit.

Sulphatedplates,lugcorrosion,partialshortcircuitduetocrackedseparatorsandotherdefectsofaleadacid
cellcauseanoticeabledropintheterminalvoltagewithcurrentflowinginthecell.Thisdropvarieswiththe
amountofcurrentflowingandinordertogetvoltagesthatcanbecomparedfrommonthtomonth,the
voltagesshouldbetakenwiththesamecurrentflowinginthecell.Thecelltestingvoltmetersinuseshouldbe
periodicallycheckedandrecalibrated,ifnecessary.Whennotinusetheyshouldbekeptinasafeplace.

6.ConditionofPlatesandDeposits

Theactivematerialinthepositiveplatesinhealthycellsinuseformorethan12months(whenfullycharged)
shouldbechocolateincolourandnegativeplateslightorbluishgreyaccordingtoage.Thechiefindicationsof
weakcellsarebadlycolouredplates,irregularityingassingorentirefailuretogasandafallinvoltageand
specificgravitybelowthatofothercells.

Innewbatteries,flakesofbrownscalewillbeseengettingdetachedfromedgeofpositiveplates.This
formationofscaleisnormal.Untilallthisscaleisdispersed,theplatecannotbeconsideredasstabilized.
Sometimespiecesofthisscalemaylodgeacrossadjacentnegativeplatesandcauseapartialshortcircuit.
Suchflakedpiecesshouldbegentlydislodgedwithathinpieceofwoolandallowedtofalltothebottomofthe
cell.Thisscalingoccursonlyontheedgesoftheplates.Theremovalofthescalesshouldbedonevery
carefullysothattheplatesarenotdamaged.

Examinecarefullythephysicalconditionoftheplatessuchascracks,distortions,accumulationofwhitish
deposits,etc.

Thecolourofthedepositsgivesagoodindicationofthestateofhealthofthecells.Whitishdepositindicates
underchargingleadingtodischargedcondition.Inhealthycells,thedepositisbrownincolourbutexcessive

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sheddingofactivematerialfromthepositiveplatesindicatesoverchargingofthebattery.Ifthisisnoticed,
reducetherateofchargeimmediately.Ifallthecellsinabatteryshowwhitishdepositsimmediateaction
shouldbetakentogiveaboostchargeatanappropriaterateandthentoincreasethetricklechargingrate
sufficientlytokeepthebatteryinahealthyconditionallthetime.Weakceilsshouldbeimmediatelyexamined
foranypossibleshortcircuitormetalliccontactbetweenpositiveandnegativeplates.Theshortcircuitshould
beremovedandthecellshouldthenbegivenspecialadditionalchargingbycuttingitoutandputtingitback
againwhenahealthyconditionisregained,afteritisattendedto.

7.InterCellConnectors

Theintercellconnectorsofthebatteryshouldbeexaminedtoensurethattheyarecleanandtight,making
perfectcontactwithcelllugsandthatnocorrosionistakingplace.Lightvaselineshouldbeappliedtoprevent
corrosion.

Inspectionofcopperinterrowconnectorsshouldalsobemadeforanysignsofcoppersulphatecorrosion
whichshouldbecleanedup.Acidproofpaintorenamelshouldbeappliedtoallexposedcopperworkinthe
batteryroomandanyflakingofpaintworkgivenpromptattention.

20221ProtectiveRelays

1.EachelectrifieddivisionshallhavespecialiststaffattachedtotheCentralRepairShoptrainedinthe
maintenance,overhauling,testingadjustmentandcalibrationofprotectiverelaysaswellasindicating,
integratingandrecordinginstruments.SuchspecialiststaffshallholdcompetencycertificateNo.TR7as
explainedinChapterXII.

2.TheCentralRepairshopshouldbefullyequippedwithnecessaryapparatus,instruments,toolsand
equipmentforoverhauling,testingandcalibrationofrelays.

3.EachSupervisorresponsibleformaintenanceandtestingofprotectiverelaysshouldmaintainaregisterin
whichfulldetailsregardingeachrelayshouldbeentered.Thedetailstoberecordedarethetypeandserial
number,PTandCTratios,rangeofsettingsavailable,characteristiccurves(whereapplicable),locationwhere
installed,schematicdiagramofconnections,normalsettingsanddetailsofcalculationsforfixingthenormal
setting.Detailsoftestsaswellasrepairscarriedoutshouldbeenteredinthisregisterfromtimetotime.
TheseparticularsshouldalsobemaintainedintheofficeofSr.DEE(TrD).

4.Noalterationsinthesettingsofprotectiverelaysshouldbecarriedoutwithoutthewrittenauthorizationof
Sr.DEE(TrD),whowillsubmitproposalsincludingdetailedcalculationsforchangesrequired,ifany,forprior
approvalofCEE.GuidelinesforsettingofrelaysaregivenintheAppendixV.

5.TheprocedureforcommissioningofprotectiverelayshasbeengiveninChapterIX.

6.Thenormalmaintenanceattentionrequiredforrelaysinserviceisgenerallyasunder

(a)Itisessentialtoensurethatthecovergasketsareingoodconditionandthefixingscrewquitetight,so
thattheinstrumentisdusttight.

(b)Manualoperationtoconfirmthattherelaysdooperatethetripcircuitsinthemannerprescribed.These
testsshouldbecarriedoutbyatleastatthelevelofAEEonceinayearforallrelays.Simultaneouslyvisual
checksonrelayconnections,conditionofthetripbattery,tripandalarmcircuits,andalsothedusttightness
ofprotectivecoversshouldbemade.Therelaycovershouldthenbesealed.Arecordshouldbemaintained
showingthedateandtimethisisdone.

Oneachoccasionwhenthesealisbrokensubsequentlythereasonsshouldberecordedinthelogbook.

(c)Distanceprotectionrelaymaybetestedforcalibrationonceinayearwithprimaryinjectionset.

(d)Secondaryinjectiontests.Theseshouldbedoneannuallypreferablybeforeonsetofbusyseason,making
useofportabletestingequipmentandatthesettingsapprovedbythecompetentauthority.Apartfromtesting
theoperationatthenormalsettingtestsshouldalsobecarriedoutatothersettingstomakesurethatthe
relayhastherequiredcharacteristic.

(e)Overhaul,benchtestsandcalibration:Thesearenecessaryonceintenyearsorwhenarelayisnotfound
functioningcorrectly.ThisworkshouldinvariablybecarriedoutonlyintheCentralRepairShopbyhighly
skilledtechniciansfullyconversantwithalldetailsofconstructionandadjustment.

Thebenchtestsandfinalcalibrationshouldbecarriedoutafteroverhaulofthemovingpartsand
measurementofcoilresistanceandotherdata.TransportoftherelaystoandfromtheCentralRepairShop
alsorequiresutmostcareincludinglockingofthemovingpartsandcarefulpackingandhandling.When
laboratorytestsarefullysatisfactory,therelaysshouldbesealedanddateofoverhaulpaintedontheouter

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coveroftherelay.

20222GuidelinesforMaintenanceofSwitchingStations

Themaintenancerequiredforequipmentinswitchingstationsismoreorlesssimilartothatfortractionsub
stationequipment,exceptthattractiontransformers,circuitbreakersandcurrenttransformersatenotpresent
andareaismuchsmaller.However,theonlyadditionalbutimportantitemwhichrequiresattentionis
conditionofthereturnfeederconnectiontoalltherails(atthefeedingposts).Thesereturnfeederconnections
areliabletobedamagedbyPermanentWaygangsintheirnormalworkofpackingandmaintainingthe
permanentway.Supervisoryofficials,therefore,shouldstresstheimportanceofthesefromtheelectrical
pointofviewtothePWIssothattheyinturnmaywarntheirmaintenancegangsnottodamagethe
connections.Inaddition,thesupervisoryofficialsshall,duringtheirperiodicalinspections,makeitapointto
inspectthereturnfeederrailconnectionsandensurethattheyareinexcellentcondition.

IVMAINTENANCESCHEDULES

20223SchedulesofInspection

1.InordertoachievehighreliabilityandZERODEFECT,andtoensureeffectivechecksonthemaintenance
workminimumschedulesofinspectionstobecarriedouteachmonthbytheTrDofficersandSenior
SubordinatesinchargeofoperationandmaintenanceofPSIequipments,areindicatedatAnnexure2.01.

Thescheduleofinspectionsasindicatedistheminimumquotatoeachofficialpermonthandshouldbe
independentofothertasks.Theywillnotbeofroutinenaturebutshallbecarriedoutindepthtoidentify:

(i)Deficienciesandshortcomings,

(ii)Lackofskillamongststaff.

(iii)Inadequaciesinmaintenancefacilities.

(iv)Constraintsexperienced.

(v)Conditionsofenvironmentwhichleadtopoorqualityofworkifany.

2.Theinspectingofficialsshouldadjusttheirinspectionsinsuchamannerastocoveralloftheinstallationsin
theirjurisdictionwithinthestipulatedperiodsandstaggertheinspectionsamongthemselvestoavoidover
inspectionsofthesomeinstallationsrepeatedlyinaveryshorttimeandneglectofotherinstallations.Acheck
listinbriefforvariousinspectionsisgivenintheAnnexure2.02.

3.Theitemsofattentionlistedhereunderatanyparticularperiodicityareoverandabovethosementionedin
thepreviousschedule.Thisshouldbekeptinviewwhilecarryingoutmaintenancework.

4.Theperiodicityoftheitemsofattentionlistedinthefollowingparagraphsmaybemodifiedtosuitlocal
requirementswiththeapprovalofCEE.

5Asregardsnewequipments,ifscheduleshavenotbeendrawnup.tentativeschedulesmaybeevolved
basedontheOriginalEquipmentManufacturer'sguidelinesandRDSO'srecommendations,keepinginviewthe
localconditionsalsoandfollowedwiththeapprovalofCEE.

6.SchedulesformaintenanceofSF6typecircuitbreakersasrecommendedbyoneofthemanufacturersare
indicatedintheAnnexure2.06.Schedulesformaintenanceofvacuumcircuitbreakerasrecommendedbyone
ofthemanufacturersareindicatedintheAnnexure2.07.Schedulesasindicatedinthefollowingparagraphs
areforminimumoilcircuitbreakers.

20224General

1.Noworkofanykindshallbecommencedonorinthevicinityofliveequipmentunlesspowersupplytothe
particularparthasbeenswitchedoffandallotherprescribedsafetymeasurestaken.

2.Toguardagainstthepossibilityofunauthorizedinterferenceandpilferagefromunattendedsubstationsand
switchingstation,allelectricaldepartmentstaffshallbevigilantandwatchforanysuchactivitywhentheyare
inthevicinity.Surprisecheckscoupledwithperiodicalinspectionswillalsoactasdeterrents.

3.TheTPCshallonceadaycheckupcommunicationtoeachofthegridsubstationsandobtainthemaximum
demandandenergyconsumptionfortheprevious24hoursandenterthefiguresinaregister.Whenever
inspectingstaffvisitthesubstationorswitchingstation,theyshallcontacttheTPConthetelephone.

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FORTNIGHTLYMAINTENANCE

20225GeneralInspectionbyaPSISupervisor

1.Goroundthewholeareaofthesubstationinspectforgeneralcleanliness,properdrainage,roadandrail
access.Thesurfaceoftheroadwayandpathwaysinthesubstationshouldbefirmandsufficientlyelevatedto
preventwaterlogging.Removeanyundergrowthofvegetationaroundtheouterperipherycutanytree
brancheslikelytocomeinthevicinityoflivelines.

2.Iflubricatingortransformeroilisstored,inspectforsecurityandfireriskandseethatnocombustible
materialisinthevicinity.

3.Examineall"Caution","Danger","ShockTreatment"andotherboards,whethertheyarecleanandwell
secured.Inspectfireextinguishers,firebucketsandFirstAidBoxes,iftheyareintactandserviceable.

4.Inspectstructureandplantfoundationsforanysinkingorcracking.Goroundthestructuralworkfor
checkingtightnessofvariousboltsandnuts.

5.Inspectallindicationlampsoncontrolpanelsforcorrectworking.

6.CarryoutinspectionsasindicatedatAnnexure2.01.

20226Battery

1.Checkallcellsgenerallyinaccordancewithpara20220.

2.Takespecificgravityandcellvoltageofpilotcellandrecordinregister.Ifanysignificantchangeisnoticed
specificgravityandvoltageforallcellsshouldbetakentoidentifyanyweakcells.Thentopupwithdistilled
waterexactlytothecorrectlevelforeverycell.

3.Checkoperationofbatterychargerandnotechargingrateinregister.

MONTHLYMAINTENANCE

20227BondingAndEarthing

Visuallyinspectallearthconnectionsandseethattheyareinorderandthateveryequipmenthasduplicate
earths.Tightenconnectingboltsandnutsasnecessary.Wherethesubstationandfeedingpostarecloseby
ensurethatsubstationstructuresareproperlybondedwiththefeedingpostandthetrackbytwoindependent
connections.

20228OilLevelinTransformers,CircuitBreakers,CTsetc.

Checkoillevelinsightgaugeglassandexaminealljoints,valves,plugsetc.foroilleakageineach
equipmentrectifyleakypartsiffoundandrestoretheoillevel.

20229Insulators

Cleanallinsulatorswithdryclothandlookforanyflashovermarks,cracks,chippings.Insulatorswhichare
badlychippedshouldbereplaced.Minorchippingscanberenderedimpervioustomoisturebyalightcoating
ofAralditeorsimilarepoxyresin.

20230TractionTransformers

1.Cleanexternallythetank,conservator,radiator,bushings,oillevelindicator,gauges,etc.withdrycloth.
2.MakeanoteintheRegisterofthemaximumtemperatureoftransformeroilondialindicatorreset
indicator.

3.Checkexplosionventdiaphragmforanydamageandpresenceofoil.

4.Checksilicagelbreather.Ifturningpinkinappearance,replaceitwithdrygel(bluecolour)andrecondition
theoldsilicagel.Ifthesilicagelistoowet,checkdielectricstrengthoftransformeroil.

5.Checkforgascollection,ifany,inBuchholzrelay

6.Checkforoilleakageontransformerbody,conservatortank,oildrainvalveandfoundations.Ifleaking,

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takecorrectiveactionbytighteningtheboltsreplacegaskets,ifnecessary.

7.Checkifheaterinthemarshallingboxisfunctioningproperly,andifallterminalconnectionsareinorder.

20231OperatingMechanismofCircuitBreakersandInterruptors

1.Openthecoverofcontrolbox.Examinetheinteriorandremovetheaccumulateddust.Ifanypartofthe
interiorisbadlyrustedindicatingentryofmoisture,findoutthecause,plugtheholesandrepainttherusted
parts.Checkinparticulariftheweatherproofgasketsareingoodconditionifnot,replacethemtomakethe
controlboxwatertightanddusttight.Examineiftheleadinginpipeconnectionsareproperlybushed,sealed
andwatertight.Checkifallpinsandchecknutsareinplace.Checkalsotierodnutsfortightness.

2.Operatethemechanismatleasttwicemanually.HaveitoperatedonremotecontrolfromRCCkeepingthe
controldooropen,observewhetherthemechanismfunctionssmoothlywithoutanyrubbingorobstruction,and
alsoiftheshockabsorberfunctionsproperlywhencircuitbreakeristripped.

3.Examinethecommutatorofthemotorandcleanwithmuslincloth.Examinecarbonbrushesandreplaceif
necessary.

4.Checkbreatherandbreatherholesforclogging.

5.Checkgearoillevelinthemechanismandreplenishit,ifrequired.'

6.Checkifheaterisfunctioningproperly.

7.Checkinterlocksoftheequipmentandassociatedisolators.

8.Checklocalpositionindicatorandremotesemaphoreindicatorforoperation.Observeforthecorrect
operationofrecordingcounter.

Aftercompletechecking,closethecoverandtestthebreakerforoperationunderremote,localandmanual
control.

20232Isolators

1.Manuallyoperateisolatorseveraltimesandobserveifitoperatessmoothlyandcorrectly.Checkinterlocks
andintegrallock,lubricatemovingpartsasnecessarywithappropriatelubricant.

2.Ifisolatorismotoroperated,checkcommutatorofmotorandcleanwithdrymullcloth,andcheckcarbon
brushesforproperbeddingandwear.Checkifmotorisworkingsmoothly,cleanlimitswitchandauxiliary
switchcontactsandchecktightnessofwiringconnections.Examinecontactorboxandsignalboxclean
thoroughlyandlubricateallgears,shafts,bearings,contactsetc.

20233Busbars,ClampsandConnectors

Immediatelyafterswitchingoffthepowersupplyandearthingthelines,feelbyhandallconnectorsand
clampsonbusbarsandequipmentterminalswhichcarryheavycurrentstoseeiftheyaretoohot.Ifany
connectionistoohot,itindicatespoorcontact.Openuptheconnectorcarefullycleanthecontactsurfaces,
touchupthehighspotsonthecontactsurfacessothatthematingsurfacesbedwelltogetherapplyavery
lightcoatofvaseline,refitandtightenup.Whereverapplicable,replacebimetallicstrip.

20234ControlandRelayPanels

1.Makeanoteofflagindications,ifany,thenreset.

2.Checkifallindicatingandrecordinginstrumentsareworkingnormallyandthepointersarenotsticky.

3.NoteandrecordintheRegistertherangeofvoltageandcurrentvariationsduringa15minuteperiodatthe
timeofthedaywheninspectionwascarriedoutAbnormalvoltageorcurrentshouldbenotedforcorrective
action.

4.Cleanthepanelsexternally.

QUARTERLYMAINTENANCE

20235BatteriesandBatteryChargers

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1.Takespecificgravityandeel!voltageofeveryindividualcellandenterintheregister.

2.Ifthebatteryisnotinafullychargedcondition,boostchargeshouldbegivenasrequiredandtrickle
chargingrateincreasedtotheextentrequired,Thisshouldonlybedonebyasupervisoryofficialafter
investigatingthecausesforexcessivedischarge.

3.Makeageneralexaminationofbatterycharger.Checkearthconnectiontothebody.

20236PTsandCTs

Theseshouldbemaintainedgenerallyonlinessimilartothatoftractiontransformersexceptforitemswhich
donotobviouslyapply.Inaddition,forPTcheckthefuseholdersontheLVsidetoseeiftheyareinorder.

20237BoosterTransformers

a)Replaceorreconditionsilicagelbreather,ifnecessary

b)Checkearthingconnectionsfrombottomofstructuretotheearthelectrodesortotherails.Checkthe
availabilityofduplicateearthstripanditsproperconnection.

c)Checkallcautionboards,nameplatesandanticlimbingdevicesforpropercondition.

d)Checkfoundationforanysinkingorcracking:Checkallstructureboltsandnutsforpropercondition.

Annualmaintenanceandperiodicaloverhaularetobecarriedout,generallyasindicatedforthetraction
transformers.

20238AuxiliaryTransformers

1.Measureinsulationresistanceoftransformerwindingandrecordvaluesalongwithtemperature.

2.TestasampleofoilforBDV.

3.Chekthatthe25kVfuseholderdropsoutfreelyonraisingthespringlatch.Checkrodgapsetting.Measure
earthresistanceofneutralconductor.

Annualmaintenanceandperiodicaloverhaularetobecarriedout,generallyasindicatedforthetraction
transformers.

HALFYEARLYMAINTENANCE

20239General

CTFO(PSI)shouldvisitthegridsubstationandascertainwhetheranysignificantchangeintheEHVgrid
networkhasoccurredduringthepastsixmonthsorareexpectedshortly.

20240TractionTransformers

1.Testoilsamplefromtankbottomforcrackletest,acidityandBDV.IfBDVisbelowtheprescribedvalue,oil
shouldbedriedout.

2.Checkwhethertherodgapsettingsonbushingsoftransformersareinorder,asperMaker'sdrawings.

3.Measureandrecordinsulationresistanceofallwindingstoearthandotherwindingswitha2500Vmegger,
alongwithtemperatureofwindingsandambienttemperature.

4,Checkallalarmandtripdevicesforproperfunctioning.

20241Isolators

1.Observeforanysignsofoverheatingandcheckthewipeofcontactblades.Cleanbladetipsandfixed
contactfingersandlightlyvaselinethecontactmakingsurfaces.

2.Cleanallarticulatedjoints,slidingandbearingsurfacesthoroughly.

3.Checkallsplitpins,locknutsandchecknutsforpropercondition.

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4.Checkforcorrectsettingandalignmentofarcinghorns.

5.Operatetheisolatorslowly,checkforsimultaneousoperationofthebladesonthepolesandcorrect
alignmentofbladetipsinthefixedcontactjawsofthepoles.Adjustifrequiredtoensurethatthebladesare
fullyhomebetweenthecontactswhenhandleisinclosedposition.

6.Checklockingarrangements.

20242ControlandRelayPanels

1.Checktightnessofallconnections,removecobwebsandwipeoffaccumulateddustwithdrycloth.

2.Checkiftapandtimesettingsoftherelaysareinorder.

3.Examinefusesforsignsofoverheatingoraging,springinessandcleanlinessofcontactmakingparts.Clean
upandlightlyvaselinetoensurepropercontact.

YEARLYMAINTENANCE

20243General

1.Inspectthefenceallroundthesubstationandbondingbetweenmetalfencingpanelsandtoearth.Puta
dropofoilinthehingesofalldoors.Repaintanyofthestructuralpartsasnecessary.

2.Openallthetrenchcoverandcleanthemcompletely,deanallculvertsandremovecobwebscheck
possibilityoflizardsorotherinsectsgainingentryintoenclosedcontrolequipment,andmaketheminsect
proof.

3.Arrangeforpaintingofwallsandmetalworksasnecessary.

4.Checkallexplosionventdiaphragmsforanydamage.

5.Checkrodgapsetting.

20244LightningArresters

1.Checkearthingterminalsandearthstripsforpropercondition.Checkconnectiontotheline.

2.Wherelightningarrestorsareprovidedwithdischargecounters,recordthecounterreading.

20245BondingandEarthing

1.Checkphysicallythesoundnessofbondingandearthingconnectionstoeveryelectricalequipment,
structuralsteel,lightningarrestoretc.andinterpanelconnections.

2.Recordearthresistancetobodyofelectricalequipmentaswellastoallpartsofthefencingandstructural
steelwork.

3.Checkiftheterminationsoftheoverheadshieldwirecoveringthewholesubstationareingoodphysical
conditionandproperlybondedelectricallytothestructures.

4.Checkandrecordresistanceofeachgroupofearthelectrodes,afterdisconnectingitfromcommonearth
system.Improve,ifnecessary.

5.Checkconditionofconnectionstotheburnedrails.

20246TractionTransformers

1.SendsamplestoapprovedlaboratoryforalltestslistedatAnnex.2.03B(IS1866)includingdissolvedgas
analysis.

2.Checkoillevelinbushings.

3.Inspectbushinggasketsforleaksandtightenbolts.

4.Movethetapsettingswitchupanddownthefullrangeafewtimessothatbyselfwipingactiongood
contactisassured.Setthetapfinallyatthecorrectpositionmakingsurethattapindicationcorrespondsto
positionofmaincontacts.

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5.Painttransformertankonsuchpartsasrequired.

20247Isolators

1.Smoothenburrs,ifanyonthebladetipsandfixedcontactfingerswithfineemerypaperandsmear
vaseline.

2.Measureclearanceofbladeinopenpositionandrecordandadjustcrankmechanism,iffoundnecessary.

3.Checktheadjustablestopsetscrewsforproperconditionandcorrectpositioning.

4.Iftheisolatorismotoroperated,measureandrecordinsulationresistanceofmotorwindingsandcontactor
coilusinga500Vmegger.

20248BusBarsandConnectors

Measurewitha'Ductor'orotherlowresistancemeasuringinstrumentthecontactresistancesofallconnections
whicharecarryingheavycurrents.

20249ControlandRelayPanels

1.Carryoutmaintenanceonrelaysasdetailedinpara20221.

2.Checkandcleanupcontrolswitchesandpushbuttoncontactsforburntorcorrodedmarkspolishthe
surfaces.Checkalsoifthecontactspringshavethecorrectspringiness.

20250BatteriesandBatteryChargers

Ifthebatteryisnotinahealthyconditionorifthereisexcessiveaccumulationofsediment,thewholebattery
shouldbereplacedwithanewset.

BatteryCharger

Openoutthecoversofthebatterychargerandblowoutalldust.Checktightnessofallconnections,bolts,nuts
andscrews.Measureandrecordtheinsulationresistanceofthetransformerwindingsofthebatterycharger
with500Vmegger.

20251PTsandCTs

1.Testoilsamplesifpossible.

2.Checkrodgapsetting,ifprovided.

3.Measureinsulationresistance.

4.CheckconditionsoffusesofPTsandterminalconnectionsforCTs.

20252SpecialMaintenanceSchedulesforMinimumOilCircuitBreakersandInterruptors

Thisschedulewillapplytominimumoilcircuitbreakersandinterruptorswiththefollowingproviso:

132kVCBs..............................................6trippingsonfault

25kVCBs...............................................30trippingsonfault

25kVInterrupters......................................250openingsonnormalcurrentforminimumoiltype

and500openingsonratedcurrentforbulkoiltype.

a)Opentheextinctionchamber,examinethecontactrodarcingtip,upperandlowercontactfingersandfixed
arcingcontactsforburringorpitting.Checkcontactspringsforlossoftemper,breaksorotherdeterioration
replacewherevernecessary.Removeanybeadsoffusedmetalfromarcingtipsandcleanpittedsurfaces.
Changethecontactswhenthewearreachesthelimitsprescribedbythemanufacturer.Tightenupallboltsand
currentcarryingparts.Checkcontactrodforcorrectalignmentandsetting.

b)TestoilsampleforBDV.Ifitfallsbelowtheprescribedvaluetheoilshouldbepurifiedorreplaced.

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c)Cleantheexplosionchamberwithdryandcleancloth.Removethecarbondepositsifanywashoutall
tracesofmoisturefromallpartswithfreshoilhavinghighdielectricstrengthandrefillwithgoodoil.

d)Inaddition,theoperatingmechanismofcircuitbreakersandinterruptorsshouldbeattendedtoannuallyas
under

1.Lubricatebearingsurfacesofrollers,bearingsandslidingsurfaceswithgoodqualitymachineoil.Sinceoil
tendstocollectdustanddirt,itshouldbeusedsparinglyandanysurplusshouldbewipedoffwithaclean
cloth.

2.Seethatalllinksandleversmovefreely.Operatethemechanismslowlybyhandtoseethatallpartsmove
freelyandnounduefrictionisnoticeable.Observethemechanismtoseethateverythingisinworkingorder.

3.Checkallpins,latches,etc.forbindingandmisalignment.Checklatchcarefullytoseethatitisnotgetting
wornsoastocauseunlatchingfromvibrationorstickingandfailuretotrip.

4.Checkthatthemechanismoperateswith80%ofthenominaloperatingvoltage.Checkandrecordthe
insulationresistance.

5.Observeoperationoftripcoilduringelectricaltrippingandtheplungerforfastactionandfreedomfromany
stickiness.Theplungershouldhavesufficienttraveltoensureanadequateimpactthatwillpositivelyrelease
thebreakerlatch.Checkinsulationresistanceofthecoil.

6.Checkifthebreakermechanismoperatessmoothlyandfreelywithoutbinding.Checkthatthecontactrodis
notbindingagainstitsguide.

7.Washoutbearings,pivots,etc.withcarbontetrachlorideiftheyaredirty,andlubricateverylightly.

8.Examinetheacceleratingspringandseethatadjustingnutsarelockedtight.

9.MeasurethelengthofthebreakerstrokeandcheckandadjustinaccordancewithManufacturer's
instructions.

10.Checkopeningandclosingpositionoftheauxiliarycontactswithrespecttothemaincontacts.Adjust
wherenecessary.Checktheconditionofthecontactsandrefinishwithfinefileifburntorcorroded.Ensure
thatgoodcontactismadewithoutexcessivefriction.Checkoperatingrodsandleverstoensurethattheyare
secureandmovefreely.Smearauxiliarycontactsurfaceslightlywithvaselineorpetroleumjelly.Drainoil
fromgearboxofthespringchargingmotorandrefilltocorrectlevelwiththerightgradeofoil.Measurethe
durationforwhichthemotorrunstochargethespringandcomparewithMaker'sinstructions.

20253PreMonsoonChecks

Beforeonsetofmonsoonseason,itshouldbeensuredthatforeveryequipmentnoscheduledmaintenance
workisoverdue.Inthescheduledinspectionjustprecedingthemonsoon,specialattentionshouldbepaidto
thevulnerablepointslikelytopermitingressofmoistureresultinginreductionindielectricstrengthofthe
equipmentsandrustingofparts.

20254OverhaulScheduleforEquipment

1.Transformers..........................Incaseofaninternalfaultoroncein710years.

2.Operatingmechanismof............Oncein10yearsorasandwhenanymajorpartlikespringshaveto
CircuitBreakerandInterruptors.tobereplacedorthemechanismissluggish,andneedsshopattentand
overhaul.

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Annexure2.02
(Para20223)

CHECKLISTFORINSPECTIONS

1.0PSIdepotsincludingSubordinateOffices

a)OHE/PSIDepots.

check

1.Staffgrievanceregister.

2.Quarterregister.
3.Attendanceregister.

4.Cleanlinessofdepot.
5.UpkeepofStores.

6.StockpositioninStores.

7.Complianceofaudit&accountinspectionnotes.

8.Test&Trialreport.

9.Availabilityoflatestdrawingsandspecifications.

10.Planningandprogressofsectionworks.

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b)Subordinateoffice:

check

1.Attendanceregister.

2.Complianceofaudit&accountinspectionnotes.

3.ComplianceofOfficer'sinspectionnotes.

4.Test&Trialreport.

5.AvailabilityofDrgs.&specification.

6.Progress&planningofsectionworks.

2.0InspectionofGridSubstation

1.Beonlookoutforanymodificationsmade/beingmadeinthepowersupplyarrangement.

2.Checkupifthereisanyequipmentunderbreakdownwhichislikelytoincreaseriskofinterruption'in
powersupplytotraction.

3.Notedownmeterreadingsandscrutinizeandrecordimportantdataregardingpowersupplyparameters
includingdailyMD,variationinvoltage,frequencyandpowerfactor

3.0InspectionofTractionSubstation

a)SwitchYard

check

1.Forvegetationgrowthandspreadingofpebbles.

2.Paintingoffencingandequipments.

3.Conditionofcabletrenches&trenchcovers.

4.Conditionofapproachroad.

b)PowerTransformer

check

1.O.T.I,andW.T.I,temperaturepresentandmaximumreadings.

2.Oillevelinconservationtank.

3.Tapchangerpositionofstandby&servicetransformer.

4.Forabnormalhumming.

5.Colourofsilicagel.

6.Forleakageofoilontransformerbody,conservatortank,oildrainvalveandradiator.

c)Circuitbreaker&interrupters:

check

1,Controlboxgasketsforwater&dusttightness.

2.Operationbylocal&remotecontrol.

3.Operatingmechanismforsmoothoperation.

4.Oillevel&leakages.

5Closingtimeofinterruptor.

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6.Numberoftrippingssincelastreplacementofoilincaseofcircuitbreakerandcounterreadingof
interruptor.

d)PT,CT,AT

check1.Leakageofoil.

e)Isolator:

check

1.Lockingarrangements.

2.Forcorrectalignmentofbladetipinthefixedcontactjaws.

3.Forcorrectmatching&alignmentofarcinghorns.

f)ControlPanel:

check

1.Fusesforthecorrectsize,overheatingoragingsigns.

2.ForlooseconnectionsatterminalBoards.

3.FunctioningofAlarms&visualindicationoncontrolpanel.

4.Functioningofauxiliaryrelays.

g)BatteryCharger&Batteries:

check

1.Acidlevel

2.presenceofsedimentation

3.Specificgravity&voltageofpilotcell

4.Presenceofsulphationandtightnessofintercellconnectors.

5.SizeoffusesofBatterycharger.

6.Voltmeterandammeterreadings.

h)Energymeter

check

1.Recordedmaximumdemand.

2.Conditionoftheseal.

i)Earthingcheck

1.Soundnessofearthconnectiontoeachelectricalequipmentandstructure.

2.Lastrecordedearthresistancereadings.

3.Buriedrailconnection.

j)Remotecontrolequipment

check

1.Generalfunctionofrelays&selectors.

2.Wiringforlooseconnectionifany.

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3.Forpresenceofdust&conditionofcubiclegaskets.

k)General

check

1.Availabilityoffirebuckets,Respirationchart,FirstAidBox,Tools&Plants.

2.WorkingofTPCPhones&emergencysockets.

3.InspectionRegisterandremarksmadetherein.

4.Historysheetsofvariousequipments.

4.0SwitchingStations

a)SwitchYard:

check

1.ForvegetationandspreadingofPebbles.

2.Paintingoffencing&equipments.

3.Conditionofcabletrenches&trenchcabins.

b)Interruptors:

check

1.Controlboxgasketsforwater&dusttightness.

2.Operationbylocal&remotecontrol.

3.Operatingmechanismforsmoothoperation.

4.Oillevel&leakages.

5.Interlockingofinterruptors&undervoltagerelayoperationatSP.

c)PT&AT

check

1.Leakageofoil.

d)Isolator

check

1.Lockingarrangements.

2.Forcorrectalignmentofbladetips,inthefixedcontactjaws&alignmentofarcinghorns.

e)Batterycharger&Batteries:

check

1.Acidlevel.

2.Presenceofsedimentation.

3.Specificgravity&voltageofpilotcells.

4.Presenceofsulphation&tightnessofintercellconnectors.

5.Sizeoffusesofbatterycharger.

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6.Voltmeter&ammeterreadings.

f)Earthing:

check

1.Soundnessofearthconnectiontoeachelectricalequipment&structures.

2.Lastrecordedearthresistancereadings.

g)General

check

1.Availabilityoffirebuckets,respirationchart,FirstAidbox,Tools&Plants.

2.InspectionRegisterandremarksmadetherein.

3.Historysheetsofvariousequipments.

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GUIDELINESFORCONDITIONMONITORINGOFTRACTIONPOWER

TRANSFORMERBYDISSOLVEDGASANALYSIS(DGA)TECHNIQUE

(Reference:RDSO'sCircularNo.ET1/PSI/M/4dated5291)

1.0Introduction

1.1Dissolvedgasanalysis(DGA)isapowerfuldiagnostictechniqueformonitoringtheinternalconditionof
transformerasitiscapableofdetectingfaultsintheincipientstage,beforetheydevelopintomajorfaultsand
resultintheoutageofthetransformer.TheconventionalBUCHHOLZRELAYisuniversallyusedintransformers
toprotectagainstseveredamages.However,itslimitationisthatenoughgasmustbegeneratedfirstto
saturatetheoilfullyandthentocomeoutorthereshouldbeagassurgetooperatethisrelay.Moreover,
BuchholzRelayisnevermeanttobeadiagnosticdeviceforpreventivemaintenanceoftransformers.

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1.2TheDGAtechniqueisverysensitiveasitdetectsgasinpartspermillion(ppm)oftheoilbyuseofthe
GASCHROMATOGRAPH.Itispossibletocheckwhetheratransformerunderserviceisbeingsubjectedtoa
normalagingandheatingorwhetherthereareincipientdefectssuchasHotSpots,Arcing,Overheatingor
Partialdischarges.Suchincipientfaultsotherwiseremainundetecteduntiltheydevelopintoamajorfailure.

2.0FormationofGasesinOilFilledTransformers

2.1Itiswellknownthatinsulatingoilinhighvoltageequipmentscanbreakdownundertheinfluenceofthe
thermalandelectricalstressestoproducehydrocarbongases,hydrogenandcarbonoxides.Gasesmaybe
formedintransformersandotherhighvoltageoilfilledequipmentduetoagingandtoagreaterextentasa
resultoffaults.Theaccumulationofgasesintransformeroilmaybesuddenduetoaseverearcingfaultor
moregradualasinthecaseofslowdeteriorationofinsulation.Theprinciplemechanismofgasformationina
transformertankcanbeclassifiedasunder:

a)Oxidation,b)Vapourisation,c)Insulationdecomposition,d)Oilbreakdown,e)Electrolyticaction.

2.2Oxidation

Carbondioxideisthegaspredominantlyliberatedduringtheprocessofoxidation.Theprocessbeginswhen
smallquantitiesofoilcombinechemicallywiththedissolvedoxygenintheoilresultinginformationoftraces
oforganicacids.Theseacidsreactwiththemetalofthetransformer,formingmetalbasedsoapswhich
dissolveintheoilandactasacatalysttoacceleratetheprocessofoxidation.

2.3Vapourisation

Thevapourisationofoiloccursatabout280Cwhilethatforwateroccursatabout100C.Thefalsealarm
ofaBuchholzrelaymaybeattributedtothefactthatthecondensationofwatervapourtakesplacewhenthe
excessmoistureinthetankisvapourizedbyaheatsource.Falsealarmcanalsooccur,whenhydrocarbons,
theconstituentsoftheinsulatingoil,vapourize.

2.4InsulationDecomposition

Thesolidinsulantsinpowertransformersaremainlyofcelluloseorresinoustype,viz.,paper,pressboard,
cotton,resinsandvarnishes.Thesesubstancescontainintheirmolecularstructuresubstantialamountsof
oxygen,carbonandhydrogen.Inthetemperaturerangeof150Cto400C,theinsulationbreakdown
resultsinliberationofhydrogen,carbondioxideandcarbonmonoxide.Above400C,thegasesformedare
relativelyless.

2.5OilBreakDown

Thedirectbreakdownofoilbyarcingresultsincrackingoftheoil.Thearomaticcontentsbreakdowninto
simplehydrocarbongasesandhydrogen.Acetyleneandmethanearethemajorconstituents.Other
hydrocarbongasesmayalsobeliberatedduetocracking,ifthenecessarytemperatureismaintainedfortheir
stableformation.

2.6Electrolyticaction

Hydrogenandoxygenareliberatedduringelectrolyticaction.Presenceofminuteandsmallparticlesoffibres
withintheoilleadstoelectrolyticaction.Lighthydrocarbongasesmayalsobepresent,ifsolidinsulationis
involved.

3.0TypesofFaultConditions

Therearethreemaintypesoffaultviz.overheatingofwindings,coreandjointspartialdischargesand
arcing.

3.1Overheating

Overheatingmetallicpartsheatupthesurroundingregionssuchaspaperinsulatingtapesandoil.Thisleadsto
thermaldeteriorationofthesematerials.Thermaldegradationofpaperproducescarbondioxide,carbon
monoxideandwater.Theratioofcarbondioxidetocarbonmonoxideistypicallyfivebutiftheratiofalls
belowthree,thereisindicationofsevereoverheatingofthepaper.Oildegradationproducesanumberof
hydrocarbongasessuchasmethane,ethane,ethylene,andacetylene.Methaneandethanearedecomposition
productsthatappearabove120Cethyleneappearsabove150Cwhileacetyleneisahightemperature
product,appearingatseveralhundreddegreescentigrade.Somehydrogenisalsoproducedalongwiththe
hydrocarbonsgases.Theproportionofthevarioushydrocarbonsvarieswithtemperature.Thisisthebasisof
thewellknownRatioCodeintroducedseveralyearsagobyDorenbergandR.R.Rogers.

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3.2PartialDischarge

Thesecondtypeoffaultconditionispartialdischargewhichoccursduetoionizationofoilinhighlystressed
areaswheregas/vapourfilledvoidsarepresentortheinsulationiscontainingmoisture.Themainproduct
duringpartialdischargeishydrogen,thoughsmallamountsofmethaneandothergaseswouldalsobepresent
dependinguponthermaldegradation.Thedisintegrationofoilandcelluloseduetopartialdischargeis
characterizedbytheremovaloftheouterhydrogenatomstoformhydrogengas.Theremainingmolecular
frameworkpolymerizesandlongchainproductssuchaswaxesareformed.Thermaldegradationisamore
predictablephenomenonwhichinvolvesthebreakupofchemicalbonds.Cellulosedecomposesultimatelyto
CO.CO2andwateroilbreakupintolowermolecularhydrocarbons.

3.3Arcing

Thethirdtypeoffaultconditionisarcing.Arcingcanoccurbetweenleads,betweenleadandcoilandbetween
otherhighlystressedregionsweakenedbyfaultconditions.Thehightemperaturescausedbyarcingresultsin
theproductionofacetyleneandhydrogen.

3.4Patternofgenerationofgasesintransformerissummarizedbelow:FAULT/PATTERN."KEYGAS
ConductorOverheatingC0/C02(CarbonOxides)OilOverheatingC2H4(Ethylene)

PartialDischargeH2(Hydrogen)

ArcingC2H2(Acetylene)

4.0SolubilityofGases

4.1Thesolubilityofgasesinoilvarieswithtemperatureandpressure.WhilesolubilityofH2,N2,CO,O2in
oilincreaseswithtemperatureandthatofC02,C2H2,C2H4andC2H6decreaseswithtemperature,solubility
ofCH4remainsessentiallyconstant.

Allthegasesbecomemoresolubleinoilwithincreaseinpressure.Solubilityofgasisoneofthefactors
contributingtothecomplexitiesinformulatingpermissiblelevelsofgasesonthebasisofservicelifeofa
transformer.Table1showsolubilityofdifferentgases25Candat1atm.Thehomogeneityofthegasesin
theoilisdependentontherateofgasgeneration,accessofthefaultareatoflowingoil,rateofoilmixingand
presenceofgasblanket.

5.DissolvedGasAnalysis(DGA)

5.1Dissolvedgasanalysis(DGA)oftheoilofatransformerinoperationisaspecializedtechniquetoassess
theinternalconditionofthetransformer.DGAisperformedbyGasChromatography.Thegasesextractedfrom
theoilbyasuitableapparatusaretransferredtotheGasChromatographsystemforanalysis.

5.2TheknowledgeofsolubilityofHydrocarbonandfixedgasesatdifferenttemperatures,ininsulatingoils
helpsininterpretationofgasanalysis.Thepermissibleconcentrationofdissolvedgasesintheoilofhealthy
transformerisshowninTableII.ThecombinationsofGaslevelsfordifferenttypesoffaultsareshownin
TableIIIwhileTableIVshowsthegascompositionbyvolumeunderarcingfaultwithparticipationofvarious
componentsofsoliddielectricsinatransformer.

5.3Whiletheabsoluteconcentrationoffaultgasesgivesanindicationofstatusofinsulationoftransformer,
whereastherelativeconcentrationofthesegasesprovidesacluetothetypeoffault.Forfaultdiagnosisthe
methodbasedonRogers'Analysisisadopted.

5.4Roger'smethod:

Thismethodholdsgoodforhydrocarbongases.Byevaluatingthegasratios,thetypeoffaultisdetected.
Fourratiosareusedviz.,Methane/Hydrogen,Ethane/Methane,Ethylene/EthaneandAcetylene/Ethylene.The
valueofratioscanbegreaterorsmallerthanunity.Theratioandtypeoffaultrepresentedbythatratioare
giveninTableV.

6.0DataCollectionandAnalysis

6.1ItisrecommendedthatDGAbeperformedregularlyonceayearoneverytransformerupto4yearsof
serviceandthereaftertwiceayearupto10yearsandthefrequencythereaftermaybeincreasedtothricea
year.

Note:WherevertheBuchholzrelayoperates,thedissolvedgasanalysisbecarriedoutimmediatelyafter
operationoftherelaytoascertainthecauseoffault.

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6.2TheresultsoftheDGAforeachtransformershouldbebuiltintoadatabankandbasedonthetrendofthe
gaslevelsoveraperiodoftimeaswellasthefaults,ifany,thatthetransformerhadsuffered,ananalysis
maybedonetoestablishtheexactnatureoftheincipientfaultthatmaybedevelopinginthetransformer.

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