KSEB Training Reporty

Industrial Training Report
I
Dept. Of EEE RIT Kottayam
INDUSTRIAL TRAINING REPORT
Submitted in partial fulfilment of the requirements for the award
of degree of Bachelor of Technology in
ELECTRICAL & ELECTRONICS ENGINEERING
Of
Mahatma Gandhi University, Kottayam
By
PONNU CHANDRAN
DEPARTMENT OF ELECTRICAL ENGINEERING
RAJIV GANDHI INSTITUTE OF TECHNOLOGY
GOVERNMENT ENGINEERING COLLEGE
KOTTAYAM 686501
2013 – 2017

II
DEPARTMENT OF ELECTRICAL ENGINEERING
RAJIV GANDHI INSTITUTE OF TECHNOLOGY
GOVERNMENT ENGINEERING COLLEGE
KOTTAYAM 686501
2013 - 2017
This is to certify that the Industrial Training report is an authentic
report presented by Ms. PONNU CHANDRAN, Reg. No. 13013878,
during the year 2015 in partial fulfilment of the requirements for the
award of Degree of Bachelor of Technology in Electrical Engineering of
Mahatma Gandhi University, Kottayam.
Radhika R. Prof. Mary George
Staff Advisor Head of the Department
Internal Examiner External Examiner

III
ACKNOWLEDGEMNENT
I express my sincere gratitude towards Prof. Mary George, Head of the Department of Electrical
and Electronics Engineering, for giving us her invaluable knowledge and excellent technical
guidance.
I would like to express my sincere thanks to Mrs. Radhika R. for her kind cooperation and
guidance.
I also thank all other faculty members of the Electrical and Electronics Department and my
friends for their help and support.
I wish to express my deep sense of gratitude to all the employees of Lower Periyar Power
Station and 220kV Substation, Poovanthuruthu for their overall direction and guidance during
the training program.
Last but not the least I thank the god almighty for having made my endeavour successful.
PONNU CHANDRAN

IV
CONTENTS
1. Section 1: Lower Periyar Power House.............................................................1
1.1 Introduction........................................................................................................3
1.2 Power station......................................................................................................4
1.3 Elements of power station............................................................................5
1.4 Lower Periyar Power Station......................................................................13
1.4.1 Introduction................................................................................ 13
1.4.2 Hydraulic system of lower periyar..............................................13
1.4.3 Hydro turbine..............................................................................15
1.4.4 Guide vane servo motors.............................................................17
1.4.5 Governer mechanism...................................................................18
1.4.6 Electo hydraulic transducer.........................................................18
1.4.7 Valve gallery................................................................................18
1.4.8 Generator.....................................................................................20
1.4.9 Bearings.......................................................................................24
1.4.10 Hydro static lubrication system..................................................25
1.4.11 Static excitation..........................................................................26
1.4.12 Cooling system...........................................................................29
1.4.13 Circuit breakers and generator transformers..............................31
1.4.14 Protection system.......................................................................33
1.4.15 Communication...................................................................................35
1.4.16 Operation of different equipment.....................................................35
1.5 Single Line Diagram..................................................................................40

V
2. Section 2:-220 kV Substation Poovanthuruthu........................................................41
2.1 Introduction................................................................................................................43
2.2 Substation................................................. ................................................................44
2.3 Elements of Substation............................ .................................................................45
2.3.1. Power Transformer............................ .................................................................45
2.3.2. Circuit Breaker....................... ............................................................................48
2. 3.2.1. SF6 Circuit Breaker.....................................................................................50
2.3.2.2. Vacuum Circuit Breaker..............................................................................51
2.3.3. Instrumental Transformers.......................................................................................51
2.3.3.1. Potential Transformer.................................................................................52
2.3.3.2. Current Transformer...................................................................................52
2.3.4. Isolator.....................................................................................................................53
2.3.5. Insulator...................................................................................................................54
2.3.6. Wave Trap................................................................................................................55
2.3.7. Bus Bars...................................................................................................................56
2.3.8. Relays......................................................................................................................56
2.3.9. Lightning Arresters..................................................................................................58
2.3.10. DC Supply.............................................................................................................59
2.3.11. Battery Charger.....................................................................................................59
2.3.12. Switch Yard...........................................................................................................59
2.3.13. Steel Towers..........................................................................................................60
2.4. 220 KV Substation
Poovanthuruthu...............................................................................................................61
2.5. Single Line Diagram.................................................................................................62
2.6. Details of 220 KV Substation
Poovanthuruthu...............................................................................................................63
3. Conclusion ...................................................................................................................66

1
SECTION:-1
LOWER PERIYAR POWER STATION

2
Acknowledgement
We the students of Govt. Rajiv Gandhi Institute of Technology, Kottayam, have undertaken
practical training at Lower Periyar Power Station, Karimanal, under the guidance and
supervision of Mr. Jayaraj (Executive engineer). We are thankful to all the employees of this
power-station who helped us to gain the practical knowledge and answered our queries to the
best of our satisfaction. We feel obliged by gaining knowledge under the esteemed guidance
of able personals at Lower Periyar Power Station.
During the training from 08-6-2015 to 12-6-2015 we have prepared this report of practical
training, which gives insight information about instruments and apparatus used in this system
and their working in brief. We can say that this report is a summary of what we have
observed and learned there.

3
1.1. INTRODUCTION
The Hydroelectric Power Plant, also called as dam or hydro power plant, is used
for generation of electricity from water on large scale basis. The dam is built across the
large river that has sufficient quantity of water throughout the river. In certain cases where
the river is very large, more than one dam can built across the river at different
locations .among the various renewable natural energy resources; the
hydropower generation has emerged as the most potential option in terms of
environmental cleanliness and cost-effective high capacity generation. The hydel
power s t a t io n have the inherent ability for instantaneous starting, stopping and load
variations, which ensures a high reliability of power system. Therefore, hydel power
stations are the best option for meeting the peak demand. Further, the generation cost
in hydroelectric projects is inflation free and reduces substantially over time after
repayment of debt. With 41 rivers, flowing down (westward) from the Western Ghats
joining the backwaters and the Arabian Sea, Kerala has tremendous potential for
hydel-power generation.
Power generation started in Kerala in 194 7 with the commissioning of
the Pallivasal hydro-electric project at the Ramaswami Ayer Headwork close to the
tea county of Munnar in the erstwhile princely State of Travancore. The Kerala
power system consists of 17 hydel stations including 2 captive power plants, 2 thermal
stations,
3 independent power producers, 5 major inter-state transmission lines, one 400
KV sub• section, and two 220 KV substations with the interconnecting grid. Kerala has
a storage capacity of 3843mu and the present storage is about 72% of the full capacity.
Mullaperiyar dam, Idukki Hydro-electric project, Idamalayar Hydro electric
project and the Lower Periyar are constructed across the Periyar. Kundala
Dam, Mattupetty Dam, Munnar head works, Ponmudi dam and the Kallarkutty
Dam are constructed across the various tributaries of Periyar.
Lower Periyar hydroelectric project (180 MW) envisages utilization of the
tail waters from the existing Neriamangalam power station and the spill from
Kallarkutty head works.
The Sengulam hydroelectric project is situated downstream of Pallivasal
Project in Mudirampuzha river, which is an important tributary of Periyar river.
Panniyar hydroelectric project is developed on Panniyar, a tributary of Mudirampuzha
river.

4
1.2. POWER STATION
A power station (also referred to as a generating station, power plant, powerhouse or
generating plant) is an industrial facility for the generation of electric power. At the centre of
nearly all power stations is a generator, a rotating machine that converts mechanical power
into electrical power by creating relative motion between a magnetic field and a conductor.
The energy source harnessed to turn the generator varies widely. It depends chiefly on which
fuels are easily available, cheap enough and on the types of technology that the power
company has access to. Most power stations in the world burn fossil fuels such as coal, oil,
and natural gas to generate electricity, and some use nuclear power, but there is an increasing
use of cleaner renewable sources such as solar, wind, wave and hydroelectric.

5
1.3.ELEMENTS OF POWER STATION
Hydroelectric power plant requires various components for generating electrical power. Some
of the major components in hydroelectric power plants are: Reservoirs, Dam, Trash Rack,
Forebay, Surge Tank, Penstock, Spillway, Prime Mover and Generator, Draft Tube. The
functions of all major components are discussed.
The basic requirement of a hydroelectric power station is a reservoir where large quantity of
water is stored during rainy season and used during the dry season. The reservoir is built by
constructing a dam across the river. The water from the reservoir is drawn by the forebay
through an open canal or tunnel. The water from the forebay is supplied to the water prime
mover through the penstock which is located at the much lower level than the height of the
water in the reservoir. Thus potential energy of water stored in reservoir is converted into
kinetic energy and made to rotate the turbine. Turbine shaft is connected to synchronous
generator or alternator for generating electricity. This generated power is stepped up using
step-up transformer and delivered to load centers or grid. The regulation of water flow to the
turbine depending on the electrical load demand is carried out by the governor system.
fig 1.1

6
Reservoir:
The function or purpose of reservoir is to store the water during rainy season and supply the
same during dry season. This is in simple, water storage area.
Dam:
Dams are structures built over rivers to stop the water flow and form a reservoir. The
reservoir stores the water flowing down the river. This water is diverted to turbines in power
stations. The dams collect water during the rainy season and stores it, thus allowing for a
steady flow through the turbines throughout the year. Dams are also used for controlling
floods and irrigation. The dams should be water-tight and should be able to withstand the
pressure exerted by the water on it. There are different types of dams such as arch dams,
gravity dams and buttress dams. The height of water in the dam is called head race.
Trash Rack:
The water intake from the dam or from the forebay are provided with trash rack. The main
function of trash rack is to prevent the entry of any debris which may damage the wicket
gates and turbine runners or choke-up the nozzles of impulse turbine. During winter season
when water forms ice, to prevent the ice from clinging to the trash racks, they are often
heated electrically. Sometimes air bubbling system is provided in the vicinity of the trash
racks which brings warmer water to the surface of the trash racks.
Surge Tank:
The main function of surge tank is to reduce the water hammering effect. When there is a
sudden increase of pressure in the penstock which can be due sudden decrease in the load
demand on the generator. When there is sudden decrease in the load, the turbine gates
admitting water to the turbine closes suddenly owing to the action of the governor. This
sudden rise in the pressure in the penstock will cause the positive water hammering effect.
This may lead to burst of the penstock because of high pressures.
fig 1.2
When there is sudden increase in the load, governor valves opens and accepts more water to
the turbine. This results in creation of vacuum in the penstock resulting into the negative
water hammering effect. Therefore the penstock should have to withstand both positive water
hammering effect created due to close of governor valve and negative water hammering
effect due to opening of governor valve. In order to protect the penstock from these water
hammering effects, surge tank is used in hydroelectric power station.

7
Penstock:
Penstock is a pipe between the surge tank and the prime-mover. The structural design of the
penstock is same as for any other pipe expect it has to bear high pressure on the inside surface
during sudden decease in the load and increase in the load. Penstocks are made of steel
through reinforced concrete. Penstocks are usually equipped with the head gates at the inlet
which can be closed during the repair of the penstocks, A sufficient water head should be
provided above the penstock entrance in the forebay or surge tank to avoid the formation of
vortices which may carry air in to the penstock and resulting in lower turbine blade
efficiency.
fig 1.3
Spillway:
The function of spillway is to provide safety of the dam. Spillway should have the capacity to
discharge major floods without damage to the dam and at the same time keeps the reservoir
levels below some predetermined maximum level.
Power House:
A power house consists of two main parts, a sub-structure to support the hydraulic and
electrical equipment and a superstructure to house and protect this equipment.
The superstructure of most power plants is the buildings that house all the operating
equipment. The generating unit and the exciter is located in the ground floor. The turbines
which rotate on vertical axis are placed below the floor level while those rotating on a
horizontal axis are placed on the ground floor alongside of the generator.
Power station contains a turbine coupled to a generator. The water brought to the power
station rotates the vanes of the turbine producing torque and rotation of turbine shaft. This
rotational torque is transferred to the generator and is converted into electricity. The used
water is released through the tail race.

8
Prime movers or Hydro Turbines:
The main function of prime movers or hydro turbines is to convert the kinetic energy of the
water in to the mechanical energy to produce the electric power. The prime movers which are
in common use are Pelton wheel, Francis turbine and Kaplan turbines.
Draft tube:
The draft tube is a part of the reaction turbine. The draft tube is a diverging discharge passage
connecting the running with tailrace. It is shaped to decelerate the flow with a minimum loss
so that the remaining kinetic energy of the water coming out of the runner is efficiently
regained by converting into suction head., thereby increasing the total pressure difference on
the runner. This regain of kinetic energy of the water coming out from the reaction turbine is
the primary function of the draft tube. The regain of static suction head in case where the
runner is located above the tail water level is the secondary purpose of the draft tube.
Generator:
The generator converts the rotational energy from the turbine shaft into electricity. Efficiency
is important at this stage too, but most modern, well-built generators deliver good efficiency.
Direct current (DC) generators, or alternators with rectifiers, are typically used with small
household systems, and are usually augmented with batteries for reserve capacity, as well as
in8verters for converting the electricity into the AC required by most appliances. DC
generators are available in a variety of voltages and power outputs.
fig 1.4
AC generators are typically used with systems producing about 3 KW or more. AC voltage is
also easily changed using transformers, which can improve efficiency with long transmission
lines. Depending on your requirements, you can choose either single-phase or three-phase AC
generators in a variety of voltages.
Frequency is determined by the rotational speed of the generator shaft; faster rotation
generates a higher frequency

9
Turbine:
The turbine is the heart of the hydro system, where water power is converted into the
rotational force that drives the generator. For maximum efficiency, the turbine should be
designed to match your specific head and flow. There are many different types of turbines,
and proper selection requires considerable expertise. A Pelton design, for example, works
best with medium to high heads. A cross flow design works better with lower head but higher
flow. Other turbine types, such as Francis, turgo, and propeller, each have optimum
applications.
fig 1.5
Turbines can be divided into two major types. Reaction turbines use runners (the rotating
portion that receives the water) that operate fully immersed in water, and are typically used in
low to moderate head systems with high flow. Examples include Francis, propeller, and
Kaplan.
Wicket Gates are the key components in Hydroelectric Kaplan turbine that controls the flow
of water from penstock to turbine (runner). There are 16 wicket gates used for each turbine.
The closing and opening of these wicket gates are controlled by a governor mechanism which
is activated by a servomotor
Impulse turbines use runners that operate without being immersed, driven by one or more
high-velocity jets of water. Examples include Pelton and turgo. Impulse turbines are typically
used with moderate-to-high head systems, and use nozzles to produce the high-velocity jets.
Some impulse turbines can operate efficiently with as little as 5 feet (1.5 m) of head.
The cross flow turbine is a special case. Although technically classified as an impulse turbine
because the runner is not entirely immersed in water, this “squirrel cage” type of runner is
used in applications with low to moderate head and high flow. The water passes through a
large, rectangular opening to drive the turbine blades, in contrast to the small, high-pressure

10
jets used for Pelton and Turgo turbines.
Regardless of the turbine type, efficiency is in the details. Each turbine type can be designed
to meet vastly different requirements. The turbine system is designed around net head and
design flow. These criteria not only influence which type of turbine to use, but are critical to
the design of the entire turbine system.
Minor differences in specifications can significantly impact energy transfer efficiency. The
diameter of the runner, front and back curvatures of its buckets or blades, casting materials,
nozzle (if used), turbine housing, and quality of components all affect efficiency and
reliability.
Drive system:
The drive system couples the turbine to the generator. At one end, it allows the turbine to spin
at the rpm that delivers best efficiency. At the other, it drives the generator at the rpm that
produces correct voltage and frequency—frequency applies to alternating current (AC)
systems only. The most efficient and reliable drive system is a direct, 1:1 coupling between
the turbine and generator.
This is possible for many sites, but not for all head and flow combinations. In many
situations, especially with AC systems, it is necessary to adjust the transfer ratio so that both
turbine and generator run at their optimum (but different) speeds. These types of drive
systems can use either gears, chains, or belts, each of which introduces additional efficiency
losses into the system. Belt systems tend to be more popular because of their lower cost.
Governing:
The purpose of governor pack is opening and closing of Main Inlet Valve and Wicket Gates
(guide vanes). The PLC is connected to a governor. It regulates the speed of the system. The
PLC command opens or energises the valve. Opening the valve causes the oil pressure to
affect the servomotor, which in turn changes the wicket gates and the runner blade
accordingly. This has a feedback mechanism. It require certain amount of power for control,
normally it is 125 bar. This pressure is maintained using a servomotor. An accumulator is
connected to governor. Accumulator is used to store nitrogen at a pressure range between
110-140 bar. The wicket gate is mounted on a ring. The pressurised nitrogen pushes the
piston, this causes the wicket gate to open and close.
AC Controls:-
Pure AC hydro systems have no batteries or inverter. AC is used by loads directly from the
generator, and surplus electricity is burned off in dump loads—usually resistance heaters.
Governors and other controls help ensure that an AC generator constantly spins at its correct
speed. The most common types of governors for small hydro systems accomplish this by

11
managing the load on the generator. With no load, the generator would “freewheel,” and run
at a very high rpm. By adding progressively higher loads, you can eventually slow the
generator until it reaches the exact rpm for proper AC voltage and frequency. As long as you
maintain this “perfect” load, known as the design load, electrical output will be correct. You
might be able to maintain the correct load yourself by manually switching devices on and off,
but a governor can do a better job—automatically.
By connecting your hydro system to the utility grid, you can draw energy from the grid
during peak usage times when your hydro system can’t keep up, and feed excess electricity
back into the grid when your usage is low. In effect, the grid acts as a large battery with
infinite capacity.
If you choose to connect to the grid, however, keep in mind that significant synchronization
and safeguards must be in place. Grid interconnection controls do both. They will monitor the
grid and ensure that your system is generating compatible voltage, frequency, and phase.
They will also instantly disconnect from the grid if major fluctuations occur on either end.
Automatic disconnection is critical to the safety of all parties. At the same time, emergency
shutdown systems interrupt the water flow to the turbine, causing the system to coast to a
stop, and protecting the turbine from over speed.
DC Controls:-
A DC hydro system works very differently from an AC system. The alternator or generator
output charges batteries. A diversion controller shunts excess energy to a dump load. An
inverter converts DC electricity to AC electricity for home use. DC systems make sense for
smaller streams with potential of less than 3 KW.AC systems are limited to a peak load that is
equivalent to the output of the generator. With a battery bank and large inverter, DC systems
can supply a high peak load from the batteries even though the generating capacity is lower.
Series charge controllers, like those used with solar-electric systems, are not used with hydro
systems since the generators cannot run without a load (open circuit). This can potentially
damage the alternator windings and bearings from over speeding. Instead, a diversion (or
shunt) controller must be used. These normally divert energy from the battery to a resistance
heater (air or water), to keep the battery voltage at the desired level while maintaining a
constant load on the generator.
The inverter and battery bank in a DC hydro system are exactly the same as those used in
battery-based, solar-electric or wind-electric systems. No other special equipment is needed.
Charge controller settings may be lower than used in typical PV and wind systems, since
hydro systems are constant and tend to run with full batteries much of the time.
Generator Transformer:
Transformers connected to generator usually supply power to a transmission line which run
from the generating plant to a bulk power load center located a considerable distance away.
Some of the general requirements of a generator transformer are as follow :
1. No voltage regulating windings, because the voltage is regulated by the field of the generator.

12
2. Fairly uniform load - the new units of high efficiency in particular are kept loaded to
maximum capacity.
3. Least need for high efficiency or quiet operation - power for losses is cheapest at a generator
station, and other equipment makes more noise than the transformer.
4. Construction can be such as to require the type of supervision and maintenance available in a
generating station.
fig 1.6
Switch Yard:
Switch yard is the most important part of a substation. In switch yard most of the part is laid
with metals to reduce earthed voltage. In the switch yard the supply taken from incoming
feeders are transferred to one or more bus bars from which they are switched on or off to
various incomers and distribution auxiliary supply etc.
fig 1.7

13
1.4.LOWER PERIYAR POWER STATION
1.4.1 INTRODUCTION
Lower Periyar Power House which is situated at Karimanal is the third
biggest generating station of K.S.E.B. The installed capacity of lower
Periyar generating station is 3x60MW and there are 6 nos. 220kV out going
feeders. This is the first generating station in KSEB using microprocessor
controlled logic circuit for the automatic operation of the generators from
shutdown status to generator status and from generator status to shutdown
status. It is the second generating station in Kerala where static excitation
system is adopted. These machines are designed for synchronous condenser
operation also. It forms one of the most important tie station in the power
grid of Kerala .The 220 kV feeders from Lower Periyar powerhouse are
1) double circuit feeder to Idukki power house,
2) double circuit feeder to 400 kV substation Madakkathra, and
3) double circuit feeder to 220 kV substation Bhrahmapuram.
During the tied operation of these lines, the 220kV bus will be the main inter
linking bus for the 4 most important major grid stations of KSE Board viz.
ldukki power house, 400kV substation Madakkathra, and 220 k V
substations Bhrahmapuram which is directly tied with Kayamkulam Thermal
station.
1.4.2 HYDRAULIC SYSTEM OF LOWER PERIYAR
Average annual generation at the power station is approximately 69MW or 609Mu.
Reservoir at Pambla along Mudirampuzha river basin with dam of 3 lm high above
nominal riverbed and 244m long across river Periyar about 5km downstream
of Panamkutty Power House form the water conductor system. Storage level of reservoir
is approximately 4.55 MCM. The dam is of concrete gravity type with a FRL of
253m.there are 5 motorized upper vents and 2 hydraulic lower vents for the operation
of dam. The intake arrangement consists of an intake well provided with a trash rack,
an intake gate and also an emergency gate. There is a level difference between dam
level and intake well level. The system also comprises 6.05 m d ia, D Shaped, 12.79
km long circular concrete lined Power Tunnel, a restricted orifice Surge
Shaft of 18 meter diameter, a 5.25 meter finished diameter, pressure shaft
of length 378 meter, branching in to three steel lined pressure shafts each
of 2.96 meter diameter and of average length of 207 meter.
A surface Power House with three machines located at Karimanal about 18km
downstream of Mudirampuzha, Periyar confluence. The power house is of l
80MW capacity with 3 units of 60 MW each mechanically coupled to Francis
turbines. The generator output is stepped up to 220KV by a 66.6 MVA power
transformer and is distributed among 6 feeder lines, two each to Idukki,
Bhrahmapuram and the 400KV Madakkathra.... .

14
Specifications of the Hydraulic System:-
Reservoir-Pambla
River basin Mudirampuzha
Storage 455MCM
Water usage 2.17MCM/MU
Dam
Type Scheme concrete gravity runoff river
Maximum water 256m
level Full reservoir 253m
level Minimum 237.76m
Draw Down level
Power Tunnel
Size and shape 6.05m,D shape
length 12.791 km
Sill level at inlet 229.00 m
Sill level at surge shaft 186.55m
Maximum velocity in tunnel for 434 m/sec
a discharge of 124.7m3 /sec
Surge Shaft
Type restricted orifice
Size 18 m dia
Top level of surge shaft 285.00 m
Minimum down surge level 197.99m
Bottom level of surge shaft 194.10m
Control gate vertical lift gate
Pressure shaft
No. of pressure shaft 1
Size and shape 5.25 m,circular
Length 378 m
Manifold (steel lined) size and shape 5.25 m, dia
Branch lines
No. of shafts 3 Nos
Size 2.96 m dia,circular
Average length 207 m

15
1.4.3HYDRO-TURBINE
Francis turbine
fig 1.8
The Lower Periyar Hydroelectric project employs the Francis Turbine. Francis
Turbine has a circular plate fixed to the rotating shaft perpendicular to its surface
and passing through its center. This circular plate has curved channels on it; the plate
with channels is collectively called as runner. The runner is encircled by a ring of
stationary channels called as guide vanes. Water is brought to the turbine and
directed to guide vanes or wicket gates. Guide vanes are housed in a spiral casing
called as volute. The exit of the Francis turbine is at the center of the runner plate.
There is a draft tube attached to the central exit of the runner. The design parameters
such as, radius of the runner, curvature of channel, angle of vanes and the size of the
turbine as whole depend on the available head and type of application altogether.
The modem Francis Turbine is an inward mixed flow reaction turbine i.e., the water
under pressure enters the runner from the guide vanes towards the centre in radial
direction and discharge out of the runner axially. The Francis turbine operates
under medium heads and also requires medium quantity of water. The head acting
on the turbine is transformed into kinetic energy and pressure head. Due to the
difference of p7ressure between guide vanes and the runner (called reaction
pressure), the motion of runner occurs. That is why a Francis turbine is also known
as reaction turbine.
The pressure at inlet is more than that at outlet. In Francis turbine runner is always
full of water. The moment of runner is affected by the change of both the potential
and kinetic energies of water. After doing the work the water is discharged to the tail
race through a closed tube called draft tube.

16
It is employed in the medium head power plants. This type of turbine covers a wide
range of heads (30m to 450m). Francis turbine doesn't allow the water to fall freely to
the tailrace level as in the case of Pelton turbine. The free end of the draft tube is
submerged deep in the tail water, thus making the entire water passage, right from
the head race up to the tail race totally enclosed.
The draft tube converts kinetic head to pressure head. About 70% conversion is
possible. By recovering pressure head in the draft tube the pressure at the runner exit
is reduced below atmosphere. This makes it possible to install the turbine above the tail
race without any loss in available head. This is an important advantage in the
reaction over Pelton turbine.
The turbine has its own thmst bearing capable of carrying the additional load of
turbine shaft, runner and hydraulic thrust making a total of three guide bearings for
the complete unit.
Specification:
Type Vertical Francis
Rated/Max 61300/67400 kw
Output design
Net head 184 m
Max gross head 204.58 m
Min net head 165 m
Rated/Max discharge 36.2/40.2 cub m3/sec
Rated speed 333.33 rpm
Run away speed 585 rpm
Direction of rotation clockwise
Max pressure rise 50%
Max speed rise 50%
The vertical shaft Francis type turbine comprise of a draft tube, spiral casing and
stay rings, guide apparatus, shaft, runner, guide bearing, shaft seal and auxiliary
items. The guide apparatus regulates the flow of water with, change in load and
also serves as a closing device. It includes top cover, pivot ring, guide vanes and
turning machinery. The mechanism for turning the guide vanes (regulating ring) is
designed to ensure simultaneous turning of guide vanes during opening or
closing of guide apparatus. Two servomotors, housed inside the pit liner, actuate
the regulating ring which in tum operates the guide vanes through regulating gear.
To facilitate atmospheric arr supply below the runner during part load operation
of turbine, the necessary connections from the aeration valve are made in the upper
cone.
The shaft sealing prevents leakage of water through clearance between top cover and
shaft sleeve. It is located b e lo w turbine guid e bearing.
To prevent the abrasive particles and dirty water corning in contact with the rubber-
sealing ring, water at a pressure slightly higher than that above the runner is
supplied at three points of the shaft seal through a micro filter from the main cooling

17
water system.
Oil level relay is provided on the bearing housing to indicate high and low oil levels
of the bearings at Unit control board [UCB]. Temperatures of guide bearing pads are
monitored by a set of resistance temperature detectors [RTD] and dial type
thermometers [DTT]. Out of eight pads, temperatures of four pads are measured
by RIDS and the remaining four by DTTS. Two RTDs measure temperature in the oil
bath.
1.4.4 GUIDE VANE SERVO-MOTORS
Guide vanes
fig 1.9
Guide vanes are fixed aerofoils that direct air, gas, or water into the moving blades of a
turbine or into or around bends in ducts with minimum loss of energy. The runner of
turbine is encircled by a ring of guide vanes. Guide Vanes are installed in the turbine to
regulate the quantity of water to the runner with change in load. These are operated
by two servomotors through guide vane operating mechanism via links & levers.
The servomotors get signals from Governor. The guide vanes are of aero flow section,
which allows the flow of water without formation of eddies in all positions. Depending
upon silt flow, the guide vanes may be made of mild steel or stainless steel with
integral machined stems, which are drilled for grease lubrication of bushes.
Two servomotors are provided for turning the regulating ring during regulation of load
on turbine and closing /opening of the guide apparatus. When the turbine load
changes during generating operation, the servo motor shall operate the guide vane
smoothly coordinating with the speed governor.

18
1.4.5 GOVERNER MECHANISM
The primary purpose of a governor for a hydroelectric unit is to control the speed and
loading of the unit. It accomplishes this by controlling the flow of water through the
turbine by adjusting the opening of the Needles I Guide vanes and by sensing the
Speed of the Machine.
The governing system consists of two parts (i) the sensing and signal
processing part. (ii) The operational part. In the operational pan hydraulic oil pressure
isused for operating vanes and valves.
1.4.6 ELECTROHYDRAULIC TRANSDUCER
The electrohydraulic transducer is the interface between the electronic signal processing
part and the hydraulic operating part. This transducer receives the electric signal
from electronic part and converts the signal into a hydraulic flow. This hydraulic signal
is hydraulically amplified and used for operating the vanes or the jets and
deflectors.
When an opening signal is received from the electronic governor, the actuator will pull
the floating valve piston to go down and pressure oil is admitted to opening side of
servomotor and servomotor gradually opens. As the servomotor opens, the feedback lever
pushes the floating lever upwards. When feedback push equals the feed forward pull,
the distributing valve piston will return to the original position and steady state is
achieved.
1.4.7 VALVE GALLERY
Valve Gallery
fig 1.10
On the upstream side there is valve gallery throughout the length of the floor. The
main equipments on this floor are Butterfly [BF] valve, water operated
servomotors, oil leakage units and the pipelines for the same. The access to the
draft tube cone and the removal of the runner for maintenance is also from this
floor.

19
The station drainage system is installed on the left hand side of the Power
Station when viewed from the downstream side.
A 2.2 m dia. double door BF valve has been provided as main inlet valve on each
penstock branch. Water operated double acting servomotor(20 kg/cm) has been
provided on the left hand side of the BF valve and is mechanically connected with a lever
and keyed to the door turn-on of the BF valve.
A 100 NB drain valve is provided on the bottom side of the BF valve to drain the
water in between the two doors of the BF valves and is connected to the penstock drain
pipe.
The servomotor is water operated. An oil operated control valve (40 kg/cm") is
provided to adjust opening and closing of the valve. For the opening of the main
inlet valve [MTV], water under pressure is taken from the spiral side and for the
closing the same is taken from the penstock side through isolating 40 ~B valves
and duplex strainers. Time of closing is 50-55 sec. The operation of the control valve
is carried out by oil pressure through a solenoid valve mounted on the MIV control
panel. If the oil pressure is low due to control failure or any other fault, when the
MIV is open, the control spring will force the operating piston down to its closed
position. This will close the MIV automatically.
All these assembly has been provided on the left side of BF valve. From the
upstream of inlet pipe of the BF valve tapping and connections are taken with
isolating valves, for operating control valve, ejector, and pressure gauges.
Bypass valve
fig 1.11
Oil operated by-pass valve and piping are provided over the top of the BF valve for
balancing the pressure on either side of the BF valve. The opening and dosing of the
valve is carried out with the help of pressurized oil taken from the oil pressure
system through a solenoid valve which is mounted on the MIV control panel. Limit
switches are provided to get the opening and closing indications for the by-pass valve
and BF valve.

20
1.4.8 GENERATOR
An alternator is an electromechanical d e vic e that converts mechanical energy to
electrical energy in the form of alternating current.
Alternators generate electricity based on the principle that, when the magnetic field
around a conductor changes, a current is induced in the conductor. Typically, a
rotating magnet, called the rotor turns within a stationary set of conductors wound
in coils on an iron core, called the stator. The field cuts across the conductors,
generating an induced emf (electromotive force), as the mechanical input causes the
rotor to tum.
The rotating magnetic field induces an AC voltage in the stator windings. Often there
are three sets of stator windings, physically offset so that the rotating magnetic field
produces a three phase current, displaced by one-third of a period with respect to
each other.
The rotors magnetic field may be produced by induction (as in a "brush-less"
alternator), by permanent magnets (as in very small machines), or by a rotor
winding energized with direct current through slip rings and brushes.
In alternators, the armature may be the rotor or stator. The rotating-field alternator has a
stationary armature winding and a rotating-field winding. The advantage of having a
stationary armature winding is that the generated voltage can be connected directly to
the load. The stationary armature, or stator, of this type of alternator holds the
windings that are cut by the rotating magnetic field ..
Rotating-field ac generator consists of an alternator and a static excitation system.
In the case of a machine with field coils, a current must flow in the coils to generate
the field; otherwise no power is transferred to or from the rotor.
The process of generating a magnetic field by means of an electric current is called
excitation. The output of the alternator section supplies alternating voltage to the load.
The only purpose for the exciter is to supply the direct current required to maintain the
alternator field. Thus, a fixed-polarity magnetic field is maintained at all times in the
alternator field windings. When the alternator field is rotated, its magnetic flux is passed
through and across the alternator armature windings. There are two types of rotors
used in rotating-field alternators. They are called the turbine-driven and salient-pole
rotors.
The windings can be lap or wave. Generators can be installed horizontally as well
as vertically based on the weight.
The Generators installed at Lower Periyar Power House are of vertical type, salient pole,
and suspended type construction. The stator winding is of two-layer bar type wave
winding. The Generator has a guide bearing positioned above the rotor, and one
guide bearing below the rotor.

21
Hydro Static [HS] lubrication system for injection of oil to the thrust bearing pads
have been provided for use during starting and stopping. The generator slip rings and
speed signal generators are located at the top. The generator excitation is provided by
separate static excitation equipment.
Specification
Maximum continuous rating 66.67 MVA
Rated power 60 MW
Rated voltage 11000V
Rated power factor 0.9 lagging
Rated frequency 50 Hz
Rated speed 333.33 rpm
No. of poles 18
Direction of rotation clockwise
Air gap at pole centre 26mm
Stator Resistance 0.00505 ohm
Phase Stator winding connection star(wave)
Field winding Resistance 0.14255 ohm
Excitation current at no load 607 amps
Excitation current at rated load 1250 A, 230 V, 287.5 KW
Stator current at rated load 3500 A
Stator:-
The different parts are:-
Frame-The stator frame is used to hold the armature windings in alternators, and in
case of larger diameter alternators (which are slow speed) the stator frame is cast
out of sections and there are holes for ventilation in the casting itself. The recent trends
to such stator construction are more in favour of using mild steel plates which are
welded together rather than castings. The stator frame is built of welded steel
structure and to facilitate transport, it is dispatched from the factory in three parts.
It has adequate depth to prevent distortion during transport and under any
operating conditions.
Core- Another integral part of the stator is the stator core. The core is constructed in
the form of laminations and the material used for the same is either magnetic iron or
steel alloy. The main purpose of lamination is to prevent loss of energy in the form
of eddy currents.
There are different types of armature slots provided in the core to insert the
conductors and the three various types are as follows.
• Wide open type slots
• Semi closed type slots
• Close type slots
The core is securely clamped by a large number of studs. Ventilation ducts are
provided at intervals along the stator core, being formed by means of non

22
magnetic steel spacing is securely welded to adjacent steel stampings. Jacking
screws are provided at the outer edge of end plates to enable the pressure of the
teeth to be adjusted.
Windings:-
The stator winding is of two layer bar type wave winding. All the bars are formed,
insulated and tested before being placed in the slots. Each bar consists of a
number of individual copper strands of rectangular section to minimize eddy
current losses. Each strand is insulated with polyesterimide varnished glass
brainding. The bars are insulated along the slot portion by adequate presses and
consolidated in a heated press. This ensures complete elimination of voids and
high factor of safety against breakdown..
Stator
fig 1.12
The end portion of the bar have flexible insulation consisting of polyester film
and glass backed mica flake tape, reinforced at intervals with layers of varnish
treated terylene tape and with glass tape for protection and finish. The joints
between the bars are made by brazing and are insulated. All connections between
bars and terminals are securely clamped. Both ends of each phase windings
are brought out to suit the terminals near the top of the stator frame..
Rotor:-
The rotor consists of a coil of wire wrapped around an iron core. Current through the
wire coil - called "field" current - produces a magnetic field around the core. The
strength of the field current determines the strength of the magnetic field. The
field current is DIC, or direct current. In other words, the current flows in one
direction only, and is supplied to the wire coil by a set of brushes and slip rings.
The magnetic field produced has, as any magnet, a north and a south pole. The
rotor is driven by the alternator pulley, rotating as the engine runs, hence the
name "rotor." The rotor is constructed with a high strength alloy steel shaft forging
that is precision machined, ground and finished to exact tolerances.

23
Rotor
fig 1.13
Poles:-
There are 18 magnet blocks on each rotor. Each magnet block has a north pole and a
south pole. The poles are arranged alternately, so north faces the stator on one block
and south on the next. The poles on the other magnet rotor are arranged in the
opposite polarity so that the north poles face south poles across the stator. In this
way, a strong magnetic flux is created through the stator between the magnet
rotors. The coils embedded in the stator are dimensioned such as to encircle the flux
from one magnet pole at a time. As the magnet blocks pass a coil, the flux through
the coil alternates in direction. This induces an alternating voltage in each turn of
the coil. The voltage is proportional to the rate of change of flux..
Damper Winding:-
The rotor is equipped with damper windings. They stabilize the speed of AC
generator to reduce hunting under changing loads. If speed tends to increase
induction-generator action occurs in damper winding.
This action places a load on the rotor tending to slow down the machine. In
case of speed decrease induction-motor action takes place.
The damper winding is of major importance to the stable operation of the
generator. While the generator is operating in exact synchronism with the power
system, rotating field and rotor speed exactly matched, there is no current in the damper
winding and it essentially has no effect on the generator operation. If there is a small
disturbance in the power system, and the frequency tends to change slightly, the rotor
speed and the rotating field speed will be slightly different. This may result in
oscillation, which can result in generator pulling out of step with possible consequential
damage.
Damping bars are of circular sections of copper which are semi closed in the pole
faces. The ends of the bars are short circuited together by copper stampings.The
damper winding is inter-connected between poles.

24
Field Winding:-
The magnetic field in the synchronous generator is created by field winding. The
field coils are square ended being fabricated from a straight length of copper
strips dove tailed and braced at the ends. At intervals down each coil the copper
is increased in width to give fins for cooling purposes..
All connections between adjacent field coils and also between field coils and slip
rings are firmly secured to the rotor.
Temperature Detectors:-
Resistance temperature detectors are built into the generator stator core and
windings. The detectors are of three wire resistance type having 100 ohms
resistance at o0c and 138.5 ohms at 100°c. The loads from the detectors are
brought out to a metal clad terminal box located in a conveniently accessible
position from which cables could be run to the indicating instrument via
generator marshalling box.
1.4.9 BEARINGS
Conventional alternators comprise of top-mounted thrust and guide bearing
supported on heavy brackets, capable of supporting total weight of generator. A
guide bearing is a plain bearing used to guide a machine element in its lengthwise
motion, usually without rotation of the element.
A bottom guide bearing combined with turbine shaft is usually provided. This
conventional design is used for high speeds (up to 1000 rpm) generators..
Thrust bearing:-
Thrust bearing in any turbo machine is used to prevent axial tolerance on the shaft.
The thrust bearing is a spring supported type in which the stationary part consist
segmental pads supported on mattress of helical springs. The rotating bearing surface
is machined accurately perpendicular to the axis of the shaft.
The bearing surface is polished to fine surface finish. The thrust pads are of stress
relived mild steel and are faced with a high quality white metal.
Each pad rests on a number of springs which are pre-compressed by a permanently
locked centre screw and finished to a standard overall length.
The springs are assembled on a heavy fabricated spring plate which is an integral part
of the thrust bearing housing. The thrust pads are prevented from moving
circumferentially by pad stops secured to the spring plate. Radial movement is
prevented by-dog damps which would also prevent the pad from rising with the
thrust block during rotor jacking operation. The thrust bearing pads are completely
immersed in oil bath. The oil is cooled by plug in oil coolers.

25
Top Guide Bearing:-
The top and bottom guide bearings are of the pivoted pad type consisting of a row
of white metalloid pads arranged in a support ring. Top guide bearing is located
above the thrust bearing, on a journal surface machined on the periphery of the
thrust collar. Sufficient insulation and protection is provided in top guide bearing to
prevent flow of shaft current through the bearing pads. The same oil bath for the
thrust pads is used for the guide bearing.
Bottom Guide Bearing:-
Bottom guide bearing is located on a journal integrally forged with the shaft. A pivot
bar is bolted to the back or each guide bearing pad to enable the pad to rock slightly to
take up a suitable position and facilitate formation of the oil film, when running. The
clearance between individual pads and the journal is set by adjusting the
shims between the back of the pad and the pivot bar. The pads are cooled by an oil
bath with plug in type coolers.
1.4.10 HYDRO STATIC [HS] LUBRICATION SYSTEM
Lubricants (solid or fluid film) are deliberately applied to produce low friction and
low wear. In hydrostatic lubrication, a thick fluid film is maintained between two
surfaces, with little or no relative motion, by an external pumping agency: a pump,
which feeds pressurized fluid to the film.
Hydrostatic lubrication requires an external pumping agency. HS bearings provide high
load-carrying capacity. Since HS bearings do not require relative motion of the
bearing surfaces to build up the load-supporting pressures as necessary in
hydrodynamic(HD) bearings by viscous shear/drag, HS bearings can be used in
applications with little or no relative motion between the surfaces.
The hydro static lubrication system has been designed to provide an oil film
between the thrust pads and the runner disc during starting and stopping when there
is little likelihood of formation of hydrodynamic oil film.
Therefore, it should always be put on service before starting the unit. However, if for
any reason the HS lubrication system is out of order, the rotor shall be jacked up and
released just before starting the unit, to ensure formation of oil film. This operation is
not necessary If the machine has been at stand still for less than 12 hours.
Brakes and Jacks:-
The generator brakes consists of a number of 'Ferodo' lined shoes which
operates against a polished circular steel brake track to the underside of the
rotor spider hub. Each brake shoe is mounted on a vertical piston moving in a small

26
cylinder. To apply/release the brakes, air would be forced into the brake cylinder in
appropriate direction from the station compressed air supply. The brake cylinders
are mounted on the bottom bracket.
The brakes are to be applied continuously starting from 30 rpm, with HS.
Lube ON and with air pressure of 4 to 5 bars for minimizing brake -dust problems.
When the machine has come to a full stop, the brake should be left on for about 5
minutes more, to flow static friction to be established between the rotating parts and
the bearing pads. If sufficient time is not allowed for the oil to squeeze out from
between the bearing surface to establish static the friction, turbine gate leakage torque
may cause the rotor to creep, which could cause damage to the thrust bearing pads.
1.4.11 STATIC EXCITATION
Lower Periyar is the second power house using static excitation in Kerala State
Electricity Board. The static excitation system consists of excitation transformer,
thyristor converter and voltage regulator. A complete system also includes control and de-
excitation circuits. It is called static excitation when you make use of solid state
components like diode and thyristors to convert to pure de and to use this de for
field excitation of synchronous generators.
The Thyristor-type static excitation system, due to its many advantages, excellent
response characteristics, easy maintenance and simplified main machine construction,
is now extensively used for medium-and large-capacity hydro-or steam-turbine
generators.
In the case of synchronous machine protection circuit's activation the automatic quick field
suppression via a de-excitation D.C. circuit breaker
and a discharge resistor is accomplished. The excitation system is equipped with a
microprocessor control system that enables voltage control, supervision, protection,
communication and signalization. The system is completely automated and adapted for
no-crew plants and for remote control from the superimposed control centre.
The main types of Exciters are:
1) Conventional D.C. Exciter.
2) Static Exciter.
3) Brushless Exciter
In modern generators, magnetic field is produced by an electromagnet.
Equipments required to produce a controlled amount of field current is known as
Excitation System.
Static Excitation Equipment:-
It consists of Regulation Cubicle, field flashing & field breaker cubicle, thyristor
cubicles, and transformer cubicle. All excitation power is normally derived from the
synchronous machine terminals through the step down excitation transformer of 850 kVA

27
rating, generally termed as the rectifier Transformer or the Excitation
Transformer, housed inside a cubicle and the thyristor converter. The voltage
regulator via pulse• triggering unit controls the thyristor converter.
As synchronous machine has low remnant voltage, the voltage built-up in the self
excitation mode is accomplished by flashing the field from an external D.C. supply
(station battery) or with AC. supply (station auxiliary) through a diode rectifier. The
control circuit is suitable to accept supervisory command signal contacts from remote
Supervisory control equipment.
The AC input supply of all electronic power supplies are given from the secondary of the
Excitation Transformer through suitable intermediate transformers.
The secondary of the Excitation Transformer feeds the thyristor bridge which consists of
parallel connected bridges to meet the field current requirement of the Machine.
The DC output of the Thyristor Bridge is fed to the generator field through field
breakers. The discharge resistance in the field circuit enables faster suppression of
stored energy in the field.
Static Excitation
fig 1.14
Power Rectifier:-
Three phase 6-pulse fully controlled thyristor bridges with fuse RC circuit, gate
circuit and de coupling reactors are provided with conduction monitoring unit to
indicate with the help of LEDs the non-conduction of any thyristor in the bridge. De•
coupling reactors provided in each arm of the bridge for di/dt protection also
improves the paralleled sharing between thyristor bridges. One redundant bridge is built
in the system such that in the event of -failure of one bridge rest of the bridges can
carry full rated excitation requirement of the machine. With 2 bridges out of
service, machine can be operated at reduced load with the remaining bridge.
Voltage Build up/field flashing:-
Electrical generators that are self excited depend on residual magnetism in the field
to start generating. If the residual magnetism has been lost, it may be restored by
briefly applying power from an external source. The brief application of power for

28
that purpose is called "flashing the field." Flashing is sometimes done manually to start
a small generator.
Voltage build up (field flashing) can be done either with the help of station battery supply
through a dropping resistor and blocking diodes stack or Station Auxiliary supply
through a step down transformer and diode bridge. At 30% of the rated generator
voltage pulses to the thyristors in the main circuits are released and they take over the build
process at about 40% of the rated generator voltage. For checking the healthiness of the
main circuit, the field flashing is kept in circuit up to 70% of the rated generator voltage
after which the field flashing circuit is automatically disconnected.
If a successful start up is not achieved during this period of time, a timer provided in
the excitation circuit, switches off the field flashing process. It is to be noted that a
minimum period of 10 minutes must elapse before field flashing is resorted once
again. For AC field flashing a diode bridge stack consists of six screws in type diode
mounted on suitable heat sink assembled side by side and can be easily replaced
from the front. The six diodes are connected to from a three-phase bridge.
Modes of Operation:-
Two independent modes of operation are envisaged namely
1. Automatic mode
2. Manual mode.
Automatic mode:-In the Automatic Mode excitation is regulated by the AVR. The
AVR compares the actual value of generator voltage which is sensed through PT after
suitably stepping down and converting into DC with the reference value set on the Auto
Reference Potentiometer. The amplified error (output of AVR) is used as control signal
to control the Grid control unit (Firing Circuit) for the Auto Channel. The output pulse of
the Grid control unit is amplified to boost the voltage level in the pulse Intermediate
amplifying stage and power supply unit. The power supply unit of me pulse Intermediate
Amplifying Stage feeds the A'VR and the Auto; I and is termed as supply A.
Manual mode:-In the manual mode the Grid control unit of the Manual channel
is directly controlled by the Manual reference potentiometer. The pulse generated by
the Manual Grid Control unit is amplified in the pulse Intermediate stage and power
supply. unit of the manual channel.
The power supply unit of the pulse Intermediate Amplifying stage feeds reference
voltage to the manual channel etc., and is termed as supply 'M'.

29
1.4.12 COOLING SYSTEM
Normally cooling water is tapped from the penstocks and connected to a common inlet
header through a duplex strainer with isolating valves on either side. The inlet
header is connected to an outlet header through many numbers of cooling water
pumps and a non-return valve. Isolating valves are provided on either side of the pumps.
Cooling Water system
fig 1.15
Normally cooling water for generator and transformer is taken from the outlet
header through valves. The cooling water pressure at outlet header is sufficient as the
same is tapped from the penstock; hence the cooling water pumps are normally not
started.
The cooling water system will be used for the following service.
1..Cooling water for turbine bearing and shaft seal.
2.Cooling water for Generator coolers and bearing.
3. Station services.
4. Transformers
Cooling water for the above requirements is taken from cooling water pit which is
connected to the tail races. The cooling water from the pit pushes through a duplex
strainer pump motor sets with non return valve [NRV]. Pressure switch has
been provided in each line which helps in the automatic start/stop of main and stand by
pump. Discharge of each pump is connected to common header. Cooling water is
supplied to Generator and turbine components through motor (4 Nos. llOHP)
operated valve. Cooling water connection for transformer and station services are
provided on the common header. Out of 4 pumps 3 pumps works as main pump
for each unit and one pump is common as stand by. An emergency cooling water
system is also provided to feed the cooling during total shutdown of the power supply..
High and Low Pressure Air System:-
H.P Air system consists of two H.P. compressor sets with air-cooled systems. Air from
compressors pass through non-return valve, isolating valve, air cooled after
coolers and finally to the H.P air receiver. Isolating valve in the H.P. airline shall
be kept open. The H.P receiver has pressure gauge and safety valve mounted on it.
Low pressure (LP) air receivers are provided to supply low-pressure air to shaft seal,
Brake & Jack panel and station service. The feeding of air to the, LP receiver is earned

30
out from the H.P. receiver through a pressure reducer. Pressure switches have been
provided on the H.P. receiver to work the compressors automatically. The main
compressor starts when the pressure drops below 37kg/sq cm and stop at 40kg/sq cm.
The stand by compressor will start at 34kg/sq cm and stop at 40kg/sq cm. One
pressure switch is set to give alarm at 32kg/sq cm.
Dewatering System:-
The de-watering system has been provided to remove water passage via. a de•
watering pump to tailrace. The de-watering sump has two oil lubricated vertical turbine
pump set (11 OHP) placed at turbine floor on the left hand side (near Unit-3) of
the Power House. The discharge from the two pumps is connected to a common
header via non-return valve and is lead to the tailrace. Level control relays nave been
provided for the automatic operation or the pump sets.
Pumps can also be operated manually by push buttons provided in the starter
panels. A high level alarm is also provided in the sump to avoid flooding of the sump.
Drainage System:-
Water from the seepage, turbine leakage delivery water during the operation of BF
valve and ejectors are taken to the drainage sump. This sump has got two vertical
turbine pumps, (2x20HP) set with motors. The discharge from the two pumps
is connected to a common header and leads to the tailrace. Level control relays have
been provided for automatic starting and stopping of pump sets and can also operate
manually by push buttons. A high level alarm is also provided in the sump..
Centralized Grease Lubrication System:-
To facilitate grease lubrication of every moving part of Inlet valve and turbine, a
centralized grease lubrication system has been provided. The system is
completely automatic with a synchronous time adjustable between 6 to 120 hours
for repeating greasing cycles. The system consist of a heavy duty reciprocating pump
drives plungers type pump with built in reduction gear, a four way solenoid valve, a
set of dose feeders with high pressure pipes and fittings. The grease lubrication have
provided on the valve door turnings on both sides with non return valves, servomotor
lines of BF valve, guide vane lower bushing through non-return valves, upper
bushings, guide vane servo motor pins and the regulating ring supporting bushes.
Lubrication systems increase the life span of machine components and they
protect from wear and corrosion. As a result, they are an inevitable part of
modern service and maintenance concepts. Lubrication systems have the task of
bringing the lubricant to the appropriate point in an exact measured quantity, at the
right time. In the field, single-line and progressive lubrication systems are largely

31
used. The choice of a suitable lubricant is largely dependent on the operational
method of the lubrication system and the application. This is why both these
factors need to be carefully scrutinized.
Synchronous Condenser Operation:-
A synchronous condenser (sometimes synchronous capacitor or synchronous
compensator) is a device identical to a synchronous motor, whose shaft is not
connected to anything but spin freely. Its purpose is not to convert electric power to
mechanical power or vice versa, but to adjust conditions on the electric power
transmission grid. Its field is controlled by a voltage regulator to either generate or
absorb reactive power as needed to adjust the grid's voltage, or to improve power factor.
Increasing the device's field excitation, results in furnishing magnetizing power
(kVARs) to the system. Its principal advantage is the ease with which the amount
of correction can be adjusted.
The energy stored in the rotor of the machine can also help stabilize a power system
during short circuits or rapidly fluctuating loads such as electric arc furnaces.
Large installations of synchronous condensers are sometimes used in association
with high-voltage direct current converter stations to supply reactive power.
1.4.13 CIRCUIT BREAKERS AND GENERATOR
TRANSFORMERS
11 KV/220 KV Transformer
fig 1.16
The combined electrical, physical, chemical and thermal properties offer many
advantages when used in power switchgears. Some of the outstanding properties of
SF6 making it desirable to use in power applications are:
• High dielectric strength

32
• Unique arc-quenching ability
• Excellent thermal stability
• Good thermal conductivity
SF6 circuit breakers of capacity 1250 A, 40 kA, 245 KV are used in this power house.
These are of air operated single break, with individual operating mechanism with one
common air compressor unit coupled to the three limbs with pipe. AH control equipment
and compressor are housed in the centre limb. The opening of the breaker is done by 15
Kg/sq. cm air pressure. While opening, the closing spring is automatically charged this
is used for subsequent closing. The breaker can be operated locally or remotely
according to the switch position.
GENERATOR TRANSFORMER
Specification:
Technical data
Make Crompton greaves make
No load voltage ratio 11KV/220KV
Tap changing circuit OFF load provided on HV side
Vector simple Yndl
Type of cooling ODWF (oil driven water forced)
Constructional details
HV line end 3 Nos,245 KV oil forced
Bushing condenser type
LV line end HV 3Nos,24KV,4000A
Neutral end Out door type bushing
Supervisory Apparatus 1 out door type bushing
• A double float type Buchholz relay with a set of alarm and trip contacts
• A dial type oil temperature indicator with two sets of contacts for alarm and trip and
maximum reading pointer
• A winding temperature indicator with maximum reading pointer, heater bulb/ and
four sets of contacts for alarm, trip, fan control, and oil pump.
• A magnetic oil gauge, 2 oil flow indicators, 2 water flow indicators.
• A No pressure release valve, pressure gauges in oil and water circuits.
• Differential pressure gauge with a set of alarm contacts
The oil is pumped through heat exchangers using motor. Water to the heat
exchangers is taken from the cooling water system controlled by motor operated
valve followed by gate valve.
While putting the transformer in service first oil pump must be started and then
only the cooling water valve is opened.

33
1.4.14 PROTECTION SYSTEM
Protection of Generator and Line
In this powerhouse modern solid-state type protection relays are installed for
generators and feeders. All the protective relays are of ABB make.
Generator - Transformer differential relay:-
It is s three phase differential relay intended for all types of autotransformers, multi
winding transformers, generator with step up transformer over all protection,
often including the auxiliary transformer in the protected zone. In our power house
overall protection of generator and transformer is adopted. The CT wiring is taken
from the generator neutral side and from 220 kV side of the corresponding unit. A
differential relay is connected so that it is supplied with current proportional to the
current to the power transformer, and current out from the transformer. The relay is
connected to the current transformers and possible auxiliary current transformers. For
transformers with tap- changers for voltage control, the average ratio of the taps should
be used for calculation. During normal operating conditions, small current flows
through the differential circuit of the relay. This current corresponds to the
excitation current of the transformer and to a current depending on the ratio error to
the current transformers. Normally these two currents only comprise a small
percentage of the rated current. The duty of the relay is to detect the internal faults
(that is the faults within the generator, power transformer, or on the connecting lines and
bus duct etc) and then rapidly initiate disconnection of the power supply. The internal
faults that can occur are
1. Short circuit.
2. Ground faults
3. Turn-to- turn faults.
When faults arise outside the current transformer, the differential circuit of the relay
maybe supplied with a relatively large current, which can be caused by ratio errors in
the current transformers or by the tap changer not being in the centre tap position. If
the tap changer is in a position 20% from the centre tap position, and the short circuit
current is 10 times the rated current/a differential current of twice the rated current
is obtained. The differential shall not operate for this differential current. In order to
make an operate value setting for such high over current unnecessary, the differential
relay is provided with a through fault restraint with restraining circuits. The relay
then will not react for the absolute value of the differential current, but for a certain
percentage differential current related to the current through the power
transformer. When energizing a power transformer, it is possible to obtain a large
inrush current in the exciting winding and then proportionally large-current in the
differential circuits of the relay. The magnitude and direction of the inrush current

34
depends on the instant of switching in the power transformer, power transformer
remanance, the design of the transformer, the type of the transformer connection, the
method of neutral grounding, the fault MVA rating of the power system and power
transformers connected in parallel.
In modem system the current can be 5 to 10 times the rated current when switching in into
the high voltage side, and 10- 20 times the rated current when switching to the low
voltage side. To prevent the relay from operating when energizing power transformer, it
is not possible, as a rule, to delay the operation during such a long time as required. Thus
an instantaneous relay must have a magnetizing Inrush restraint and there by utilize a
certain characteristic difference between the inrush current and the fault current.
Auxiliary CTs are used to balance the current to the relay. In addition auxiliary CT may
be used to reduce the effective leakage burden of the long secondary leads. The
differential zone of the relay can include up to one kilometre of high voltage cable
since adequate filtering provides security against high current oscillations.
Bus Bar Protection Differential Relay:-
Internal bus faults occur less frequently than line- faults. On the other hand, a bus fault
tends to be appreciably more severe, both with respect to the safety of personnel,
system stability and the damage at the point of fault. The fact that bus faults occur
relatively seldom is therefore of little comfort to the engineer in-charge subsequent
to a major system shutdown caused by the Sack of adequate bus relay.
When an internal bus fault occurs the magnitude of the fault current and its D.C.
component may be so large that the line CT's (current transformers) saturate within 2-
3ms. In such cases it is essential that the bus differential relay operates and seals in
within 2ms, i.e. Prior to the saturation of the line CT's. This high speed is necessary
because when a line CT saturates its output e.m.f. tend to drop to zero.
ln the event of an external fault, just outside the line CT's of a relatively small
feeder, the fault current may in an extreme case be as large as 500 times the rating of
the feeder. The line CT's of the faulty feeder are then likely to saturate at an even higher
speed, particularly so if the remanence left in the core from a previous fault
has an unfavourable polarity. The response of the restraint circuit of the differential
relay must therefore be at least the same high speed as that of the operating circuit, if
mal-operation is to be avoided.
Distance relay for feeder protection:-
Distance relaying is used to a large extent to provide protection against ground and
phase faults on HV and EHV networks, The operation of all distance relays is based
on information available through main current and voltage transformers.
Sometimes additional information may be required from other apparatus such as
receiver equipment in a communication link between two distance relays.
But, the action of a protective relay cannot only be based on the sole
estimation of currents and voltages in the primary system/ but must also take
into consideration the steady-state and transient characteristics of the relay

35
input sources, namely the instrument current and voltage transformers. The
demands made on protective relays are steadily increasing owing to such factors as
the growing short-circuiting power and the demand of consumers for greater
reliability in their power supply..
1.4.15 COMMUNICATION
Power Line Carrier Communication (PLCC):-
PLCC System is established at LP Power Station through the 220 KV feeders LP•
Brahmapuram, LP-Madakkathara & LP-Moo]amattom. Inter Circuit phase to
phase coupling is used for the system. The feeders are provided with carrier inter trip
protection coupler system. BPL make 9505 and 6515 model panels are used for the
communication system. An exchange MDX 50 BPL make is used for linking PLCC
phones to the panels. The station code of LP is '055'. The communication system
works on power supply of 48V DC.
The data and status of Generators and feeders are transmitted to the Load
Despatch (LD) station Kalamassery through the PCNCOM make PLCC panel
established the scheme up to Madakkathara and from there to LD station through optical
fibre cable.
AC Supply fail alarm for the PLCC Battery charger is wired to Unit No 1
annunciation panel. On initiation of this alarm in the CIR, the operator must inspect
the carrier room for the reason of power failure.
1.4.16 OPERATION OF DIFFERENT EQUIPMENTS
Procedure for Stand By Cooling Water Pump Operation:-
In case the main pump of any unit is not functional, Stand by Cooling Water Pump
(CW4) can be used for starting and running of any machine. Stand by Cooling
Water Pump runs on station auxiliary supply.
Sequence of Operation During Starting:-
• Switch OFF the MCCB of the faulty C. W.P and put the selector switch in
NORMAL position. Start the machine as usual. When the
C.W. Valve of the machine is opened, Switch OK the Stand By Pump from the UCB
of the respective machine. (The Stand By Pump can be Switched ON locally by
putting switch to TEST position and pressing the START button locally from the C.W.
Pump control panel at Turbine floor).
• At the same time short the terminals 64 & 67 in terminal block TB3 of the
respective machine in Auto Sequencer Panel in Control Room, for getting the
command from the sequencer for executing next step. When next step is executed
the shorting can be removed.

36
The remaining procedures are same as usual for starting the machine.
• While changing the machine supply Stand By Pump will not be affected.
• After synchronization of the machine, if the Stand by pump is switched on in
TEST position, the selector switch can be put back to normal.
Note: - If a machine is to be run using Stand By Pump it is better to put the machine
in service as last one.
Sequence Of Operation During Stopping:-
While Stopping- Switch OFF the machine having Stand By Pump first.
Do the Stopping procedure as Usual. After breaking, when the machine comes to
stand still, Switch OFF the stand by pump either from the UCB (Stop command is to
be given from the UCBs of all machines ) or by putting the Selector Switch in TEST
position and press the OFF push button locally. When Machine comes to standstill
change the selector switch, of Stand by Pump, back to NORMAL.
Starting Of Machine During 'Black Out' Using Emergency Cooling Water
system:-
• Avail the Station Supply from DG Set.
•To start a machine from Black Out, Switch OFF the CVP MCCB of the
concerned machine and Switch OFF the MCCB of Stand By Pump. The selector
switch of both the Pumps should be in NORMAL position.
• Initiate machine Start Up sequence from Control Desk.
•When the CW Valve of the machine opens, OPEN the Emergency Cooling Water
Valve fully. (If required the Emergency Cooling Water Pumps can be put in to service
from DG supply)
• Short the concerned terminals of the Main and Stand pumps at Sequencer panel.
(Main pump-TB3 - 64,67, Stand by TB3 - 68,71- if required).
• When the machine Voltage and Frequency reaches the required level
(before synchronization) change the supply from GA to GB.
• Put the Main Cooling Water Pump selector in TEST, Switch ON the Main
Cooling Water Pump MCCB and put the selector to NORMAL (the CWP
will start automatically).
• Close the Emergency cooling water valve.
• Synchronize the Machine and Normalize the Auxiliary supply.
Procedure To Be Followed During Tripping Of
All machines If auxiliary Supply is Available:-
Switch off the MCCBs of the Standby and any of the two (say #2 and #3) Main
Cooling Water Pumps immediately and then change the station supply (otherwise the

37
LT Breaker may trip). Change the Auxiliary supply of all Machines. Open the
Emergency Cooling Water valve (Emergency Cooling Water Pump can be put
into service if required). Confirm that all the Governor Pumps are running. If not
try to switch ON locally. Otherwise close the Isolation valve at Pressure Receiver
Tank. Now stop the Machines one by one. After the machines comes to
standstill, close the Emergency Cooling Water valve. Give stop command to the
Cooling Water Pump of U#2 and U#3 from UCB. Close the cooling water valve
from UCB and confirm. Check the Break Dust collector in OFF condition.
If auxiliary supply is not available:-
Switch off the MCCBs of the Standby and all the Main Cooling Water Pumps
immediately. Then only avail DG Set Supply and change the station supply
(otherwise the LT Breaker/DG Set may trip). Change the Auxiliary supply of all
Machines. Open the Emergency Cooling Water valve (Emergency Cooling Water
Pump can be put into service if required). Confirm that all the Governor Pumps
are running. If not try to switch ON locally. Otherwise close the Isolation valve at
Pressure Receiver Tank. Now stop the Machines one by one.
After the machines comes to standstill, close the Emergency Cooling Water valve.
Give stop command to the Cooling Water Pumps from UCB. Close the cooling
water valve from UCB and confirm. Check the Break Dust collector in OFF condition.
Procedure for pneumatic breaking:-
Breaking of machine during stopping:-
When the Machine speed reaches 10 Hz (20% of rated speed) and getting
confirmation from Chief Operator, (AE should confirm that the HS Pump is ON, if
not, start locally). Fully open the Air valve Near the LP air receiver Tank in Turbine
Floor. Open the Air admission Valve near the Brake & Jack panel in the Shaft Room.
Press the RESET Button until the pressure inside the Brake cylinder fully released
(the hissing sound stops). Apply brakes by pressing APPLY push button. Confirm
that ANY ON and ALL ON indications are obtained. When the machine speed
reaches Zero and Mechanical Brakes Off status is displayed on the CD, the Chief
Operator should inform the concerned to release the Brakes.
For releasing the brakes, apply RESET button as above. Apply RELEASE push button
until the ALL OFF indication is obtained. If ALL OFF indication is not getting, close
the air valve at shaft room and apply RELEASE until the pressure gauge reads
Zero, then conduct a visual check up inside the Barrel to confirm that, all brakes
are released.

38
Procedures to be followed at Brake Jack panel before Starting of Machine:-
Fully open the Air valve Near the LP receiver Tank in Turbine Floor. Open the Air
admission Valve near the Brake & Jack panel in the Shaft Room. Press the RESET
Button and confirm that ANY ON and ALL ON indications are OFF and ALL
OFF indication is ON. The indications GEN Start Not Ready and Syn. Start Not
Ready in Control desk should get OFF. In the Display panel at CD "Air Pressure
Normal" and "Mechanical Brakes reset" status will vanish. Now the Machine is ready
for Starting.
Machine start procedure:-
Start procedure::-
• Close the 220 KV Isolator of machine from Control Desk.
• Select Release - Close (A or B Bus)
• Physical verification of lsolator contacts for proper closing must be done by AE.
• Give direction to the Generator Floor AE to make ready the machine for Starting
• OPEN Air Valve and RESET brakes.
•The glowing "Gen. Start Not Ready" indication lamp in CD will fail.
• The Machine is now READY for Starting.
• Set the Speed Setting Indicator in its marked position using Raise-Lower Speed
Setting push button
• Switch ON the MCBs in the Transformer Annunciation Panel,
Machine Annunciation panel and Vibration & Rotor Temperature Indicator Panel
•Switch ON Transformer Oil Pump and Cooling water Valve from the
Transformer Control Desk.
Synchronizing:-
•Put the key, open the lock and put the Synchronising Selector S/W in CD to
CHECK position. Select Release+ 'Synch'.
•Adjust the voltage and frequency of the incoming M/c to that of Bus using excitation
auto sel. and speed setting Raise-Lower Push Button
• When the Incoming Machine frequency approaches the Bus frequency, Switch ON
the Synchronoscope Selection Switch in Vertical panel.
• When the machine frequency matches system frequency and the green lamp
of synchroscope glows steadily, Synchronize the machine .Select Release+ CB ON
• Increase the Load Suddenly to l 5MW using R-L of Guide vane position (MW)
•Increase the Load gradually to 45MW using G.V limit PB.
• Change the Auxiliary supply from Bus to Machine.

39
Shutdown Procedure:-
• Load reduced to 45MW for All Machines
• (Change the station auxiliary to other Machine or Karimanal Feeder)
• Change Machine Auxiliary to Station Auxiliary
• Select Display ON/OFF
• Using Speed Setting Push Button Reduce the Load to 40 MW
•By using Guide Vane Raise - Lower (MW) reduce the load to 20 MV
• (During this time the Output Setting must be >50)

40
1.5 SINGLE LINE DIAGRAM

41
SECTION: 2
220KV SUBSTATION
POOVANTHURUTHU

42
Acknowledgement
We the students of Govt. Rajiv Gandhi Institute of Technology, Kottayam, have undertaken
practical training at 110 kV Substation Poovanthuruthu, under the guidance and supervision
of Mr. Jacob (Assistant Executive Engineer) of 220KV Substation Poovanthuruthu. We are
thankful to all the employees of this substation who helped us to gain the practical knowledge
and answered our queries to the best of our satisfaction. We feel obliged by gaining
knowledge under the esteemed guidance of able personals at Poovanthuruthu substation.
During the training from 15-6-2015 to 19-6-2015 we have prepare d this report of
practical training, which gives insight information about instruments and apparatus used in
this system and their working in brief. We can say that this report is a summary of what we
have observed and learned there.

43
2.1.INTRODUCTION
We all know that electrical power systems are playing an important role in our daily routine.
Electrical power is generated in power stations by different processes and from there it is
transmitted to substations, which are located in different places through transmission lines.
Then it is delivered to the consumer through a large network of transmission and distribution
cables.
In electrical systems the most important components are the Power Transformers,
circuit breakers, lightning arresters, instrument transformers, relays, wave traps, isolators, bus
bars etc.

44
2.2. SUB–STATION
Substation is a part of an electrical generation transmission and distribution system.
Substation transforms voltage from high to low, or the reverse or performs any of the several
other important functions. Between generating station and consumer electric power may flow
through several substations at different voltage levels.
Substations may be owned and controlled by an electrical utility, or may be owned by
a large industrial or commercial customer. Generally substations are unattended, relying on
SCADA for remote supervision and control.
Substations may include transformers to change voltage levels between high transmission
voltages and lower distribution voltages, or at the interconnection of two different
transmission voltages. The word substation comes from the days before the distribution
system became a grid. As central generating stations became larger, smaller generating plants
were converted to distribution stations, receiving their energy supply from a larger plant
instead of using their own generators. The first substations were connected to only one power
station, where the generators were housed, and were subsidiaries of that power station.
The electrical substation design is influenced by following aspects:
1. Rated voltage of incoming and outgoing lines
2. Total MVA to be transferred
3. Geographical area available
4. Step up and step down
5. Switching substation
6. Receiving substation
7. Distributing substation
8. Industrial substation

45
2.3.ELEMENTS OF SUBSTATION
2.3.1.POWER TRANSFORMER
fig 2.1
The Power Transformers are those transformers installed at the ending or receiving
end of long high voltage transmission lines. The distribution transformers (generally pole
mounted) are those installed in the location of the city to provide utilization voltage at the
consumer terminals. Power transformers are used in transmission network of higher voltages
for step-up and step down application (400 kV, 200 kV, 110 kV, 66 kV, 33kV) and are
generally rated above 200MVA.They have usually has one primary and one secondary, and
one input and output.
Power transformers generally operate at nearly full – load. However, a distribution
transformer operates at light loads during major parts of the day.
The performance of the power transformers is generally judged from commercial efficiency.
The rating of a high transformer is many times greater than that of distribution transformer
and the flux density is also higher
Power transformer’s primary winding always connected in star and secondary
winding in delta. In the Substation end of the transmission line, The power transformer
connection is star-delta.( for the purpose of step down the voltage level)
In the star up of the transmission line (H-T), the connection of the power transformer is delta
– star (for the purpose of step up the voltage level)

46
Transformer Core:-
A physical core is not an absolute requisite and a functioning transformer can be
produced by placing the windings near each other, an arrangement termed as ‘air-core’
transformer. The air which comprises the magnetic circuit is essentially lossless, and so and
air core transformer eliminate loss due to hysteresis in the core material. The leakage
inductance is inevitably high resulting in very poor regulation, and so such designs are
unsuitable for usein power distribution. They have however very high bandwidth, and are
frequently used in radio-frequency applications for which a satisfactory coupling coefficient
is maintained by carefully overlapping the primary and secondary windings. They are also
used for resonant transformers such as tesla coils where they can achieve reasonably low loss
in spite of the high leakage inductance.
Windings:-
The conducting materials used for the winding depends upon the application, but in all
cases the individual turns must be electrically insulated from each other to ensure that the
current travels throughout every turn. For small power and signal transformers, in which
currents are low and the potential difference between adjacent turns is small, the coils are
often wound from enamelled magnet wire, such are Formvar wire. Larger power transformers
operating at high voltages may be wound with copper rectangular strip conductors insulated
by oil-impregnated paper and blocks of pressboard.
Bushings:-
Large transformers are provided with high voltage insulate bushings made of polymers or
porcelain. A large bushing can be a complex structure since it must provide careful control if
the electric field gradient without letting transformer leak.
Tap Changer:-
A tap changer is a connection point selection mechanism along a power transformer
winding that allows a variable number of turns to be selected in discrete steps. A transformer
with a variable turns ratio is produced, enablingstepped voltage regulation of output. The tap
selection may be made via an automatic or manual tap changer mechanism.
Cooling Equipment:-
ONAN Cooling of Transformer:-
This is the simplest form of cooling system. The full form of ONAN is “Oil Natural Air
Natural”. Here natural convectional flow of hot oil is utilized for cooling. In convectional
circulation of oil, the hot oil flows to the upper portion of the transformer tank and the vacant

47
place is occupied by cold oil. This hot oil which comes to the upper side will dissipate heat in
the atmosphere by natural conduction, convection and radiation in air and will become cold.
In this way the oil in the transformer continually circulate when the transformer is put into
load. As the rate of dissipation of heat in air depends on dissipating surface of the oil tank, it
is essential to increase the effective surface area of the tank,so additional dissipating surface
in the form of tubes or radiators are connected to the transformer tank. This is known as
radiator bank of transformer.
ONAF Cooling of Transformer:-
Heat dissipation can obviously be increased by increased by increase in surface area, but
it can be made further faster by applying forced air on that dissipating surface. Fans blowing
air on cooling surfaces is employed. Forced air takes away the heat from the surface of the
radiator and provides better cooling than natural air. The full form of ONAF is “Oil Natural
Air Forced”. As the heat dissipation rate is faster and more in ONAF transformer cooling
method than in ONAN cooling system, electrical power can be put into more load without
crossing the permissible temperature limits.
OFAF Cooling of Transformer:-
The heat dissipation rate can be still improved if the oil circulation is accelerated by
applying some force. In OFAF cooling system the oil is forced to circulate within the closed
loop of the transformer tank by means of oil pumps. OFAF means “Oil Forced Air Force”
cooling methods of transformer. The main advantage of this system is that it is a compact
system and for same cooling capacity OFAF system occupies much lesser space than former
two systems of transformer cooling. Actually in Oil Natural cooling systems , the heat comes
out of the conducting part of the transformer is displaced form its position, is a slower rate
due to convectional flow of oil but in oil forced cooling systems the heat is displaced from its
origin as soon as it comes out in the oil, hence rate of cooling becomes faster.
 For all T-6 models – 0.35to .84kg/cm2(any one value as per demand)
 For all T-3 models – 0.35to .84kg/cm2(any one value as per demand)
Port openings
 For all T-6 models- about 150mm Dia.
 For all T-3 models- about 70mm Dia.
Oil/Winding Temperature indicator:-
Scientific Controls:-
Mechanical Instruments are incorporates proven design features acquired from many years of
experience in providing Temperature Indicators/Controllers for Power& Distribution
Transformers.

48
Oil Temperature Indicator:-
The Oil Temperature Indicator (OTI) measures the Top oil Temperature. It is used for control
and protection for all transformers.
Winding Temperature Indicator:-
The winding is the one component with highest temperature within the transformer and,
above all, the one subject to the fastest temperature increase as the load increases. Thus to
have a total control of temperature parameter within the transformer, the temperature of
winding as well as top oil must be measured. An indirect system is used to measure winding
temperature as it is dangerous to place a sensor close to the winding due to heavy voltage.
The indirect measurement is done by means of a built-in Thermal Image.
Winding Temperature Indicator is equipped with a specifically designed Heater which is
placed around the operating bellows through which passes a current proportional to the
current passing through the transformer winding subject to the given load. Winding
temperature is measured by connecting the CT Secondary of the transformer through a shunt
resistor inside the Winding Temperature Indicator to the Hater Coil around the operating
Bellows. It is possible to adjust gradient by means of Shunt Resistor.
In this way the value of the winding temperature indicated by the instrument will be equal to
the one planned by the transformer manufacturer for a given transformer load.
2.3.2.CIRCUIT BREAKER
fig 2.2
A circuit breaker is a manually or automatically operated electrical switch designed to
protect an electrical circuit from damage caused by overload or short circuit. Its basic
function is to detect a fault condition and interrupt current flow. Unlike a fuse, which

49
operates once and then must be replaced, a circuit breaker can be reset (either manually or
automatically) to resume normal operation. Circuit breakers are made in varying sizes, from
small devices that protect an individual household appliance up to large switchgear designed
to protect high voltage circuits feeding an entire city.
Operation
All circuit breakers have common features in their operation, although details vary
substantially depending on the voltage class current rating and type of the circuit breaker.
The circuit breaker must detect a fault condition; in low voltage circuit breakers this is
usually done within the breaker enclosure. Circuit breakers for large currents and high
voltages are usually arranged with pilot devices to sense a fault current and to operate the trip
opening mechanism. The trip solenoid that releases the latch is usually energized by a
separate battery, although some high voltage circuit breakers are self-contained with current
transformers, protective devices and internal control power source.
Once a fault is detected, contacts within the circuit breaker must open interrupt the circuit;
some mechanically stored energy (using something such as springs or compressed air)
contained within the breaker is used to separate the contacts, although some of the energy
required may be obtained from the fault current itself. Small circuit breakers maybe manually
operated, larger units have solenoids to trip the mechanism, and electric motors to store the
energy to the springs.
The circuit breaker contacts must carry the load current without heating, and must also
with stand the heat of the arc produced when interrupting (opening) the circuit. Contacts are
made of copper or copper alloys, silver alloys and other highly conductive materials. Service
life of the contacts is limited by the erosion of contact material due to arcing while
interrupting the current. Miniature circuit breakers (MCB) and moulded-case circuit breakers
(MCCB) are usually discarded when the contacts have worn, but power circuit breakers and
high voltage circuit breakers have replaceable contacts.
When a current is interrupted, an arc is generated. This arc must be contained, cooled and
extinguished in a controlled way, so that the gap between the contacts can again withstand the
voltage in the circuit. Different circuit breakers use vacuum, air, insulating gas, or oil as the
medium the arc forms in. Different techniques are used to extinguish the arc including.
 Lengthening /deflection of the arc
 Intensive cooling ( in jet chamber)
 Division into partial arcs
 Zero point quenching (Contacts open at the zero current time crossing of the AC
waveform, effectively breaking no load current at the time of opening. The zero
crossing occurs at twice the line frequency, i.e. 100 times per second for 50 Hz and
120 times per second for 60 Hz)
 Connecting capacitors in parallel with contacts in DC circuits

50
Finally, once the fault condition has been cleared, the contact must again be closed to restore
power to the interrupted circuit.
2.3.2.1.SF6 CircuitBreaker
fig 2.3
A circuit breaker in which the current carrying contacts operate in Sulphur Hexafluoride
or SF6 gas is known as an SF6 Circuit Breaker.
SF6 has an excellent insulating property. SF6 has high electro-negativity. That means it
has high affinity of absorbing free electron. Whenever a free electron collides with SF6 gas
molecule, it is absorbed by that gas molecule and forms a negative ion.
The attachment of electron with SF6 gas molecule may occur in two different ways
1)SF6+e=SF6
-
2)SF6+ e = SF5
-+F
These negative ions obviously much heavier than a free electron and therefore over all
mobility of the charged particle in the SF6 gas is much less as compared to other common
gases. We know that mobility of charged particle is responsible for conducting current
through a gas.
Hence for heavier and less mobile charged particle in SF6 gas, it acquires gas very high
dielectric strength. Not only the gas has a good dielectric strength but also it has the unique
property of fast recombination after the source energizing the spark is removed. The gas has
also very good heat transfer property. Due to its low gaseous viscosity (because of less
molecular mobility) SF6 gas can efficiently transfer heat by convection. So due to its high
dielectric strength and high cooling effect SF6 gas is approximately 100 times more effective
arc quenching media than air. Due to these unique properties of this gas SF6 Circuit Breaker

51
is used in complete range of medium voltage and high voltage electrical power system. These
circuit breakers are available for the voltage ranges from 33KV to 800KV and even more.
2.3.2.2.VacuumCircuit Breaker
fig 2.4
A vacuum circuit breaker is such kind of circuit breaker where
the arc quenching takes place in vacuum. The technology is suitable for mainly medium
voltage application. For higher voltage vacuum technology has been developed but not
commercially viable. The operation of opening and closing of current carrying contacts and
associated arc interruption takes place in a vacuum chamber in the breaker which is called
vacuum interrupter. The vacuum interrupter consists of a steel arc chamber in the centre
symmetrically arranged ceramic insulators. The vacuum pressure inside a vacuum interrupter
is normally maintained at 10-6 bar.
2.3.3.INSTRUMENT TRANSFORMERS
Instrument Transformers are high accuracy class electrical
devices used to isolate or transform voltage or current levels. The most common usage of
instrument transformer is to operate instruments or metering from high voltage or high
current circuits, safely isolating the secondary control circuitry from the high voltages or
currents. The primary winding of the transformer is connected to the high voltage or high
current circuit, and the meter or relay is connected to the secondary circuit.
Instrument transformers may also be used as an isolation transformer so that secondary
quantities may be used in phase shifting without affecting other primary connected devices.

52
In Poovanthuruthu Substation there are a total of current transformers and potential
transformers. They are mainly used for metering purpose and protection by operation of
various relays.
TYPES:
2.3.3.1. Potential Transformer:-
fig 2.5
Potential transformers are also called voltage transformers (VT) are a parallel connected type
of instrument transformer. They are designed to present negligible load to the supply being
measured and have an accurate voltage ratio and phase relationship to enable accurate
secondary connected metering
.2.3.3.2.Current Transformer
fig 2.6

53
Current transformers (CT) are a series connected type of
instrument transformed. They are designed to present negligible load to the supply being
measured and have an accurate current ratio and phase relationship to enable accurate
secondary connected metering.
Current transformers are often constructed by passing a single primary turn either an
insulated cable or an uninsulated bus bar through a well-insulated toroidal core wrapped
with many turns of wire. This affords easy implementation on high voltage bushing
insulators and using the pass-through conductor as a single turn primary.
A current clamp uses a current transformer with a split core that can be easily
wrapped around a conductor in circuit. This is a common method used in portable current
measuring instruments but permanent installations use more economical types of current
transformer. Specially constructed wireband CTs are also used, usually with an
oscilloscope, to measure high frequency waveforms or pulsed currents within pulsed
power systems. One type provides an IR voltage output that is proportional to the
measured current; another called a Rogowski coil, requires an external integrator in order
to provide a proportional output.
2.3.4. ISOLATOR
fig 2.7
Circuit breakers always trip the circuit but open contacts of breaker cannot be physically
visible from outside of the breaker and that is why it is recommended not to touch any
electrical circuit by just switching off the circuit breaker.
So for better safety there must be some arrangement so that one can see open condition of
the section of the circuit before touching it. Isolator is a mechanical switch which isolates a

54
part of circuit from system as when required. Electrical isolators separate a part of the system
from rest for safe maintenance works. So definitions of isolator can be rewritten as Isolator is
a manually operated mechanical switch which separates a part of the electrical power
normally at off load condition.
Isolators are classified into two:
1.Line Isolator
2.Bus Isolator
Line Isolator:-
Line Isolator is the isolator which is situated in between potential transformer and current
transformer. This is the isolator which is coming directly from line. This isolator has an
inbuilt provision for grounding the main transmission lines so that work can be done on them.
Bus Isolator:-
This is the isolator which is coming directly from the bus. They are used to isolate the various
buses present in the switch yard.
2.3.5.INSULATORS
fig 2.8
An insulator is a material whose internal electric charges do
not flow freely, and therefore very hard to conduct an electric current under the influence of
an electric field.
A perfect insulator does not exist, but some materials such as glass, paper and Teflon which
have high resistivity, are very good electrical insulators. A much larger class of materials,

55
even though they may have lower bulk resistivity, are still good enough to insulate wiring and
cables. Examples include rubber like polymers and most plastics. Such materials can serve as
practical and safe insulators for low to moderate voltages.
Insulators are used in electrical equipment to support and separate electrical conductors
without allowing current through themselves. An insulating material used in bulk to wrap
electrical cables or other equipment is called insulation. The term insulator is also used more
specifically to refer to insulating supports used to attach electric power distribution or
transmission lines to utility poles and transmission towers hold the conductors and prevent
current through conductors to pass through the poles to the ground.
2.3.6. WAVE TRAP
fig 2.9
Wave traps in electrical systems are used for power plant communication through
transmission wires. It is a combination of low inductances in series and high capacitances in
parallel with transmission wires in power frequencies. But communication signals are very
low amplitude and very high frequency signals. So, these signals are nearly open circuited by
the inductance and short circuited by capacitance. That is how wave trap power and
communication waves are used in PPC

56
2.3.7.BUS BARS
In electrical power distribution, a bus bar is also spelled as busbar or sometimes
incorrectly as buss bar, with the term bus being a contraction of the Latin word omnibus. It is
a strip or bar of copper, brass or aluminium that conducts electricity within a switchboard,
distribution, substation, battery bank or other electrical apparatus. Its main purpose is to
conduct electricity, not to function as a structural member.
The cross-section size of the bus bar determines the maximum amount of current that can
be safely carried. Bus bars can have cross sectional area as little as 10 mm2 but electrical
substations may use metal tubes of 50 mm in diameter (20 mm2) or more as bus bars. An
aluminium smelter will have very large bus bars used to carry tens of thousands of amperes to
the electrochemical cells that produce aluminium from molten salts.
fig 2.10
2.3.8.RELAYS
A relay is an electrically operated switch. Many relays use an electromagnet to operate a
switching mechanism mechanically, but other operating principles are also used, where it is
necessary to control a circuit by a low-power signal (with complete electrical isolation
between control and controlled circuits), or where several circuits must be controlled by one
signal. The first relays were used in long distance telegraph circuits, repeating the signal
coming from one circuit and re-transmitting it to another. Relays were extensively used in
telephone exchanges and early computer to perform logical operations.

57
A type of relay that can handle the high power required to directly control an electric
motor or other loads is called a contactor. Solid-state relays control power circuits with no
moving parts, instead using a semiconductor device to perform switching. Relays with
calibrated operating characteristics and sometimes multiple operating coils are used to protect
electrical circuits from overload faults; in modern electrical power systems these functions
are performed by digital instruments called “protective relays”.
Electromagnetic Relay:-
Electromagnetic relays are those relays which are operated by electromagnetic action.
Modern electrical protection relays are mainly microprocessor based, but still
electromagnetic relay holds its place. It will take much longer time to be replaced the all
electromagnetic relays by microprocessor based static relays. So before going through details
of protection relay system we should review various types of electromagnetic relays.
Electromagnetic Relay Working:-
Practically all the relaying device are based on rather one or more of the following types of
electromagnetic relays.
a) Magnitude measurement
b) Comparison
c) Ratio measurement
Principle of electromagnetic relay working is on some basic principles. Depending upon
working principle these can be divided into following types of electromagnetic relays.
i) Attracted Armature type relay
ii) Induction Disc type relay
iii) Induction Cup type relay
iv) Balanced Beam type relay
v) Moving Coil type relay
vi) Polarised Moving Iron type relay
Attraction Armature Type Relay:-
Attraction Armature type relay is the most simple in construction as well as its working
principle. These types of electromagnetic relays can be utilized as either magnitude relay or
ratio relay. These relays are employed as auxiliary relay, control relay, overcurrent,
undercurrent, overvoltage, under-voltage and impedance measuring relays.

58
Hinged armature and plunger type constructions are most commonly used for these types
of electromagnetic relays. Among these two constructional designs, hinged armature type is
more commonly used.
2.3.9. LIGHTENING ARRESTERS
A lightning arrester, also known as lightning conductor, is a device used to on electrical
power systems and telecommunication systems to protect the insulation and conductors of the
system from the damaging effects of lightning. The typical lightning arrester has a high
voltage terminal and a ground terminal. When a lightning surge (or switching surge, which is
very similar) travels along the power line to the arrester, the current from the surge is diverted
through the arrester, in most cases to the earth
In telegraphy and telephony, a lighting arrester is placed where wires enter a structure,
preventing damage to electronic instruments within and ensuring the safety of individuals
near them. Smaller versions of lighting arresters also called surge protectors are devices that
are connected between each electrical conductor in power and communication systems and
the earth. These prevent the flow of the normal power or signal currents to ground, but
provide a path over which high voltage lightning current flows, bypassing the connected
equipment. Their purpose is to limit the rise in voltage when a communication or power line
is struck by lightning or is near to a lightning strike.
If the protection fails or is absent, lightning that strikes the electrical system introduces
thousands of kilovolts that may damage the transmission lines, and can also cause severe
damage to transformers and other electrical or electronic devices. Lightning produce extreme
voltage spikes in incoming power lines can damage electrical home appliances.
fig 2.11

59
2.3.10.DC SUPPLY
fig 2.12
DC Supply is one of the most essential parts of a substation because all the relays are
working on DC Supply. So even if AC Supply is not available the circuit breaker should
work. For this DC Supply is very essential.
2.3.11.BATTERYCHARGER
The battery charger is used to provide dc supply to the substation. It is used to convert
the AC signal to DC signal, for that purpose it employs a rectifier circuit.
2.3.12.SWITCHYARD
fig 2.13

60
Switch yard is the most important part of a substation. In switch yard most of the part is
laid with metals to reduce earthed voltage
. In the switch yard the supply taken from incoming feeders are transferred to one or more
bus bars from which they are switched on or off to various incomers and distribution
auxiliary supply etc.
2.3.13.STEELTOWERS(TransmissionTowers):-
fig 2.14
A transmission tower (colloquially termed an electricity pylon in the United Kingdom and
part of Europe, and a hydro tower in certain provinces of Canada where power generation is
mainly hydroelectric) is a tall structure, usually a steel lattice tower, used to support an
overhead power line. They are used in high voltage AC and DC systems, and come in a wide
variety of shapes and sizes. Typical height ranges from 15 to 55 metres (49 to 180 ft) though
the tallest are the 370 metre (1214 ft) towers of a 2700 metre long span of Zhoushan Island
Overhead Power line Tie. In addition to steel, other materials may be used including concrete
and wood.
There are four major categories of transmission towers: Suspension, Terminal, Tension,
and Transposition. Some transmission towers combine these basic functions. Transmission
towers and their overhead power lines are often considered to be a form of visual pollution.
Methods to reduce the visual effect include undergrounding.

61
2.4.110 KV SUBSTATION
POOVANTHURUTHU
Here the characteristic property ie voltage is changed and transmitted. That is 220 KV is
changed and transmitted to 110 KV , 66 KV and 11 KV . This is a Transformer Substation.
fig 2.15
CHARACTERISTICS OF POOVANTHURUTHUSUBSTATION:-
The incoming 220 KV feeders in the substation are :
1. Brahmapuram(Diesel Plant)
2. Sabarigiri(Moozhiyar)
3. Kayamkulam(Feeder from new pallom)
4. Idukki(Feeder from new pallom)

62
Similarly, There are three voltage outgoing feeders
1. 110kV Outgoing:
1. Pallom-Chengannur 1(PLCE No.1)
2. Pallom-Chengannur 2(PLCE No.2)
3. MRF- Pallom(PL-MR)
4. Pallom –Chengalom(PL-CN)
5. Pallom-Ayarkunnam(PL-AY)
6. Singulam -Pallom(SCM-PL)
2. 66kV Outgoing:
1. Pallom- Mavelikkara No.1
2. Pallom- Mavelikkara No.2
3. Pallom- Ettumannoor No.1
4. Pallom- Ettumannoor No.2
5. Pallom-Gandhinagar
3.11kV Outgoing :
1. Puncha North
2. Puncha South
3. Puncha Central
4. Travancore Cements Ltd
5. Aymanam
6. Kottayam

63
MAIN COMPONENTS
Main components we observed in the visit are listed below:
1. Circuit Breakers
2. Lightning Arresters
3. wave-traps
4. Instrument Transformer
5. Transmission Lines
6. Isolators
7. Protection Relays
8. Transformers
CIRCUIT BREAKER
These are used as switching devices in high power lines. They are capable to make , brake
and carry current under normal circuit conditions and abnormal conditions such as short
circuit.
Properties of circuit breaker devices are :
The different types of circuit breakers are :

64
And we observed SF6 Circuit Breaker and Air Blast Circuit Breakers
1. SF6circuit breaker
In such circuit breakers, sulphur hexaflouride (SF6) gas is used as the arc quenching medium.
The SF6 is an electro-negative gas and has a strong tendency to absorb free electrons. The
contacts of the breaker are opened in a high pressure flow of SF6 gas and an arc is struck
between them. The conducting free electrons in the arc are rapidly captured by the gas to
form relatively immobile negative ions. This loss of conducting electrons in the arc quickly
builds up enough insulation strength to extinguish the arc. The SF6 circuit breakers have been
found to be very effective for high power and high voltage services.
2. Air blast circuit breaker
It is a comparatively high speed device and prevents re striking .Here , the arc quenching is
by purely compressed air. The contacts are normally kept closed by spring pressure. when
opens air is admitted in arc extinguish chamber at high pressure and it pushes the moving
contact away and against spring pressure. The arc produced is extinguished by this air blast.
LIGHTNING ARRESTER
A lightning arrester is a device used on electrical power systems and
telecommunications systems to protect the insulation and conductorsof the system from the
damaging effects of lightning. The typical lightning arrester has a high-voltage terminal and a
ground terminal. When a lightning surge (or switching surge, which is very similar) travels
along the power line to the arrester, the current from the surge is diverted through the
arrestor, in most cases to earth.
In telegraphy and telephony, a lightning arrestor is placed where wires enter a structure,
preventing damage to electronic instruments within and ensuring the safety of individuals
near them. Smaller versions of lightning arresters, also called surge protectors, are devices
that are connected between each electrical conductor in power and communications systems
and the Earth. These prevent the flow of the normal power or signal currents to ground, but
provide a path over which high-voltage lightning current flows, bypassing the connected
equipment. Their purpose is to limit the rise in voltage when a communications or power line
is struck by lightning or is near to a lightning strike.

65
WAVE TRAP
A line trap (high-frequency stopper) is a maintenance-free parallel resonant circuit, mounted
inline on high voltage AC transmission power lines to prevent the transmission of high
frequency (40 kHz to 1000 kHz) carrier signals of power line communication to unwanted
destinations. Line traps are cylinder like structures connected in series with HV transmission
lines. A line trap is also called a wave trap.
The line trap acts as a barrier or filter to prevent signal losses. The inductive reactance of the
line trap presents a high reactance to high-frequency signals but a low to mains frequency.
What this does is prevent carrier signals from being dissipated in the substation or in a tap
line/branch of the main transmission path and grounds in the case of anything happening
outside of the carrier transmission path. The line trap is also used to attenuate the shunting
effects of high voltage lines.
Line traps are connected in series with power line and thus their coils are rated to carry the
full line current. The impedance of a line trap is very low at the power frequency and will not
cause any significant voltage drop.
INSTRUMENT TRANSFORMERS
A transformer intended to supply measuring instruments, meters , relays and other similar
apparatus are called Instrument Transformer
Current Transformers
A current transformer is defined as an instrument transformer in which the secondary current,
in the normal conditions of use is proportional to the primary current and differs in phase
from it by an angle, which is approximately zero for an appropriate direction of the
connections.
Current transformers are therefore used with the measuring instruments to:
(a) Isolate the instruments from the power circuits.
(b) Standardise the instruments, usually at 5 amps or 1 amp.
Primary current
The primary current of the CT depends on the load on the circuit at which CT is connected.
The standard values are 10,15,20,30,50,75,100,150,200,300,400,600,800,1000 and 2000.The
selection should be based on the load in the circuit.

66
Secondary current
The standard values of rated secondary current shall be 1A and 5A. For distribution
applications 5A is the standard secondary current. For substations application 11kV metering
CT is having 5A secondary current . For 66Kv to 400kV metering 1A secondary current is
used.
Potential Transformer
Potential transformers (PT) (also called voltage transformers (VT)) are a parallel connected
type of instrument transformer. They are designed to present negligible load to the supply
being measured and have an accurate voltage ratio and phase relationship to enable accurate
secondary connected metering. They are used for measurement of high voltages by means of
low range voltmeters or for energizing the potential coils of wattmeters and energymeters.
potential transformer may have several secondary windings on the same core as a primary
winding, for use in different metering or protection circuits. The primary may be connected
phase to ground or phase to phase. The secondary is usually grounded on one terminal.
Potential transformers are of shell type because such a construction develops high degree of
accuracy.
TRANSMISSION LINE
We were able to observe different types of transmission cables at poovanthuruthu. A
transmission line is a specialized cable or other structure designed to carry alternating current
of radio frequency, that is, currents with a frequency high enough that their wave nature must
be taken into account.
DIFFERENT TYPES OF TRANSMISSION LINES:-
1) Balance Two Wire Line
In this type of construction for two wire transmission lines the
insulated spacers are used in order to maintain the distance between the transmission lines or
between the two conducting wire equally throughout.
2) Coaxial cable
Coaxial lines confine virtually all of the electromagnetic wave to the area inside the cable.
Coaxial lines can therefore be bent and twisted (subject to limits) without negative effects,
and they can be strapped to conductive supports without inducing unwanted currents in them.
4.6. ISOLATOR
Isolator is used to ensure that an electrical circuit is completely de-energised for service or
maintenance. Such switches were used substations, where machinery must have its source of
driving power removed for adjustment or repair. High-voltage isolation switches are used in
electrical substations to allow isolation of apparatus such as circuit breakers, transformers,

67
and transmission lines, for maintenance. The dis-connector is usually not intended for normal
control of the circuit, but only for safety isolation. Dis-connector can be operated either
manually or automatically (motorized dis-connector). We familiarized with different type of
isolators.
4.7. PROTECTION
Feeder protection
The feeder may be an EHT transmission line (short, medium or long) or sub transmission line
(in the distribution system).
The protection shall be
1. Overcurrent and earth fault protection
2. Distance protection
3. Pilot wire protection
Overcurrent protection
It is the simplest and cheapest means of protection. No voltage connection is required for this.
Two phases of one earth fault protection provide complete protection of three phase circuit.
Distance protection
Whenever the overcurrent relaying is found slow or selective, distance protection is used.
Distance provides primary or back up protection in single schemes. It may be single or three
stepped.
Auto re-close schemes
The majority of fault occurring in HV transmission line are of transient in nature (ie.
lightning) and can be cleared without affecting the system stability, if the circuit is
momentarily tripped at both ends, and reclosed. In the feeders only short reclosing is
recommended. But in radial feeders, multiple short reclosing can be attempted to eliminate
semi-permanent fault (also). Single phase and three phase reclosing facility in conjunction
with high speed distance schemes and carrier inter-trip can be provided for 220kV line. For
110kV, 66kV line only three phase reclosing has been provided (mainly due to breaker
limitations).
Anti-pumping feature is incorporated in the circuit breaker or in the auto reclosing scheme to
avoid repeated reclosing operation during permanent fault(s).
Conditions for auto re-close:-
1. Time to be allowed for the arc to de-ionize so that it will not restrike during reclosing.
2. The opening and closing times of circuit breaker at two ends.

68
3. The probability of transient fault that will allow high speed reclosure of faulty lines.
Transformer protection
Fault in a transformer may be in the external connection or in the internal circuit.
4.8.TRANSFORMER
A transformer is a static machine used for transforming power from one circuit to
another without changing frequency. Since the invention of the first constant potential
transformer in 1885, transformers have become essential for the AC transmission,
distribution, and utilization of electrical energy.
4.8.1. USE OF POWER TRANSFORMER
Generation of electrical power in low voltage level is very much cost effective. Hence
electrical power is generated in low voltage level. Theoretically, this low voltage level power
can be transmitted to the receiving end. But if the voltage level of a power is increased, the
current of the power is reduced which causes reduction in ohmic losses in the system,
reduction in cross sectional area of the conductor i.e. reduction in capital cost of the system
and it also improves the voltage regulation of the system. Because of these, low level power
must be stepped up for efficient electrical power transmission. This is done by step up
transformer at the sending side of the power system network. As this high voltage power may
not be distributed to the consumers directly, this must be stepped down to the desired level at
the receiving end with the help of step down transformer. These are the uses of electrical
power transformer in the electrical power system.
Two winding transformers are generally used where ratio between high voltage and
low voltage is greater than 2. It is cost effective to use auto transformer where the ratio
between high voltage and low voltage is less than 2. Again three phase single unit
transformer is more cost effective than a bank of three single phase transformer unit in a three
phase system. But still it is preferable to use than the later where power dealing is very large
since such large size of three phase single unit power transformer may not be easily
transported from manufacturer's place to work site.
4.8.2 AT POOVANTHURUTHU SUBSTATION
Transformers at Poovanthuruthu substation were introduced to us by Mr. Biju , an
employee of Kerala State Electricity Board. His expertise in the respective field helped us in
understanding the transformer operation well. At Poovanthuruthu substation, two set of single
phase autotransformers of are used in converting 220 kV to 110 kV. The station capacity is
400 MVA. It is cost effective to use autotransformer where the ratio between high voltage
and low voltage is less than 2. At Poovanthuruthu, three phase transformers are used in
stepping down the voltage level to 66 kV and 11 kV. But we concentrated our studies on the
220/110 kV transformer. At Poovanthuruthu, power transformers are star- star connected,
distribution transformers are delta- star connected and tertiary winding is delta connected.

69
Tertiary windings are used to avoid harmonics and to avoid unbalancing current created
during faults. The main components of transformer which we studied are described below.
4.8.3 TRANSFORMER CONSTRUCTION
The core, which provides the magnetic path to channel the flux, consists of thin
strips of high-grade steel, called laminations, which are electrically separated by a thin
coating of insulating material. he core is held together by, but insulated from, mechanical
structures and is grounded to a single point in order to dissipate electrostatic buildup. Core
steel is cold-rolled, grain-oriented steel. In autotransformer, the single continuous winding is
divided into a number of "tappings" to produce different voltages. An appropriate number of
turns are provided between each tapping to produce the required voltage, based on the turns
ratio between the complete winding and the tapping. A useful method of calculating unknown
voltages on an autotransformer, if the numbers of turns on the various tappings are known, is
to use the volts per turn method described on the Basic Transformer Operation page. Unlike a
conventional transformer with primary and secondary windings, the autotransformer does not
provide any isolation between input and output.
4.8.4 CONSERVATOR TANK OF A TRANSFORMER
Conservator tank at Poovanthuruthu is half oil filled. This is a cylindrical tank
mounted on supporting structure on the roof the transformer main tank. The main function of
conservator tank of transformer is to provide adequate space for expansion of oil inside the
transformer. When the transformer is loaded and ambient temperature rises, the volume of oil
inside transformer increases. A conservator tank of transformer provides adequate space to
this expanded transformer oil. It also acts as a reservoir for transformer insulating oil. When
volume of transformer insulating oil increases due to load and ambient temperature, the
vacant space above the oil level inside the conservator is partially occupied by the expanded
oil. Consequently, corresponding quantity of air of that space is pushed away through
breather. On other hand, when load of transformer decreases, the transformer is switched off
and when the ambient temperature decreases, the oil inside the transformer contracts. This
causes outside air to enter in the conservator tank of transformer through silica gel breather.
4.8.5 CONSTRUCTION OF CONSERVATOR TANK
This is a cylindrical shaped oil container closed from both ends. One large
inspection cover is provided on either side of the container to facilitate maintenance and
cleaning inside of the conservator. Conservator pipe, i.e. pipe comes from main transformer
tank, is projected inside the conservator from bottom portion. Head of the conservator pipe
inside the conservator is provided with a cap. This pipe is projected as well as provided with
a cap because it prevents oil sludge and sediment to enter into main tank from conservator.
Generally silica gel breather fixing pipe enters into the conservator from top. If it enters from
bottom, it should be projected well above the level of oil inside the conservator. This
arrangement ensures that oil does not enter the silica gel breather even at highest operating
level.

70
4.8.6 BUCHHOLZ RELAY
The Buchholz relay working principle of is very simple. Buchholz relay function
is based on very simple mechanical phenomenon. It is mechanically actuated. Whenever
there will be a minor internal fault in the transformer such as an insulation faults between
turns, break down of core of transformer, core heating, the transformer insulating oil will be
decomposed in different hydrocarbon gases, CO2 and CO. The gases produced due to
decomposition of transformer insulating oil will accumulate in the upper part the Buchholz
container which causes fall of oil level in it.
Fall of oil level means lowering the position of float and thereby tilting the
mercury switch. The contacts of this mercury switch are closed and an alarm circuit
energized. Sometime due to oil leakage on the main tank air bubbles may be accumulated in
the upper part the Buchholz container which may also cause fall of oil level in it and alarm
circuit will be energized. By collecting the accumulated gases from the gas release pockets on
the top of the relay and by analyzing them one can predict the type of fault in the transformer.
More severe types of faults, such as short circuit between phases or to earth
and faults in the tap changing equipment, are accompanied by a surge of oil which strikes the
baffle plate and causes the mercury switch of the lower element to close. This switch
energized the trip circuit of the circuit breakers associated with the transformer and
immediately isolate the faulty transformer from the rest of the electrical power system by
inter tripping the circuit breakers associated with both LV and HV sides of the transformer.
This is how Buchholz relay functions.
4.8.7 SILICA GEL BREATHER
Whenever electrical power transformer is loaded, the temperature of the
transformer insulating oil increases, consequently the volume of the oil is increased. As the
volume of the oil is increased, the air above the oil level in conservator will come out. Again
at low oil temperature; the volume of the oil is decreased, which causes the volume of the oil
to be decreased which again causes air to enter into conservator tank. The natural air always
consists of more or less moisture in it and this moisture can be mixed up with oil if it is
allowed to enter into the transformer. The air moisture should be resisted during entering of
the air into the transformer, because moisture is very harmful for transformer insulation. A
silica gel breather is the most commonly used way of filtering air from moisture. Silica gel
breather for transformer is connected with conservator tank by means of breathing pipe.
Silica gel crystal has tremendous capacity of absorbing moisture. When air
passes through these crystals in the breather; the moisture of the air is absorbed by them.
Therefore, the air reaches to the conservator is quite dry, the dust particles in the air get
trapped by the oil in the oil seal cup. The oil in the oil sealing cup acts as barrier between
silica gel crystal and air when there is no flow of air through silica gel breather. The color of
silica gel crystal is dark blue but, when it absorbs moisture; it becomes pink. When there is
sufficient difference between the air inside the conservator and the outside air, the oil level in
two components of the oil seal changes until the lower oil level just reaches the rim of the

71
inverted cup, the air then moves from high pressure compartment to the low pressure
compartment of the oil seal. Both of these happen when the oil acts as core filter and removes
the dust from the outside air.
CONCLUSION
We were able to get to know more about substations and the different components used in
substation. We were able to know the difference between switching station and distribution
substation. We got an overview of working of different sections in substations. We also
familiarized with the working of different types of transformers, circuit breakers, lightning
arrestors and other major power handling equipments of the substation. We learned about the
steps of power transformation and various specifications to be taken care when doing so. We
also learned about the protection of important machines in the substation

KSEB Training Reporty

More Related Content

What's hot

Viewers also liked

Similar to KSEB Training Reporty

KSEB Training Reporty