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A TECHNICAL REPORT
PRESENTED TO
BY
NOVEMBER, 2018
i
REHABILITATION OF 90MVA 330/132kV TRANSFORMER 5T2B BAY
BY
NOVEMBER, 2018.
ii
ACKNOWLEDGMENT
I sincerely appreciate all who have contributed to my engineering experience so far. I thank
Engr. A. O. Dim and Engr. (Mrs.) F. M. Ekoko for their support and unrelenting effort in
mentorship. Thanks to all the staffs of PC&M Akangba sub-region for their positive
contribution.
I thank my loving wife and son who have made the writing of this technical report possible.
I give all glory to God who is the giver of life, wisdom and knowledge.
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ABSTRACT
The report attempts to present my personal experience for the past five (5) years in the field of
engineering. The report summarizes one out of the numerous projects I have been involved in
the execution during my post graduate engineering and professional career. Chapter one is a
brief introduction of myself and also my job responsibility as a member of the Protection,
Control and Metering department. Chapter two present the project proper which is on the
Lagos. My involvement is to ensure that all aspect of the project is done according to project
Safety precaution taken, problems encountered with solution applied were discussed in the
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TABLE OF CONTENTS
Abstract …………………………………………………… iv
v
2.5 Transformer marshalling box ……………………………. 11
Chapter 3:
vi
LIST OF FIGURES
Figure 2.1 Banked 5T2A and 5T2B before the rehabilitation work ……………...... 8
Figure 2.3 The newly installed 330kV circuit breaker name plate ………………. 13
LIST OF TABLES
Table 2.2 Sample of CB cable schedule showing few control wiring ………… 16
Table 2.6 Transformer differential relay stability testing for stable condition … 21
Table 2.7 Transformer differential relay stability testing for unstable condition …21
Table 2.8 HV phase pickup (Id = 20% of 0.524) secondary in amps ………….. 22
Table 2.9 MV phase pickup (Id = 20% of 0.924) secondary in amps ………….. 22
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ABBREVATIONS
ACRONYMS MEANING
KV KILOVOLTS
KVA KILO VOLT AMPERE
MVA MEGA VOLT AMPERE
BCU BAY CONTROL UNIT
REF RESTRICTED EARTH FAULT
SBEF STANDBY EARTH FAULT
PC&M PROTECTION CONTROL AND METERING
TCN TRANSMISSION COMPANY OF NIGERIA
AC ALTERNATING CURRENT
DC DIRECT CURRENT
CT CURRENT TRANSFORMER
VT VOLTAGE TRANSFORMER
TB TERMINAL BLOCK
HV HIGH VOLTAGE
LV LOW VOLTAGE
TV TERTIARY VOLTAGE
IR INSULATION RESISTANCE
MW MEGA WATT
PRV PRESSURE RELIEF VALVE
OLTC ON-LOAD TAP CHANGER
SOTF SWITCH ON TO FAULT
CB CIRCUIT BREAKER
MCBs MINIATURE CIRCUIT BREAKERS
TS TRANSMISSION STATION
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CHAPTER TWO
2.1 INTRODUCTION
90MVA 330/132kV 5T2B was installed and commissioned since 1968. Since then no major
rehabilitation work has been carried out on the transformer. Hence its rehabilitation became
necessary. The rehabilitation of 90MVA 330/132kV transformer 5T2A started on the 8th of
April, 2017 and ended on the 14th of June, 2017. This project is one among the numerous
projects I was involved in the station. It involves all the departments in TCN, Akangba sub-
region but for the purpose of this report, jobs done mostly by the PC&M department in which
The rehabilitation of 90MVA 330/132kV 5T2B transformer bay with its associated protection
and control panels at Akangba Transmission Station became necessary due to the following
reasons:
The transmission system components of more than 50 years were obsolete and
over aged, hence have exceeded their normal service life and needed replacement.
5T2B and 5T2A share a common breaker as shown in figure 1, this makes
switching flexibility difficult. Outage on one of the transformers will require the
other one to be taken out of service. Hence a separate circuit breaker and current
1
The electro-mechanical relays were obsolete and needed to be replaced with
The control and protection cables needed replacement because they were
deteriorated and have weak insulation due to age and often results to open circuit
faults.
Isolators remote operations were faulty hence switching operations were done
breakdown
2
Q1 = MAIN BUS ISOLATOR
Q2 = RESERVE ISOLSTOR
Q5 = BYPASS ISOLATOR
Q9 = TRANSFORMER ISOLATOR
Q8 = EARTH SWITCH
Q0 = CIRCUIT BREABER
Figure 2.1: Banked 5T2A and 5T2B before the rehabilitation work and final unbanking
3
2.3 SCOPE OF THE PROJECT
i. The circuit was completely de-energized. All fuses removed and all MCB switched
off.
ii. All tripping and alarm signals from the transformer were carefully disconnected to
avoid interference with 90MVA 330/132kV transformer 5T2A since both shares a
iii. Control and signal cables were disconnected from all disconnector and earth switches
iv. The old earthing switch along with its associated materials and terminal connectors
were dismantled.
v. The old Isolators at both the primary and secondary of the transformer with their
vi. The old Bay Marshalling Kiosk (BMK) at the HV and LV sides of the transformer
were dismantled.
vii. The old control and protection panels at the 330kV and 132kV control rooms were
decommissioned and dismantled as the primary and secondary of the transformer will
viii. Equipment base for the new 330kV breaker, disconnector and earth switches were
constructed..
ix. The new NARI control and protection panels were installed and all relays configured.
4
x. The new Alstom 330kV circuit breaker was installed with new control and protection
cables laid.
xi. Installation of new disconnector and earth switches were carried out with new control
xii. Installation of new set of 330kV Alstom current transformers (CT) was also carried
out.
xiii. Installation of new BMK in the 330kV and 132kV side of transformer 5T2B.
xiv. Laying of new transformer protection cables, termination and tagging done from the
xv. Laying of new control/protection cables, termination and tagging done from the newly
It is noteworthy to state that most of the jobs were done simultaneously provided they do not
interfere with each other. This was done to enable the completion of the project within time
frame.
The transformer name plate contains data that enabled us, the protection engineers determine
the CT ratio that will be used on the HV and LV side of the transformer. Table 2.1 shows the
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Table 2.1 Transformer Details
DETAILS SPECIFICATIONS
HV/LV – Yy0
Vector symbol
HV/Tertiary – Yd1
Nominal Tap 5
Tertiary 1255Amps
Phases 3/3/3
Frequency 50Hz
New control cables (19C X 2.5mm2) was laid for the wiring of these auxiliary protections
from the transformer marshalling box to the relay panel and terminated according to figure
2.2. Main tank and OLTC oil level alarm were batched together.
6
TR MB TR13+R1
TB1-129
MAIN TANK BUCHOLZ ALARM XB5-15
TB1-137
MAIN TANK BUCHOLZ TRIP XB5-10
TB1-115
OLTC BUCHOLZ TRIP XB5-11
TB1-128
MAIN TANK OIL LEVEL ALARM XB5-20
TB1-112
LV WINDING TEMP. TRIP 2 XB5-13
TB1-111
TV WINDING TEMP. ALARM 2 XB5-18
TB1-113
TV WINDING TEMP. TRIP 2 XB5-14
TB1-120
COMMON XB5-3
A new ALSTOM 330kV SF6 circuit breaker was installed at the primary side of the
transformer 5T2B to separate it from 5T2A. The circuit breaker is made up of the following
parts.
A. Interrupting unit
B. Insulating Column
C. Support structure
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D. Operating unit
E. Breaker cubicle
New control cables were laid from the circuit breaker to the control and relay panel at the
330kV control room. This is for breaker remote control and operation.
Figure 2.3: The newly installed 330kV circuit breaker name plate
8
2.6.1 MATERIALS, TOOLS AND EQUIPMENT USED.
Erecting crane with adequate load-carrying capacity and height as specified in the
manual
Lifting cables
Torque wrenches
Steel brushes
It is very important to note that all equipments (transformer, breakers, isolators, current
transformers and voltage transformers) wiring were done according to the cable schedule
prepared from the equipment manuals. This schedule follows the format shown in table 2.2
while the cable numbering system followed the pattern in figure 2.4. This makes the job
easier and faster. A cable numbering system explained below was used.
Nevertheless, the manuals were made available at the site for reference purpose or
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4 06 1 19
THIS FIELD IS OPTIONAL AND IS ALPHABET A, B OR C
BASED ON THE CABLE USED AS PARALLEL RUN
BAY NUMDER
1 FOR 132KV
3 FOR 33KV
4 FOR 330KV
10
Table 2.2: Sample of Circuit Breaker cable schedule showing few control wiring
INTERCONNECTION
EQUIPMENT DESIGNATION LENGTH
CABLE DETAILS
APPLICATION REMARK
NO.
(M)
FROM TO SIZE CORE FROM TO
CB-Q0 BMK
406119 19CX2.5CU 17 1 TB3-1 TB4-14 COMMON
HV SIDE HV SIDE
PH Y CLOSE B/I
2 TB3-2 TB4-15
FOR BCU
PH Y OPEN B/I
3 TB3-10 TB4-16
FOR BCU
PH Y B/I FOR
5 TB5-58 TB4-18 TB3-1,TB3-
SPRING CHARGE
9, TB1-42,
TB1-50
CB REMOTE SHALL BE
7 TB1-49 TB4-20
MODE SHORTED
AT CB
8 TB5-5 TB4-31 R PH COIL 1 OPEN
CUBICLE
14 SPARE
… SPARE
11
… SPARE
19 SPARE
Two isolators were installed at the secondary side of the transformer. At the primary side, six
isolators were installed with the transformer isolator having an earth switch.
All these were wired to the control panels. The installation procedure is summarized below
Procedure
Surge arresters were installed on each phase conductor just before it enters the transformer at
the primary side to give protection to transformer by discharging lightning and switching over
voltages to earth. The surge arrester is grounded, hence creating a low impedance path to
ground for energy from an over-voltage transient. At normal operating voltages, the surge
12
arrester acts as an insulator, isolating the phase conductor from ground. These opposing
characteristics are typically achieved through the use of a Varistor , which has different
resistances at different voltages. Almost the same procedures used for the disconnecting
A set of new Alstom current transformers (CTs) were installed at the transformer primary.
the magnitude of current flowing in the primary circuit to a value suitable for meters and
on its secondary a quantity, what truly represents the applied quantity on its primary. They are
used for the purposes of protection, control and metering. The CTs has four cores. Core one
was used for metering, core two was used for differential protection, core three was used for
overcurrent protection and core four was used for bus bar protection.
Protection and control panels were mounted and properly positioned in the control room.
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2.11 COMMISIONING TEST
Commissioning test was carried out on the transformer and all installed equipment. Omicron
CPC100, High voltage insulation tester, Frejer 300 relay test system etc, are some of the test
The differential relay actually compares primary and secondary current of the transformer. If
any unbalance is sensed, the relay will actuate and inter trip both the primary and secondary
circuit breaker of the transformer. The secondary of the CTs at HV and LV sides are connected
together in such a way that their currents oppose each other. In other words, the secondary of
CTs are connected to the same current coil of a differential relay in such an opposite manner
that there will be no resultant current in that coil in a normal operating condition of the
transformer. But if any major fault occurs within the differential zone it alters the normal ratio
of the transformer, hence the current at both side of the transformer will not remain the same.
This causes a resultant current to flow through the current coil of the differential relay, this
will actuate the relay and inter trip both the primary and secondary circuit breaker of the
transformer.
14
Table 2.3: General information and data
Description Setting
Slope 1 20%
Slope 2 50%
15
Slope 3 75%
Table 2.6: Transformer Differential Relay Stability testing for stable condition
HV LV Id Ir
Table 2.7: Transformer Differential Relay Stability testing for unstable condition
HV LV Id Ir
The stability test is also called out-zone test. This test is carried out to ensure that the
differential relay will remain inoperative with the fault outside the differential protected zone.
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415Vac was applied on primary terminals with the secondary terminals shorted outside the
protected zone of the relay to create a fault. The three phases of the circuit were short-
It is expected that: Primary output = Secondary output (Because the short circuit has no effect
Expected Actual
IA 0.1048 0.104
IB 0.1048 0.101
IC 0.1048 0.109
Expected Actual
Ia 0.1848 0.1849
Ib 0.1848 0.1848
Ic 0.1848 0.1850
17
2. TRANSFORMER OVERCURRENT RELAY
CT Ratio = 300/1
IA 1.5 A
2Times 0.35 sec 0.3510sec
18
2.12 BILL OF ENGINEERING, MEASUREMENT AND EVALUATION FOR THE
Table 2.13: Bill of Engineering, Measurement and Evaluation (BEME) for the project.
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CHAPTER THREE
3.1 SAFETY
Safety was a major factor that was considered in all aspect of the projects reported. Situations
where there were clashes between safety and time limit for job execution or cost, safety was
considered as the priority. The following safety rules were adhered to:
ii. Ensuring all worker had personal protective equipment (PPE) on at all time
iii. Ensuring there is proper guard against theft/damage and promptly reporting same.
iv. Report all observed abnormal conditions in apparatus to the appropriate section.
v. Studying and using the most effective and efficient method of doing the work.
vi. Seeing that no one is permitted to do work for which he/she is not qualified.
viii. Always briefing all workmen on the plan of work before work is started.
ix. Being courteous and considerate of the public and each other.
xi. Consuming intoxicants, narcotics, and alcoholic beverages was strictly prohibited.
xii. Ensuring that there was open channel to forward any constructive
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3.2 CHALLENGES ENCOUNTERED AND SOLUTIONS
1. Complete de-energization of the station was not possible hence outages were taken in
2. There was the challenge of limited resources such as tool boxes. We ensured available
3. Some of the conductor clamps supplied could not house the existing conductors. Such
4. Personal protective equipments (PPE) were not sufficient on site especially for the
students on industrial training. Old PPE which were still okay were made available for
them.
5. Safety signs were not properly positioned at strategic places hence those safety signs
were printed on paper and pasted at those places temporarily for the duration of the
project.
3.3 RECOMMENDATION
operator. This will help to reduce delay in carrying out outages when the date arrives. Most
times outages were not granted but postponed because the application was not promptly
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The importance of the right training for power system engineers cannot be over emphasized.
Continuous technical based trainings both locally and internationally is recommended for
engineers to enable them adapt quickly to new technological advancement in the field.
Also, only qualified field engineers should go for Factory Acceptance Test (FAT) for power
system equipment/materials in order to ensure that equipment are according to standards and
specifications.
3.4 CONCLUSION
Engineering has helped to solve most of the needs of mankind. This should motivate our
government to invest adequately in science and technology. Most problems faced by Nigeria
today (corruption, epileptic power supply, decayed infrastructure, etc) can only be solved if
the right attention and resources is channeled toward engineering. As an engineer, there is
need to always observe highest standard in our job and be innovative so as to sustain the
reputation of the profession and as such every engineer should be committed to constant
learning and professional development. Priority should be given to standards and design
specification.
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