Professional Documents
Culture Documents
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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