Professional Documents
Culture Documents
ON
FAILURE OF
220 KV AND ABOVE VOLTAGE CLASS
SUBSTATION EQUIPMENT
NOVEMBER, 2012
TABLE OF CONTENTS
Subject
Pages
Introduction
3-26
27-30
31-33
34-35
-1-
1.0
Introduction
In order to investigate the failure of 220 kV and above substation equipment
and recommend measures to avert recurrence, a Standing Committee under
Section 73, Clause(1) of the Electricity Act, 2003, comprising experts in the
field of design and operation of EHV Substations from CEA, various power
utilities and research/academic institutes was constituted. As part of such
activity, CEA has received between October, 2011 and 30th September, 2012,
failure reports in respect of following equipments from various utilities:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
Name of Substation
Utility/Owner of substation
Faulty Equipment
Power Transformer-III
Rating
Make
Sr. No.
BH8930/1
Year of manufacturing
2003
Year of commissioning
Date
and
time
of :
occurrence/discovery of fault
10
October 2011
11
Operation
12
Present
condition
of :
equipment
Details
of
previous :
maintenance
Replaced
13
14
15
Sequence
of
events/ :
-3-
Description of fault
On 17.10.11 at 18:45 hrs transformer III tripped alongwith operation of
following protection systems:
a. Differential protection (87)
b. Bucholz trip (30A)
c. Bucholz alarm (30D)
d. Master relay (86A & 86B)
On-duty operation staff rushed to the yard and found fire at 100 MVA
transformer-III. The staff used all available fire extinguishers to put down the
fire but fire could not be controlled because of very high intensity. The fire
was brought under control by fire tenders used by fire brigade personnel.
The status of load shared by all 4 nos. 100 MVA transformers prior to this
incidence is as under:
a. 2 nos. transformers connected to 220 kV bus-I were running in parallel
and 68 MW load was being fed by each.
b. Other 2 nos. transformers connected to 220 kV bus-II were running in
parallel feeding 56 MW (transformer-III) and 52 MW (transformer-IV)
load.
16
17
Conclusion/recommendations :
Last test results of Oil DGA, capacitance and tan delta prior to the fault do not
indicate any abnormality in the oil, winding or bushing. Magnetic balance test
and measurement of IR value, magnetizing current and transformer earthing
performed on 19.08.11 were also satisfactory.
Operation of differential protection, master relay and bucholz relay indicates
occurrence of fault inside tank. It is understood that the transformer-III has
completely been damaged due to fire and is beyond repair.
Most substations of DTL are running overloaded. It is recommended to reduce
the load as a short term measure and provide additional transformation
capacity as a long term measure. DTL must install High Velocity Water Spray
System or Nitrogen based Fire Protection System at their substations as soon
as possible.
3.0
Name of Substation
Utility/Owner of substation
-4-
Faulty Equipment
Rating
Make
Sr. No.
24527
Year of manufacturing
1985
Year of commissioning
Date
and
time
of :
occurrence/discovery of fault
10
26.12.11
11
Operation
12
Present
condition
equipment
13
Details
of
maintenance
14
15
Sequence
of
Description of fault
of :
previous :
events/ :
-5-
Awaiting repair/replacement
Periodical
maintenance
(i.e.
measurement of IR value, cleaning of
bushings and clamp connectors, bucholz
trip test, WTI/OTI alarm/trip test,
replacement of silica gel, observing oil
level of bushing and conservator tank
etc.) was being carried out since
commissioning.
Thermo graphical inspection for clamps
& connectors of reactor was carried out
on 19.11.11 and no hot spots were
observed.
Last measurements of capacitance and
tan delta of bushings and windings of
reactor were carried out on 07.12.10 and
results were found satisfactory. DGA
test of oil was carried out on 20.09.10
and no abnormality was observed.
IR value and PI were measured on
02.04.11 and found satisfactory.
No history of faults
All control cables for Y-phase Bus Reactor were found burnt and damaged.
HV bushing of the reactor blasted and fire took place. Radiator bank was
found de-shaped and collapsed due to heat. Emulsifier pipe line for reactor
got damaged. Post Insulator connected adjacent to the reactor also got
damaged. LA connected in Y-phase was flamed and its surge counter was
damaged.
B-phase reactors WTI, OTI with cable and breather and emulsifier pipe line
got damaged and top portion of HV bushing got flamed.
R-phase reactors top plate gasket got damaged and minor oil leakage was
found. Its neutral bushing was found intact but its cable and collar were found
damaged. Associated 400 kV LAs bottom portion was found damaged.
Following protection systems had operated:
a. Restricted Earth Fault (REF) protection
b. Bucholz trip (R,Y & B phase)
c. Pressure Relief Valve (PRV) trip (Y-phase)
High winding and oil temperature was recorded in Y-phase Reactor.
16
17
Conclusion/recommendations :
Last test results of Oil DGA, capacitance and tan delta prior to the fault do not
indicate any abnormality in the oil, winding or bushing. IR value and
Polarization index of Y-phase reactor measured on 02.04.11 were also
satisfactory.
Operation of REF, bucholz and PRV indicates occurrence of fault inside tank.
LV tests (magnetizing current test, magnetic balance test, and turn ratio test
etc.) may be carried out on reactor after replacing the damaged bushings,
cables and LA. Oil may be tested for DGA and BDV.
Internal inspection may be carried out at site and its condition may be
assessed. If possible, the reactor may be repaired at site as per prevailing
practices and periodic maintenance schedule may be continued.
4.0
Name of Substation
Utility/Owner of substation
-6-
Faulty Equipment
Power Transformer
Rating
Make
Sr. No.
600447
Year of manufacturing
1982
Year of commissioning
10
Date
and
time
of :
occurrence/discovery of fault
Information received in CEA :
11
Operation
12
Present
condition
equipment
of :
Replaced
13
Details
of
maintenance
14
15
Sequence
of
Description of fault
previous :
03.04.12
events/ :
17
Conclusion/recommendations :
-8-
5.0
Name of Substation
400/220/132 kV grid
Meramundali, Odisha
Utility/Owner of substation
Faulty Equipment
Rating
220 kV
Make
Siemens
Sr. No.
10509002
Year of manufacturing
2009
Year of commissioning
Date
and
time
of :
occurrence/discovery of fault
10
03.04.12
11
Operation
12
Present
condition
equipment
13
Details
of
maintenance
14
15
Sequence
of
Description of fault
of :
previous :
substation,
Nil
events/ :
Faulty CT was replaced with a new CT and the feeder was charged
successfully on 23.02.12 at 17:03 Hrs.
16
17
Conclusion/recommendations :
It is assumed that SF6 loss alarm would have been left open accidentally
because of which no alarm signal was heard by operating staff in the control
room. Continuous monitoring of SF6 gas is required and periodical
maintenance should be done.
6.0
Name of Substation
Utility/Owner of substation
North
Eastern
Electric
Corporation Ltd. (NEEPCO)
Faulty Equipment
Rating
Make
Sr. No.
24115
Year of manufacturing
1980
Year of commissioning
1988
Date
and
time
of :
occurrence/discovery of fault
10
29.03.12
11
Operation
12
Present
condition
equipment
of :
Replaced
13
Details
of
maintenance
14
previous :
:
- 10 -
Power
15
Sequence
of
Description of fault
events/ :
On 21/02/12, Kopli Unit IV machine was synchronized with the grid at 16:30
hrs. The unit was generating at 49 MW load as per schedule. But the machine
tripped at 20:02 hrs with the following fascia indications:
1. GT A phase bucholz alarm
2. GT A phase bucholz operated
3. Excitation Equipment Stage I
The following relays operated:
1. Trip relay 86A, 86B, 86C
2. GT A phase bucholz trip realy 83GTX
3. GT differential A Ph 87 GTA
The unit was kept under shutdown for detailed investigations since tripping.
On 22.02.12, both the generator transformers of Phase-A & C were
disconnected from bus duct (11kV side) and HV side.
On checking Phase-A of GT, the following were observed:
(a) Accumulation of gas was observed in bucholz relay
(b) Oil level in conservator dropped to almost empty mark
(c) Oil leakage from two nos. of heat exchanger cooler tube
16
17
Conclusion/recommendations :
This GT has failed for the first time since its commissioning in year 1988. It
has served for about 24 years without giving any trouble.
Operation of differential relay indicates internal fault in GT and operation of
bucholz relay indicates formation of gases inside GT. Results of tests done
after failure indicate deterioration of insulation resistance and insulating oil.
Since the GT was commissioned in 1988, ageing may also be one of the
reasons for insulation deterioration. GT may be opened after consultation with
manufacturer and its condition from inside may be assessed for whether it
could be repaired.
There is no oil and water differential pressure gauge in the cooler line, which
had been removed by NEEPCO due to its malfunctioning and which may have
allowed the water to enter in the oil line and consequently damaged the
windings. It is recommended that the same be reinstalled.
Water being used for the cooling system has very low PH value and because
of this corrosion takes place in the water tubes and metal parts of the heat
exchanger resulting in tube failure. Periodical maintenance is recommended
for heat exchanger tubes.
- 11 -
Name of Substation
230/110 kV
Tamilnadu
Utility/Owner of substation
Faulty Equipment
CVT (Y-phase)
Rating
230 kV/110 V
Make
Sr. No.
9701/1997
Year of manufacturing
1997
Year of commissioning
Date
and
time
of :
occurrence/discovery of fault
10
16.04.12
11
Operation
12
Present
condition
equipment
13
Details
of
maintenance
14
15
Sequence
of
Description of fault
of :
previous :
Cuddalore
substation,
events/ :
In CVT connected in 230 kV Neyveli feeder, heavy sound and smoke was
- 12 -
detected at about 18:45 hrs on 30.03.12. On inspection, the CVT got flashed
over and loop jumper between CVT and wave trap got released from CVT
point and hung near by the wave trap support insulator without tripping the
feeder. Oil leakage in CVT was also noticed.
16
17
Conclusion/recommendations :
Name of Substation
230/110
kV
Tamilnadu
Utility/Owner of substation
Faulty Equipment
CVT (Y-phase)
Rating
230 kV/110 V
Make
HBB
Sr. No.
IB048299
Year of manufacturing
Year of commissioning
Date
and
time
of :
occurrence/discovery of fault
10
16.04.12
11
Operation
12
Present
condition
equipment
13
Details
of
maintenance
14
of :
previous :
:
- 13 -
Trichy
Awaiting repair/replacement
substation,
15
Sequence
of
Description of fault
events/ :
17
Conclusion/recommendations :
Name of Substation
Utility/Owner of substation
Faulty Equipment
Rating
Make
Sr. No.
24530
Year of manufacturing
1985
Year of commissioning
Date
and
time
of :
occurrence/discovery of fault
10
12.06.12
11
Operation
- 14 -
12
Present
condition
equipment
of :
13
Details
of
maintenance
14
15
Sequence
of
Description of fault
previous :
Awaiting repair/replacement
Periodical
maintenance
(i.e.
measurement of IR value, cleaning of
bushings and clamp connectors, bucholz
trip test, PRV trip test, WTI/OTI
alarm/trip test, replacement of silica gel,
observing oil level of bushing and
conservator tank etc.) was being carried
out since commissioning.
Last measurements of capacitance and
tan delta of bushings and windings of
reactor
and DGA test of oil were
carried out on 01.03.12 and results were
found satisfactory.
Top cover gasket, HV bushing, damaged
cables, WTI & OTI were replaced; oil
was filtered and all routine tests and
tripping tests were carried out on
05.03.12.
Information not available
events/ :
All control cables for B-phase Bus Reactor were found burnt and damaged.
HV bushing of the reactor blasted and fire took place. Emulsifier pipe line for
reactor got damaged. Post Insulator connected adjacent to the reactor also got
damaged. Surge counter of LA connected in Y-phase was damaged.
Following protection systems had operated:
a. Restricted Earth Fault (REF) protection
b. Bucholz trip (R,Y & B phase)
c. Pressure Relief Valve (PRV) trip
High winding and oil temperature was recorded in B-phase Reactor.
16
17
Conclusion/recommendations :
Last test results of Oil DGA, capacitance and tan delta prior to
not indicate any abnormality in the oil, winding or bushing.
value in B-phase showed decrease in value from 2945 M
02.04.11 to 1270 M measured on 07.12.11. IR value in
registered 1460 M on 29.02.12.
- 15 -
Operation of REF, bucholz and PRV indicates occurrence of fault inside tank.
LV test may be carried out on reactor after replacing the damaged bushings,
cables and LA. Oil may be tested for DGA and BDV.
Internal inspection may be carried out at site and its condition may be
assessed. If possible, the reactor may be repaired at site as per prevailing
practices and periodic maintenance schedule may be continued.
10.0
Name of Substation
Utility/Owner of substation
Maharashtra
State
Electricity
Transmission Co. Ltd. (MSETCL)
Faulty Equipment
CT (B-phase) in Warora-Chandrapur
feeder
Rating
Make
Sr. No.
12768
Year of manufacturing
2008
Year of commissioning
Date
and
time
of :
occurrence/discovery of fault
10
09.05.12
11
Operation
12
Present
condition
equipment
of :
Replaced
13
Details
of
maintenance
14
15
Sequence
of
Description of fault
previous :
events/ :
Name of Substation
Utility/Owner of substation
Maharashtra
State
Electricity
Transmission Co. Ltd. (MSETCL)
Faulty Equipment
Rating
Make
M/s ABB
Sr. No.
ID 220820
Year of manufacturing
1999
Year of commissioning
Date
and
time
of :
occurrence/discovery of fault
10
09.05.12
11
Operation
12
Present
condition
equipment
of :
Replaced
13
Details
of
maintenance
14
15
Sequence
of
Description of fault
previous :
events/ :
- 17 -
17
Conclusion/recommendations :
Name of Substation
Utility/Owner of substation
Maharashtra
State
Electricity
Transmission Co. Ltd. (MSETCL)
Faulty Equipment
Rating
Make
M/s Elpro
Sr. No.
A-0428-83-1895
Year of manufacturing
Year of commissioning
1975
Date
and
time
of :
occurrence/discovery of fault
10
09.05.12
11
Operation
12
Present
condition
equipment
of :
Replaced
13
Details
of
maintenance
14
previous :
:
- 18 -
15
Sequence
of
Description of fault
events/ :
17
Conclusion/recommendations :
Name of Substation
Utility/Owner of substation
Maharashtra
State
Electricity
Transmission Co. Ltd. (MSETCL)
Faulty Equipment
Rating
220 kV
Make
M/s CGL
Sr. No.
114821
Year of manufacturing
1988
Year of commissioning
Date
and
time
of :
occurrence/discovery of fault
10
09.05.12
11
Operation
12
Present
condition
equipment
of :
Replaced
- 19 -
13
Details
of
maintenance
14
15
Sequence
of
Description of fault
16
17
previous :
events/ :
14.0
Name of Substation
400
kV
Chandrapur
Maharashtra
Utility/Owner of substation
Maharashtra
State
Electricity
Transmission Co. Ltd. (MSETCL)
Faulty Equipment
LA (B-phase)
Rating
400 kV
Make
Sr. No.
54 ABCD
Year of manufacturing
Year of commissioning
Date
and
time
of :
occurrence/discovery of fault
10
09.05.12
11
Operation
12
Present
condition
equipment
of :
Replaced
- 20 -
substation,
13
Details
of
maintenance
previous :
14
15
Sequence
of
Description of fault
events/ :
16
17
Conclusion/recommendations :
No additional information was provided by the utility in spite of reminders.
Hence no concrete reason may be ascertained for failure. However, periodic
condition monitoring with the use of various diagnostic tools is recommended
for all substation equipment.
15.0
Name of Substation
Utility/Owner of substation
Maharashtra
State
Electricity
Transmission Co. Ltd. (MSETCL)
Faulty Equipment
Rating
Make
Sr. No.
Year of manufacturing
1996
Year of commissioning
Date
and
time
of :
occurrence/discovery of fault
10
09.05.12
11
Operation
12
Present
condition
equipment
of :
Replaced
- 21 -
Station,
13
Details
of
maintenance
previous :
14
15
Sequence
of
Description of fault
events/ :
At 23:13 hrs, pole-I & II of converter breaker and tie breaker were tripped on
AC bus differential protection and AC bus overcurrent protection. Hence,
inspection of AC yard was carried out. During inspection, Y-phase CT of tie
bay was found blasted from secondary core terminal box with oil spreading
around the CT in AC yard.
16
17
Conclusion/recommendations :
Name of Substation
Utility/Owner of substation
Faulty Equipment
Power Transformer
Rating
Make
Sr. No.
24669
Year of manufacturing
1986
Year of commissioning
Date
and
time
of :
occurrence/discovery of fault
10
26.07.12
11
Operation
- 22 -
12
Present
condition
equipment
of :
13
Details
of
maintenance
14
15
Sequence
of
Description of fault
previous :
Replaced
events/ :
17
Conclusion/recommendations :
M/s CGL is of the opinion that Y phase winding has been damaged.
Formation of acetylene gas in excess of threshold value indicates generation
of very high temperature which may be due to arcing in the tank. Operation of
differential relay, bucholz relay, AC supervision relay and PRV also indicates
occurrence of internal fault in transformer. LV tests also point towards internal
fault. M/s CGL is of the opinion that the transformer is not repairable at site.
Need for repairing may be evaluated on the basis of benefit cost analysis,
considering the fact that the transformer would need to be transported to
manufacturers works. It is noted that the transformer is 26 years old.
Periodic condition monitoring with the use of various diagnostic tools is
recommended for all substation equipment.
Most substations of DTL are running overloaded. It is recommended to reduce
the load as a short term measure and provide additional transformation
- 23 -
capacity as a long term measure. DTL must install High Velocity Water Spray
System or Nitrogen based Fire Protection System at their substations as soon
as possible.
17.0
Name of Substation
Utility/Owner of substation
Faulty Equipment
Rating
400 kV
Make
M/s CGL
Sr. No.
26188
Year of manufacturing
2003
Year of commissioning
Date
and
time
of :
occurrence/discovery of fault
10
26.07.12
11
Operation
12
Present
condition
of :
equipment
Details
of
previous :
maintenance
Replaced
14
Nil
15
Sequence
of
Description of fault
13
events/ :
16
17
Conclusion/recommendations :
Upon physical inspection, it was found that each stack diaphragm was opened
and leakage current monitor was burst.
Periodic condition monitoring with the use of diagnostic tools is
recommended.
18.0
Name of Substation
230/110 kV
Tamilnadu
Utility/Owner of substation
Faulty Equipment
CVT (B-phase)
Rating
230 kV/110 V
Make
M/s WS
Sr. No.
780110
Year of manufacturing
1978
Year of commissioning
Date
and
time
of :
occurrence/discovery of fault
10
03.09.12
11
Maintenance
12
Present
condition
equipment
13
Details
of
maintenance
14
15
Sequence
of
Description of fault
of :
previous :
Villupuram
substation,
Replaced
events/ :
Oil leakage from CVT was noticed on 08.08.12 at 10:45 hrs during normal
- 25 -
17
Conclusion/recommendations :
It is difficult to pin point any particular reason for failure of CVT. Since CVT
was in service for about 29 years, ageing may be one of the reasons for failure.
Periodic condition monitoring with the use of various diagnostic tools is
recommended for all substation equipment.
- 26 -
19.0
Summary of Failures of substation equipment in Tamil Nadu during 2011 to 2012 (September) for which brief information was
provided by Sh. B. Abdul Rahim, SE, TANTRANSCO during Meeting held on 30.10.12.
Sl.
No.
Name
of
the Equipment details
Substation/ feeder
1.
230/110
Thudialur S/s
28.12.2011
23:34 Hrs
2.
YOM: 1995
DOC: 07.02.2005
13.10.2011
23:08 Hrs
3.
230/110
Alagarkoil S/s
Not Available
10.01.2012
20:17 Hrs
4.
230
kV 230
kV
SF6 TELK
CheckkanuraniBreaker (Y phase)
860028-2
TTPS-I feeder
YOM: 1988
DOC: 22.03.1990
29.02.2012
08:05 Hrs
5.
YOM: 1997
30.03.2012
- 27 -
S/s
6.
7.
8.
PT TELK
730037-2
YOM: 1988
DOC: 27.03.1989
WSI
YOM: 1988
DOC:
available
CGL
11966
Not available
9.
SF6 TELK
860028-10
10.
11.
13:15 Hrs
15.04.2012
18:05 Hrs
15.04.2012
not 18:05 Hrs
05.06.2012
05:36 Hrs
YOM: 1988
DOC:
available
16.07.2012
not 18:12 Hrs
YOM: 1995
DOC:
available
YOM: 1995
DOC:
available
21.07.2012
not 19:52 Hrs
- 28 -
13.08.2012
not 18:20 Hrs
12.
13.
400
kV
Thoppur S/s
14.
15.
TELK
23014409
16.
400
kV 230 kV
Sriperumbudur S/s phase)
17.
18.
LA
YOM:
not 18.02.2011
available
07:19 Hrs
DOC: 23.03.88
YOM:
not 12.10.2011
available
19:45 Hrs
DOC: 11.08.1988
HBB
113150342
YOM:
not 04.11.2011
available
16:30 Hrs
DOC: 23.03.1989
Alstom
20051129
YOM:
not 05.12.2011
available
08:30 Hrs
DOC: 01.06.2007
(R CGL
4853
Alstom
20051022
CGL
4887
YOM: 1999
DOC: 30.06.2002
25.08.2012
16:46 Hrs
YOM:
not
available
DOC: 12.03.2007
YOM: 1999
DOC: 16.10.2000
02.12.11
08:17 Hrs
- 29 -
22.11.2011
16:04 Hrs
19.
29.10.2011
00:06 Hrs
Submitted by
- 30 -
- 31 -
The Committee also suggested that DTL make changes, if required, in the
power transformer specifications to avoid frequent failures. DTL might ask
manufacturers for a longer warranty period.
Failure of equipment at substations in Tamilnadu was discussed with Shri B.
Abdul Rahim, S.E., TANTRANSCO. He informed that faulty CVTs at Cuddalore,
Trichy and Villupuram have been replaced. Since no protection operated in case of
failure at Cuddalore and Trichy, it was difficult to pin point any particular reason for
failure. Sh. Rahim pointed out that all periodic testing of substation equipment is done
by a separate testing wing. He also informed that service life of CVT is generally
considered to be 15 years. CVTs at Cuddalore, Trichy and Villupuram had served for
14 years, 28 years and 29 years respectively. As the CVTs at Trichy and Villupuram
had served for 28 and 29 years respectively, so ageing may be the reason for their
failure. Not much information was available with the Committee in respect of failure
of 400 kV LA at Alamathy substation. Sh. Rahim agreed to provide more information
through E-mail to the secretariat of the Committee.
Sh. Satbir Singh, SE, SRPC, informed that in Southern Region protection
audit of important substations was being done. This was appreciated by the
Committee.
The Committee was of the view that various diagnostic tools as suggested in
Central Electricity Authority (Technical Standards for Construction of Electrical
Plants and Electric Lines) Regulations, 2010, should be used regularly for periodic
maintenance and condition based maintenance of substation equipment.
The meeting ended with thanks to the chair.
- 32 -
Annexure - I
LIST OF PARTICIPANTS
TANTRANSCO, Tamilnadu
Shri B. Abdul Rahim, S.E., Villupuram
- 33 -