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Chapter 1:
Government vide order No. 69 BSR 2001 Bangalore, dated 15/02/2002 has
unbundled KPTCL and formed four distribution companies.
Consequent to this the function of distribution of power has been totally separated
from KPTCL. KPTCL is now vested with the responsibility of transmitting power
all over the State and construction and maintenance of Stations and lines of 66KV
and above.
The four newly formed independent distribution companies, which were
registered on 30/04/2002, are Bangalore Electricity Supply Company, Mangalore
Electricity Supply Company, Hubli Electricity Supply Company and Gulbarga
Electricity Supply Company. They have started functioning w.e.f.. 01/06/2002.
These companies are incharge of distribution of power within their jurisdiction.
The Fifth Distribution Company Chamundeshwari Electricity Supply Corporation
limited is a company incorporated under the company act 1956 and is a successor
entity to Karnataka Power Transmission Corporation Limited (KPTCL) and
MESCOM in respect of Distribution and retail supply of Electric power for five
districts. Its operation started from 01.04.2005 as per the GOK order E.N.08
P.N.R 2005/262.
PCKL was incorporated on 20th August, 2007 under the Companies Act, 1956
and commenced its business operations with effect from 16th October, 2007.
PCKL is responsible for capacity addition and procuring power on behalf of the
ESCOMs from various sources including purchase of power through Energy
Exchange, Banking (SWAP) as well bilateral transactions. PCKL also co-
ordinates with other States and Central Government agencies on power related
issues.
The erstwhile Mysore State had the enviable and glorious position of
establishing the first major hydro-electric generating station at Shivasamudram as
earlyas 1902 for commercial operation. The art at that time was still in its infancy,
even in the advanced countries. The longest transmission line, at the highest voltage
in the world, was constructed to meet the power needs of mining operations at Kolar
Gold Fields. The generating capacity of the Shivasamudram Power House gradually
increased to 42 MW in stages. To meet the increasing demand for power, the
Shimsha Generating Station, with an installed capacity of 17.2 MW, was
commissioned in the year 1938.
The power demand was ever on the increase, for industries and rural
electrification, and additions to generating became imperative. The 1st stage of 48
MW and 2nd stage of 72 MW of the Mahatma Gandhi Hydro-Electric Station were
commissioned during 1948 and 1952, respectively. Subsequently, the Bhadra
Project, with an installed capacity of 33.2 MW, and the Thungabhadra Left Bank
Power House, with an installed capacity of 27 MW at Munirabad were
commissioned during 1964 and1965, respectively.
The state of Karnataka, with availability of cheap electric power, and other
infrastructure facilities, was conducive for increased tempo of industrial activity. It
effect from 1st June 2002 and five distribution companies were formed. The four
newly formed independent distribution companies, which were registered on
30.01.2002, are Bangalore Electricity Supply Company (BESCOM), Mangalore
Electricity Supply Company (MESCOM), Hubli Electricity Supply
Company (HESCOM), Gulbarga Electricity Supply Company (GESCOM), and
Chaumundeshwari Electricity Supply Company (CESCOM). These companies are
in charge of distribution of power within their jurisdiction.
elaborate manner in the detailed policy statement and the IPP policy framed by
the Government of Karnataka. To provide a statutory frame work, the KER Act
99 came into force from 1st June 1999.
Corporatization of KEB
As a first step in the reform process, the erstwhile KEB was corporatized
to form Karnataka Power Transmission Corporation Limited (KPTCL) and
operationalized w.e.f 01.08.1999 under the Companies Act 1956. KPTCL was
then vested with transmission and distribution functions. Simultaneously, another
entity called Visvesvaraya Vidyut Nigama Limited (VVNL) was also formed to
take care of the generation portion of the erstwhile KEB. (This VVNL is now
merged with KPCL Karnataka Power Corporation Limited).
Formation of Regulatory Commission (KERC)
As per the provisions of the Central Regulatory Commissions Act 98 and
also as per the KER Act 99, the State Government must establish a State
Regulatory Commission with a view to regulate the activities of the sector in the
areas of generation ,transmission , and distribution .
Accordingly the Government of Karnataka established the Karnataka
Electricity Regulatory Commission (KERC), a quasi judicial body and
operationalized it from 15.11 1999. It is a three member commission that looks
into various operational parameters of the power sector utilities, prescribes
standards and enforces them through regulations. KERC is the sole authority for
determining electricity tariff. Without the order of the commission, neither
KPTCL nor ESCOM can alter the electricity tariff to the consumer.The
commission determines the tariff through a transparent process wherein all the
stake holders are involved and sufficient opportunity given to them in public
hearings.
Unbundling-Formation of ESCOMs.
In the second phase of reforms, the KPTCL was unbundled, to separate the
transmission and distribution functions. Four Electricity Supply Companies
(ESCOMs) were formed on regional basis, viz Bengaluru Electricity Supply
Company, (BESCOM),Mangalore Electricity Supply Company (MESCOM),
GENERATION : KPCL
TRANSMISSION : KPTCL
DISTRIBUTION : ESCOMs--BESCOM, HESCOM, GESCOM,
MESCOM, CESCOM.
KPTCL is now vested with responsibility of transmitting power all over the
State and construction and maintenance of Stations and lines of 66kV and above.
KPTCL will transmit power from various power producers to it to the distribution
companies. To enable easier operation of the system, KPTCL has been divided into
six zones, each headed by a Chief Engineer, fifteen circles, each headed by a
Superintending Engineer, fifty-seven divisions, each headed by an Executive
Engineer and over two hundred and seventy sub-divisions, each headed by an
Assistant Executive Engineer.
Following are the six Transmission Zones of KPTCL each headed by a Chief
Engineer.
The Electricity Act 2003 does not permit the transmission utility to
involve in electricity trading. (i.e. bulk buying and selling electricity). Therefore
from 10th June 2005, trading activity has been detached from KPTCL and vested
with the respective ESCOMs.
However, for providing guidance to the ESCOMs and coordination purposes, the
State Government has established a State Power Procurement and Coordination
cell(SPPCC).
Chapter 2
In compliance with the set tasks and accomplishment of the set objectives and
standards of KPTCL and effective utilization of manpower and resources, R.T Circle, has
established for carrying activities of periodical testing, calibration, troubleshooting,
Inspection, witnessing and assisting TL&SS staff during overhauls, breakdowns, repair &
maintenance works.
R.T subdivision Ballari one among the RT circle Mnirabad and is actively engaged
in the activities of Pre-Commissioning and Commissioning of equipment’s in New &
existing substations. There are 13 substations which comes under RTSD Ballari, where if
any fault or problem occurs among them will be solved by RT AEE/AE/mechanics.
Vision:
The vision of the R.T circle is to maintain high standards in electrical power
system testing through its technical competence and espousing accredited standards. With
a relentless pursuit of safety compliance, economical operation and a perpetual focus on
training and education in a quest to educate the masses to adopt the best practices of
operations in order to achieve the best Quality and Un interrupted supply to our
consumers.
Mission:
Values:
Safety, quality, system reliability and adaptation of ethical practices in operations
of protection systems are basic foundations of the R.T Division Ballari..
Chapter 3
Electrical safety testing is essential to ensure safe operating standards for any
product that uses electricity. Various governments and agencies have developed stringent
requirements for electrical products that are sold world-wide. In most markets it is
mandatory for a product to conform to safety standards promulgated by safety and
standard agencies and To conform to such standards, the product must pass safety tests
such as the high voltage test (also called as Dielectric voltage-withstand test or high
potential test), Insulation Resistance Test, Ground (Earth) Bond & Ground Continuity
Test & Leakage Current Test (also called as Line Leakage Test, Earth Leakage Current
Test, Enclosure Leakage Current Test or Patient Leakage Current Test). These tests are
described in IEC 60335, IEC 61010 and many other national and international standards.
During internship period the some of the electrical equipment test were conducted
and they are explained below,
When a current is too high to measure directly or the voltage of the circuit is too
high, a current transformer can be used to provide an isolated lower current in its
secondary which is proportional to the current in the primary circuit. The induced
secondary current is then suitable for measuring instruments or processing in electronic
equipment.
Objective:
CT Rating:
The above 5P20 refers to even though there is increase in rated current upto 20
times the percentage error will be only 5%. And 0.2 class means CT with a burden rating
of B-0.2 can tolerate an impedance of up to 0.2 Ω on the secondary circuit before its
accuracy falls outside of its specification
Test includes,
MEGGER TEST:
This test is conducted by using hand driven motor megger tool where it generates
1000v dc, the insulation resistance is measured w.r.t primary, secondary and ground.This
is done to know whether the resistance of the winding is capable of carrying the rated
current and also which do not degrades, the test results are shown below,
PRI-GRD 2000 Ω
CORE2 10000 Ω
CORE3 10000 Ω
CORE 2000 Ω
2
CORE 2000 Ω
3
RATIO TEST:
This test is to ensure the turn’s ratio of CT at all taps. The primary current of minimum of
25% rated primary current to be injected on primary side of CT with secondaries
shorted and the secondary current can be measured and recorded for all cores.
Limits: The obtained turn’s ratio should match with rated nameplate ratio.
This test is done by connecting booster transformer with the rating of 200A,
usually test will be done at 10% & 25% of the rated current and this test is the most
important test where in the test results are above 5% error then this test will fails so the
test results are must carefully taken in order to avoid error in measurement and results are
tabulated below,
POLARITY TEST:
Polarity test is to confirm the polarity marking on the CT primary and secondary
and verify it is matching with drawing. More ever it is giving an idea, how to connect the
secondaries to make the protection (like directional, differential) and metering function
properly.
This test gives the polarity of the CT to which side it has to connect in the line.
The above tests are performed to ensure proper working of current transformer, if
the CT is fails in ratio test then it should not be used for further application and it has to
be replaced. So ratio test is very important in this case and it has to be carried out
carefully.
The polarity test should be as per the markings otherwise, it would cause different
problems which causes failure of its operation.
actually loading the transformer, these two assessed tests give the test results which are
used to determine the equivalent circuit parameters.
• These tests are usually performed to know the core losses and copper losses
• But here this test is done to check whether the alignment of OLTC has done
successfully after the maintainance work has been done by the concerned contractors.
RY YB BR ry yb br
Usually the tap number 5 gives the exact transform of voltage as per ratio, the
designers had designed like that we have 17 taps in the transformer and the voltages are
shown in above table we can see at tap number 5 the voltage transform is nearly close to
ratio.
In this test the secondary short circuited by TPST swith and measures the primary
and secondary current by applying 425v. The results shows that the primary currents are
less where secondary currents are almost double because the primary is the HV side and
voltage is high and secondary is LV side and voltage is 50% of primary. Again at tap
number 5 the currents at secondary is 2 times greater than the primary current.
After the results are tabulated RT AE has concluded that the transformer is
working properly as per the ratio and informed substation incharge to charge the
transformer.
Fig. above shows the parts of a typical SF6 circuit breaker. It consists of fixed
and moving contacts enclosed in a chamber (called arc interruption chamber) containing
SF6 gas. This chamber is connected to SF6 gas reservoir. When the contacts of breaker
are opened, the valve mechanism permits a high pressure SF6 gas from the reservoir to
flow towards the arc interruption chamber. The fixed contact is a hollow cylindrical
current carrying contact fitted with an arc horn. The moving contact is also a hollow
cylinder with rectangular holes in the sides to permit the SF6 gas to let out through these
holes after flowing along and across the arc.
In the closed position of the breaker, the contacts remain surrounded by SF6 gas
at a pressure of about 2·8 kg/cm2. When the breaker operates, the moving contact is
pulled apart and an arc is struck between the contacts. The movement of the moving
contact is synchronised with the opening of a valve which permits SF6 gas at 14 kg/cm2
pressure from the reservoir to the arc interruption chamber. The high pressure flow of
SF6 rapidly absorbs the free electrons in the arc path to form immobile negative ions
which are ineffective as charge carriers. The result is that the medium between the
contacts quickly builds up high dielectric strength and causes the extinction of the arc.
1. Moving contact
2. Fixed contact.
During normal operation of the power system, both the contacts are closed so that
there is normal flow of current.
And whenever the fault occurs, moving contact gets separated from fixed contact
so as to interrupt the circuit and healthy part of the power system is isolated from the
faulty part. But in the case which we were involved in the sub-station is there was mis-
alignment of the fixed contact and the moving contact as shown below.
Fig 3.4: Contacts alignment under normal condition and flashover condition
So due to this mis-alignment between the contacts there was arc struck between
these contacts and heat was produced.
Due to this heat produced, the SF6 gas got expanded and one phase limb of the
CB got exploded.
Remedy:
The faulty or affected limb was replaced and pre-commissioning test carried out.
1. Megger Test
2. Breaker Timing Test
MEGGER TEST:
The insulation resistance (IR) test (also commonly known as a Megger) is a spot
insulation test which uses an applied DC voltage (typically either 250Vdc, 500Vdc or
1,000Vdc for low voltage equipment <600V and 2,500Vdc and 5,000Vdc for high
voltage equipment) to measure insulation resistance in either kΩ, MΩ or GΩ.
• This test is conducted to measure operation times of all types of HV and EHV
breakers under charged switch yard condition.
Mode1- Close
Mode 2- Trip
Mode 3- Auto recloses (N/A)
Fig 3.6: SCOT MXP kit used for breaker timing test
Specification:
TEST RESULTS:
A pure insulator when is connected across line and earth, it behaves as a capacitor. In
an ideal insulator, as the insulating material which acts as dielectric too, is 100 % pure,
the electric current passing through the insulator, only have capacitive component. There
is no resistive component of the current, flowing from line to earth through insulator as in
ideal insulating material, there is zero percent impurity.
In practice, the insulator cannot be made 100% pure. Also due to the ageing of
insulator the impurities like dirt and moisture enter into it. These impurities provide the
conductive path to the current. Consequently, leakage electric current flowing from line
earth through insulator has also resistive component.
For good insulator the resistive component of leakage current is quite low. The
healthiness of an electrical insulator can be determined by ratio of resistive component to
capacitive component.
For good insulator this ratio would be quite low. This ratio is commonly known as
tanδ or tan delta.
The equipment to be tested is first isolated from the system. A very low frequency
test voltage is applied across the equipment whose insulation to be tested. First the
normal voltage is applied. If the value of tan delta appears good enough, the applied
voltage is raised to 1.5 to 2 times of normal voltage, of the equipment. The tan delta
controller unit takes measurement of tan delta values.
There are two ways to predict the condition of an insulation system during tan
delta or dissipation factor test. First, one is, comparing the results of previous tests to
determine, the deterioration of the condition of insulation due ageing effect. The second
one is, determining the condition of insulation from the value of tanδ, directly. No
requirement of comparing previous results of tan delta test.
Test Result:
KV mA C Tan Delta
The impact of such errors may range from simply being a nuisance (tripping
occurs repeatedly on energization, requiring investigation to locate and correct the errors)
through to failure to trip under fault conditions, leading to major equipment damage,
disruption to supplies and potential hazards to personnel.
The strategies available to remove these risks are many, but all involve some kind
of testing at site. Commissioning tests at site are therefore invariably performed before
protection equipment is set to work. The aims of commissioning tests are:
1. To ensure that the equipment has not been damaged during transit or installation
2. To ensure that the installation work has been carried out correctly
3. To prove the correct functioning of the protection scheme as a whole
The tests carried out will normally vary according to the protection scheme
involved, the relay technology used, and the policy of the client. In many cases, the tests
actually conducted are determined at the time of commissioning by mutual agreement
between the client’s representative and the commissioning team.
The following tests are invariably carried out, since the protection scheme will not
function correctly if faults exist.
Wiring diagram check, using circuit diagrams showing all the reference numbers
of the interconnecting wiring
General inspection of the equipment, checking all connections, wires on relays
terminals, labels on terminal boards, etc.
Insulation resistance measurement of all circuits
In addition, the following checks may be carried out, depending on the factors noted
above (not covered in this technical article):
Secondary injection test on each relay to prove operation at one or more setting
values
Primary injection tests on each relay to prove stability for external faults and to
determine the effective current setting for internal faults (essential for some types
of electromechanical relays)
Testing of protection scheme logic
At some point during commissioning, the alarm and trip settings of the relay
elements involved will require to be entered and/or checked. Where the complete scheme
is engineered and supplied by a single contractor, the settings may already have been
entered prior to dispatch from the factory, and hence this need not be repeated.
The method of entering settings varies according to the relay technology used. For
electromechanical and static relays, manual entry of the settings for each relay element is
required. This method can also be used for digital/numerical relays.
However, the amount of data to be entered is much greater, and therefore it is usual to use
appropriate software, normally supplied by the manufacturer, for this purpose. The
software also makes the essential task of making a record of the data entered much easier.
NMC (Neutronics Manufacturing Company) make Relay testing Kit in one unit,
is suitable to test different types of Relays like over current, over voltage, under voltage,
earth fault etc. The Test Kit will be in one unit. Meters, Terminals, Indicators, Regulator
Knob, Timer Display etc. will be fitted on the horizontal panel of the cabinet which can
be approached by opening the top hinged lid. An input chord of 2 meters length
with 3 pin plug will be provided. Loading transformer, Measuring CT& protection circuit
will also be housed within the same unit.
Technical features:
Current Range : 0-1, 2, 5, 10, 20A at 5V, 0-50, 100, 200A at 50V
If the relay is said to be okay, the recorded time and the TSM must be same. If
any difference between these two then the relay need to be replaced.
Numerical relays was invented in the early 1980s by Edmond O. Schweitzer. SEL,
ARENA, and ABB Group’s are the early forerunners in this area. In the mid-1990s
numerical relays had nearly replaced the solid state and electromechanical relays.
Programmability.
Computing function.
Small Size.
Numerical relays are built with integrated functions like protection, control,
monitoring and measuring are available today in numeric power system protection
devices. Also, the communication capability of these devices facilitates remote
control, monitoring and data transfer.
The operation of numerical relay is shown in the above diagram. A current signal
from CT is converted into proportional voltage signal using I to V converter. The
AC voltage proportional to load current is converted into DC using precision
rectifier and is given to multiplexer which accepts more than one input and gives
one output.
The figure above shows the connection diagram for the relay testing.It consist of
omricon test kit, laptop, relay under test connections are done as shown above and proper
grounding is ensured.
The CMC 256plus is the first choice for applications requiring very high
accuracy. This unit is not only an excellent test set for protection devices of all kinds but
also a universal calibrator.
Its high precision allows the calibration of a wide range of measuring devices,
including: energy meters, measuring transducers, power quality measurement devices and
phasor measurement units (PMU).
Its unique accuracy and flexibility make the CMC 256plus ideal for protection
and measurement equipment manufacturers for research and development, production
and type testing.
Built in Timer.
Auxiliary DC supply.
Once setting is done the test kit will develop the required voltages and currents
which are needed for the testing.
These outputs are given as relay inputs as trip signal, once the relay is tripped then
test kit will calculate the trip timings and other required data and display it in the result
dialog box in the laptop.
Chapter 4
During our internship period we have visited many sub stations to encounter the
errors or problems in the substation and few important issues are explained below.
Due to aging and heavy operations of the circuit breaker there is a jamming in
contacts of the R-phase limb during breaker opening time. We have inspected for the
fault and suggested for the replacement of the breaker and after replacement megger, and
breaker timing test are done and verified the results with the standards.
Due to interchange in the phase sequence of Y & B energy meter showing the
faulty measurements. We examined by using the online test kit and concluded that the
phase sequence is interchanged by observing the phasor diagram and reversed the
connections to the energy meter and verified the result.
Due to manufacture problem there was a problem near the CT terminal which
leads to the crack and burnt of the CT so after inspection of the CT suggested for the
replacement.
Also there was a problem in spring charging mechanism of the circuit breaker.
We inspected the motor and find it was healthy. After inspecting the gear mechanism it is
found that some of the teeth of the gear box are broken and suggested for either
replacement or repair.
Due to fault in the battery charger DC supply for the protection system is supplied
only when supply mains is ON, after inspection it is found that the diodes used for the
conversion of AC to DC are failed and suggested for replacement.
After replacement also float current is below the specified value so inspected for
any failure in the cell of a battery array, it is found that three cells of the battery array are
faulty and suggested for replacement but for emergency use we bypassed the faulty cells
and restored the required current.
The Trivector meter is a measuring instrument which measures the kW, kVAr, the
kVA of a power line. These instruments can measure both power as well as energy.
Trivector meters are normally used in substations and to measure the power flowing
through the feeders. They are used for billing power drawn by industrial customers. The
Trivector enables the simultaneous measurement of different electrical parameters which
enables accurate assessment of the power consumed.
In earlier days, the electromechanical trivector meters were used. Today, though,
almost all Trivector meters are of the static type. Modern Trivector meters can measure
many parameters apart from the active, reactive and apparent power.
The below figure shows the L&T ETV meter and connection diagram. While
doing connections if any one phase is reversed then meter will not record the reversed
phase current i,e energy recording for the phase reversal will be zero so it is noted that
care has to be taken while making connections to terminal boards and to energy meter.
Chapter 5
It was one of my best experience for carrying out my internship in relay testing
subdivision. We were about 2 students in my orientation group Since it would be an
industrial internship, so I decided to talk to Executive Engineer regarding permission for
internship. They agreed for an internship of 16 weeks. I started my internship from
August 2016 to November 2016.
The main focus of my internship was to know the procedure of testing and
troubleshooting the electrical equipments used in substation. The report consists of a brief
introduction of the organization and its functions .It also includes my personal learning
what I learnt over there and how was my experience in Relay testing subdivision writing
this report.
The internship program was a good platform to learn things such as: Teamwork,
Communication with higher authorities, maintaining records etc and also I learned the
importance of Maintaining time, appearance, leadership qualities.
First of all we learned how to observe single line diagram and layout diagram.
We have studied the manner in which equipments are arranged in the substation.
As we are in relay testing subdivision we are fortunate to observe testing of
various equipments such as:
Current Transformer.
Potential Transformer.
Circuit Breaker.
Relays.
Transformer etc.
We learned to operate various kits which are used for testing of equipments such
as:
Circuit Breaker Timer Kit.
Tan Delta Test Kit.
Omricon Numerical Relay Test Kit.
NMC Make Electro Mechanical Relay Test Kit.
Megger.
Time Management:
Time management is very important aspect in our subdivision because delay may
cause complete failure in the equipment, huge amount of revenue loss due to shutdown of
equipments, also sometimes causes risk to human life. working here gave us an
opportunity to learn efficient time management and resource management. Time
Management plays a very important role not only in organizations but also in our
personal lives.
Communication Skills:
Personality Development:
Every individual comes with a unique set of strengths and weakness, but working
in RTSD gave us an opportunity to overcome my weakness with proper suggestions from
higher authorities. Also observed lot of things about our appearance from the authorities
during field work, meetings, and office hours.
Written Skills:
Many employers consider written skills to be one of the most important job skills,
working in RTSD gave us a platform in learning and exhibiting our written skills.
Here we could get the practical knowledge about the theory subjects learned in
the previous classes.
Recognizing that financial and economic limitations play a more important role in
all engineering activities.
Understanding the formal and informal relationships in an industrial organization
so as to promote favorable human relations and teamwork.
Appreciating that engineering is an expanding field and that learning has no
limitations.
CONCLUSION
Overall training was very helpful in gaining technical knowledge as well as the
professional ethics followed in industries. Training was highly beneficial for
understanding the various operational aspects of substations and RT division. The
training involved thorough learning, understanding and application of various technical
aspects in real time. Training gave exposure to practical application of theoretical aspects
in real time.
I believe this training would help me in building a good platform for my career.
REFERENCES
1. www.kptcl.in
2. www.Elecrical4u.com
3. www.electricalstudy.com
4. Testing and commissioning of Electrical Equipments by Ramesh
L.Chakrasali Electrical Dept SDMCET Dharwad.