This document provides an executive summary of a 400kV switchyard project in Mundra, India. It includes lists of typical switchyard drawings, quality work being done on the switchyard including earthing and bolting, testing equipment being used, applications of equipment like CTs and isolators, the SCADA system, transformer oil standards, inspection procedures, stringing of transmission lines, project issues, documentation, and project management and quality management functions. Quality control tools mentioned include control charts.

1. SIEMENS LTD
Project Executive
ET HS

2. EXECUTIVE SUMMARY OF 400KV
SWITCHYARD ( MUNDRA)
FIRST UMPP OF INDIA
TRANSMISSION SUBSTATIONS AND SWITCHYARD
CONTROL & PROTECTION

3. Contents
1. Summary of the project
2. Drawings list of switchyard
3. Quality work of the switchyard
4. Testing kit
5. Application of the equipment
6. SCADA system
7. Transformer oil standard
8. Inspection procedure of the equipments
9. Stringing of HV Line
10. Project issue
11. Documents of the project
12. Project management function
13. Nature of TQM

4. Summary of the projects
 Since 6-Jun-2011, I am working with M/s siemens ltd as project executive of
400kv switch yard on Mundra project. There are so many quality points
raised by the clients such as Improper earthing, cable laying, cable tray
erection, bolting, painting ,Rusting of the structural material, jump ring of
moose wire and progress etc. these are the points which is pinching
company management and disturbing the site progress. As per my Boss
instruction I have stars my work and found that switchyard is in very bad
condition earth strip of the tower, equipment is not connected to the
specified position and not touch the equipment body. Earth pits of the
switchyard is hearting the siemens status and quality, same condition of the
above mentioned points. I have feel that , I am going to face the very
challenging job on this site. Man power is also a very big problem for me
because the balance erection work is also in pick situation. We are behind
the progress curve. Material management of site is very bad, on site no
body is taking responsibility to take to maintain the material handling.

5. TYPICAL SUBSTATION DRAWINGS LIST
1.Coversheet/index and legends
2.Elementary one line diagram
3.Relay one line diagram
4.General arrangement of plan site plan, section and details
5.Substation plan section and details
6.Foundation plan and details
7.Structure plan and details
8.Grounding plan and details
9.Raceway plan and details
10.Ducts bank and high voltage cable plan details
11.Controll building plan , section and details
12.Relay control panels lay out and wiring diagram
13.Three line diagram and ac and dc scam tics
14.Equipment yard external connection diagram
15.Clamps and connectors diagram
16.Cable schedule
17.Emergency supply diagram
18.Utility diagram

6. Earthing and earth pit work

7. Bolting of tower and equipment structure

8. 1.POLARITY TESTER-
To measure the CT Polarity.
2.HV TRANSFORMER-To inject high voltage
for testing like KPV of CT and Ratio for CVT
3.LOADING TRANSFORMER
Equipment for measure the Ratio of CT
4.TANDELTA KIT-To measure
the value of Capacitance and
Tan delta for CVT,REACTAR
and LA
5.INSULATION RESISTANCE METER
To measure the Insulation resistance value of
CT,CVT,LA,ISOLATOR,BREAKER,REACTAR
EMVT,WAVE TRAPER and CABLES
6.DC POWER PACK-To provide DC source
for Testing of Auxiliary Relay Testing
7.TRANSFORMER WINDING
RESISTANCE METER-TO measure the
value of Transformer Winding
Resistance
8.Tongue Tester- To measure small value of
Current and voltage for CT Ratio and KPV
CVT Ratio.
9.SECONDARY INJECTOR TEST KIT
10.Transformer Oil Tester
SAT KIT DESCRIPTION

9. CURRENT TRANSFORMER
CT are of two types : live tank, dead tank.
• in live tank the ct primary & secondary are on top.
• in dead tank ct the primary is on top and secondary cores are on bottom
of tank.
• Steps down high current to low current for two reasons mainly
measurement & protection purpose.
• The secondary current for all ct is commonly 1 or 2 amps.
• The no of secondary cores depends on recruitment mainly 2 ,4 or 5 etc.
• For measurement purpose separate core should be used because of
100% accuracy is needed..
• the material used for secondary of metering ct is nickel iron alloy.
• the material used for secondary of protection ct is grain oriented silicon
steel.
• Note: The secondary cores of ct should never be opened because of high
voltage will be at the terminal.
.

10. APPLICATION OF CT.
B
Protection C.T.
Measuring C.T.
1.Isolate measurement & control ckt.
From high voltage
2.Measur current for power measurement
and control
3.Perform ckt. Control, protection and
current limiting
4.Signaling for dis. Protection, tariff
metering and for BCU
5.Diff. protection
6. Reduce the current to lower level to be
measured more easily.
7.Primary current, Load of the current
transformer is measured, & secondary is
the range of the current
8.

11. LIGHTING ARRESTOR
Application
1.lightning arrester is used to suppress the abnormal
voltages which are caused due to lightning etc.
2.LA basically requires a non linear material.
3.It requires high resistance to limit the discharge
current.
4.It requires low resistance during surges etc.

12. Basic circuit for LA testing

13. COMUNICATION SYSTEM OF SENDING AND
RECEIVING END SWITCHYARD(A(RED& B(BLUE)
WT CVT CVT WT
PLCCRELAY
BR TRIP TRIP BR
PLCC RELAY
Transmission line

14. REQUIREMENTS OF PROTECTIVE RELAYS
SENSITIVITY : The relay shall be sensitive to operate for
minimum quantity of operating parameter.
SELECTIVITY: The relay/scheme should be able to select the faulty
section and isolate.
SPEED : The relay should operate faster so that fault is
isolated as fast as possible.
RELIABILITY: The relay/scheme should operate for all types of fault with
repeatability and reliability.
COST: The relay/scheme should be economical .

15. APPLICATION
Wave trap is a parallel tuned indicator-capacitor ‘tank’
circuit made to be resonant at the desired communication
frequency . It is the effort to utilize the same
transmission line between two substation for the purpose
of communications. At this communication frequencies
the tank ckt. Provide the high impedance and does not
allow to pass through them and onto the substation bus
and into transducer.
WAVE TRAP
Wave trap and line trap is current rated device it is undesirable to
operate such equipment above the name plate ratings. In the
most cases uprating, wave trap will require replacement.

16. ABT system is the meter oriented and moniter the block wise
parameter for the accounting purpose
ABT METER

17. ISOLATOR
Application
1.It is used to make or break the circuit under no load condition .
2.Mostly there are two types of isolators: hcb (horizontal centre break),
double break etc.
3.Double break isolators is mostly used for low voltage rating.
4.Again these hcb are of two types : gang operated & individual operated
per phase).
Note: A isolator cannot be operated under load condition.

18. CAPACITOR VOLTAGE TRANSFORMER
Application
1.Basically a cvt steps down high voltage to low voltage with help of capacitors. Hence
the name capacitor voltage transformer.
2.The secondary terminal voltage of cvt are 63.5v
3.A cvt consists of : 2 coupling capacitors, compensating reactor, step down transformer
and Ferro resonance suppression circuit.
4.The use of compensating reactor is to compensate the phase displacement in
capaictor elements.
5.Ferro resonance in cvt is due to the capacitor in voltage divider in series with
inductance of transformer.
6.The Ferro resonance circuit is brought to resonance by disturbances in network that
may saturate the iron core which leads to insulation breakdown.

19. Application
CIRCUIT BREAKER
.1.It is used to break or make the circuit under both (load & no load) condition.
2.While opening of breaker a huge amount of spark will be at open & closed contacts. For
reliable operation of breaker the arc should be extinguished immediately after opening of
moving contacts.
3.For arc extinguish mainly : vacuum, sf6,air are used.
4.For low voltage ratings mainly vacuum & air blast breakers are used.
5.For high voltage sf6 breakers are commonly used.

20. REACTOR
1.It is used to compensate the Ferranti effect in long
distance lines.
Ferranti effect: receiving end voltage is greater than
sending end.
2.It is always connected in parallel to line.
3.It is used in terminal end of transmission line to
neutralize the reactive power generated by the line
capacitance
4. It consumes reactive power
5.It reduce the voltage at receiving end
Application
In reactor there are only 3- windings and one neutral and one
netral grounding reactor which is link with reactor neutral
bushing

21. SCADA SYSTEM
The energy control center receives various type of data from the
power system . This data include breaker status, tap changer
position, amp, voltage, volts, watts, VARs, and other quantities
both digital and analog again data travels over distances ranging
from few miles to several hundred.
In most modern energy control center , the remote data monitoring
and system control function for substation application are
performed by SCADA system.

22. Recommended limits of unused mineral oil filled in
transformer as per IS-1866-2000
Property Highest voltage of Equipment
(KV)
<72.5 72.5-170 >170
Appearance Clear, Free from sediment and
suspended matter
Density at 29.5˚C (g/cm2),Max 0.89 0.89 0.89
Viscosity at 27˚C (cSt),Max 27 27 27
Flash Point (˚C),Min 140 140 140
Pour Point (˚C),Max -6 -6 -6
Total acidity(mgKOH/gm),Max 0.03 0.03 0.03
Water content (ppm), Max 20 15 10
IFT at 27˚C (mN/m),Min 35 35 35
Tanδ at 90˚C, Max 0.015 0.015 0.010
Resistivity at
90˚C(x10e12ohm-cm),Min
6 6 6
BDV (KV),Min 40 50 60

23. Recommended limits of used mineral (In Service) oil filled in
transformer as per IS-1866-2000
Property Highest voltage of Equipment (KV)
<72.5 72.5-170 >170
Appearance Clear and without visual contaminations
Water content (ppm), Max No Free water 40 20
BDV (KV),Min 30 40 50
Total acidity(mgKOH/gm),Max 0. 3 0. 3 0. 3
IFT at 27˚C (mN/m),Min 15 15 15
Resistivity at 27˚C(x10e12ohm-cm),Min 1 1 1
Resistivity at 90˚C(x10e12ohm-cm),Min 0.1 0.1 0.1
Tanδ at 90˚C, Max 1.0 1.0 0.2
Flash Point (˚C),Min Maximum decrease of 15˚C from initial value
Sediment and sludge No sediment or precipitable sludge should be
detected. Results below 0.02% by mass may
be neglected.

24. SITE INSPECTION CHECK

25. STRINGING OF POWER TRANSMISSION LINE
General concept of the sag calculation of the transmission line for extra
high voltage lines, the ground clearance shall be 5.2m plus 0.30m for every
33kV and also consider the atm. Condition such as temperature variation.
Sag in m=(Conductor wt. in kg/m)* square of (span in meter) /8* (tension in
kg)

26. SPECIAL ISSUES WORKED OUT DURING THE PROJECT
DEVELOPMENT
1.Configuration of bay screens;
2.Configuration and finding solutions for the line differential protections
and line-transformer unit.

27. CONSTRUCTION AND COMMISSIONING
1.Providing system components at the substation level (FAT- sub-systems)
2.Documentation elaboration and Technical project approval (Technical
Committee TE)
3.Equipping the cubicles and system tests (FAT system )
4.Bay by bay commissioning (procedure and tests SAT)

28. DOCUMENTATION OF THE PROJECT
1. Tower erection protocol and equipment structure protocol
2. Equipment erection protocol such as CT, BR,CVT,
EMVT,WT,ABT,ISOLATOR ,
3. SAT report of all equipment

29. Project Management Functions
 Scoping – setting the boundaries of the project
 Planning – identifying the tasks required to complete
the project
 Estimating – identifying resources required to
complete the project
 Scheduling – developing a plan to complete the
project
 Organizing – making sure members understand their
roles and responsibilities
 Directing – coordinating the project
 Controlling – monitoring progress
 Closing – assessing success and failure

30. QUALIT PLANNING QUALITY ASSURANCE QUALITY CONTROL
PROJECT QUALITY MANAGEMENT
1- INPUTS
-Quality policy
-Scope statement
-Product description
-Standards and regulations
-Other process outputs
2- TOOLS AND TECH.
-benefit/ cost analysis
-Benchmarking
-Flowcharting
-Design of experiments
3- OUTPUTS
-Quality management plan
-Operational definitions
-checklists
-Inputs to other processes
1- INPUTS
-Quality management plan
-result of quality control
measurements
-Operational definitions
2- TOOLS AND TECH.
-Quality planning tools and
techniques
-Quality audits
3- OUTPUTS
-Quality improvement
1- INPUTS
-work results
-quality management plan
-Operational definitions
-checklists
2- TOOLS AND TECH.
-inspection
-Control charts
-Pareto diagrams
-Statistical sampling
-flowcharting
-Trend analysis
3- OUTPUTS
-Quality improvement
-Acceptance decisions
-rework
-Completed checklist
-Process adjustment

31. Nature of PQM
 Project quality management must address both the
management of the project and the product of the project.
 Failure to meet quality requirements in either dimension
can have serious and negative consequences for any or all
of the project stakeholders

32. Tools and Techniques for Quality Control
 Control Charts
1. These charts are graphical representations that display
the result of a process over time and are used to
determine if the process is “in control”
2. When in control the process should not be adjusted ,
however it may be changed in order to provide
improvements
3. Control charts may be used to monitor any type of output
variable
4. Control charts are most often used to monitor repetitive
activity in production but can also be used to monitor cost
and schedule variances