RECENT FAILURES IN

SWITCHYARD EQUIPMENTS
AND LEARNINGS.
By
MUNISH MISHRA
DGM(OS)
NTPC LTD

CONTENTS

Failure of newly supplied AREVA make, 400 kV

CTs at DADRI,KORBA,BARH.
VSTPP: Stage#3 400 kV string insulator disc
failure
Dadri Gas & Thermal: 33 kV ICT LA failure.
RhSTPP: CT Failures.
Jhajjar : PT Experience.
Dadri 400kv Bus TRIP.
Jhajjar DC Failure.

DADRI,KORBA etc ExperienceCTs

M/S Areva make 400KV(dead tank) CTs were

supplied to DADRI,KORBA,FARAKKA.
These have been commissioned in various
bays.
Y Phase CT of Mandola-2(D) burst in April11.
Y Phase CT of Mandola-1(D) burst in July11.
R Phase CT of U#7 (K) burst in Dec11.
Other Phase CTs were also replaced due to
peripheral damages.

Experience- CTs

Failures occurred within few months of

charging.
After the first failure.
Electrical Test Results did not show any
abnormality for other CTs.
DGA of oil samples suggest elevated fault
gases i.e. Hydrogen, in some CTs.Hence it
was decided to remove such CTs from
service and observe gas trend in others.

Experience- CTs

In spite of this ,a second incident occurred

in the Mandola line -1 in July 11 .
This CT showed normal levels of gases in
the earlier testing.
The earlier removed CTs were
investigated at OEM works.
Decision was taken to remove all such
CTs from service till root cause is
established (for Dadri).

Learnings

Internal galvanizing was deteriorating

gradually, giving suspended metal traces
in oil and on insulation, resulting in internal
PD. Decision for No internal galvanizing
to be done in CTs.
Practices have been revised since.
CT MBs should have been away from the
CTs.

SSTPP 400 kV CT FAILURE

SSTPP 400 kV CT FAILURE

VSTPP: Failure of Disc Insulator at

400 kV Switchyard

Disc insulators commissioned by BHEL in

Stage-3 S/Y started failing. 400 kV Bus#6
tripped due to insulator string failure of Rphase of Bus on Bus bar protection.
Initially BHEL suggested to wash these.
However a detailed study revealed that in
spite of a more polluted environment for
Stage-1&2 ,such problem never existed.

VSTPP: Failure of Disc Insulator at 400 kV

Switchyard

No traces of tracking due to pollution.

At the time of failure: Weather: Sunny
No over voltage.
Insulation test and capacitance measurement
carried out on same lot insulators.
Thermo vision scanning carried out. Difference
in temperature found along the string.

VSTPP: Test Results

Disc IR 15 sec
No.

Tan
Delta
(%)

Cap
(pF)

IR 15 sec Tan Delta Cap

Wet
(%)
(pF)
Wet
Wet

1
2
3
4
5
6
7
8
9
10

7
5
54.17
11
96.44
97.65
72.35
91.67
94.61
97.83

41
41.5
55.9
46.2
219.4
130.8
57.2
61.5
88.3
100.9

222 G
200 G
186 M
10.5 G
2.94 M
9.75 M
72.6 M

137 G
167 G
189 M
9.3 G
5.4 M
10.1 M
69.5 M
29.4 M
17 M
9 M

6.09
4.48
51.29
9.76
98.85
97.93
69.92

40.5
41.3
54.7
45.7
192.8
128.3
55.9

VSTPP: Test results

Disc IR 15 sec
No.

Tan
Delta
(%)

Cap
(pF)

11

3.72 M

98.81

161.9

12

61 M

76.36

47.4

13

4.4 M

98.72

153

14

4.2 G

IR 15 sec Tan Delta Cap

Wet
(%)
(pF)
Wet
Wet

HEALTHY INSULATOR
1

264 G

38.3

183 G

2.93

38.3

214 G

2.74

36.4

236 G

2.42

36.2

224 G

2.51

36.1

264 G

2.18

35.9

36 G

29.63

194.3

10.9 G

29.7

193.9

650 M

53.95

195.1

404 M

55.45

175.7

VSTPP: Learnings

Deviation in IR and capacitance indicate

varied voltage variation along the string.
Detailed failure analysis done at BHEL.
BHEL agreed to replace the entire
defective lot free of cost due to the reason
that there was some Quality issue in the
complete lot.
PID of insulator strings and thermo vision
scanning can provide early signs of failure.

Dadri Gas & Thermal: LA failure

ICT 33 kV winding delta connected and in

floating condition.
52 kV surge arrestors provided for ph-ph
protection against surges.
33 kV LA provided between Phase-Earth.
Online health assessment can not be done
for phase to phase surge arrestors.

LEARNINGS

MANDATORY TESTING IN ANNUAL S/D.

OBSERVE FOR ANY CEMENTING
CRACKS OR DIAPHRAM PROBLEMS.
(can be covered with selastic compound
till replacement).
THERMOSCANNING (All stacks ).

RIHAND- CT Failures.

Areva CT burst on initial charging.

Reason of failure , NO OIL .
Level Dial Gauge was showing normal
level of Oil.
Other CTs checked found Oil has been
drained by making a hole probably at the
time of transit.

LEARNINGS
Test results at site to be critically examined for
any deviations from previous/factory test results.
Measurement of C1 and C2 both.
Ensure OIL level when commissioning a New
CT.
(a) If Gauge Glass is available, level can be seen.
(b) If Dial Gauge is there then level must be
ensured by other means.

JHAJJAR-PT

Generator Bus Duct PT was showing erratic

readings.
PT was sent to OEM and a detailed
investigation carried out.
Problem identified in jointing procedure of
Primary Winding.
The Manufacturer has been advised corrective
measures and procedure standardization.

DADRI 400KV BUS TRIPPING

Maint work taken up in 02 bays together

with Bus under S/D.
Clearance given to charge the bus without
removing temporary earth at bay 13.
BB-1 and 2 both tripped plunging the
station to total AC failure.

LEARNINGS
PTW system must be followed in true
spirit.
Protection system should be reliable.
Option of charging of Bus from remote
end line breaker of lesser importance.

JHAJJAR DC FAILURE

One section of DCDB made OFF inadvertently.

System remained charged thru shorted diodes.
DCDB A became Dead on starting EOP.
Since both DCs failed for 11kv Swgr. ID fan
VFD went into Runback mode (wrong
configuration of contact).
Unit tripped,400 kv breaker opened but
changeover to Station supply could not take
place.

JHAJJAR DC FAILURE

UES could not be charged thru DG set as it

took time to start.
DC Jop was started but it tripped on O/L.
Hot M/C came to a standstill and damaged two
bearings.

LEARNINGS

DCDB interlocks not in place.

DCDB alarms (monitoring) not commissioned.
DC drive ,O/L protection connected to trip.
D G Set should start on auto irrespective of
AC/DC failure .
The two DC supplies to any Swgr / System
should be from separate sources.

ONLINE TOOLS FOR

PREDICTING FAILURES

THERMOSCANNING. (ALL EQUIP.)

P D ( CT)
THIRDHARMONIC LEAKAGE CURRENT
MONITORING.(L As)
VOLTAGE MONITORING OF CVTs.
P I D.
CORONA DISCHARGE.

OFFLINE TESTING

TAN DELTA.(CVT, CT, GRADING CAP)

DGA (CT)
DCRM (BREAKERS)
DEW POINT OF SF6. (BREAKERS)

PRACTICES

HOT LINE WASHING.

HOT LINE ATTENDING OF HOTSPOTS ,
REPLACEMENT OF STRINGS /
INSULATORS ETC.
ADVANCEMENTS
OPTICAL CTS
COMPOSITE INSULATORS.