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ON
FAILURE OF
SUBSTATION EQUIPMENT
NOVEMBER, 2012
TABLE OF CONTENTS
Subject Pages
Introduction 2
-1-
1.0 Introduction
15 Sequence of events/ :
-3-
Description of fault
The status of load shared by all 4 nos. 100 MVA transformers prior to this
incidence is as under:
a. 2 nos. transformers connected to 220 kV bus-I were running in parallel
and 68 MW load was being fed by each.
b. Other 2 nos. transformers connected to 220 kV bus-II were running in
parallel feeding 56 MW (transformer-III) and 52 MW (transformer-IV)
load.
17 Conclusion/recommendations :
Last test results of Oil DGA, capacitance and tan delta prior to the fault do not
indicate any abnormality in the oil, winding or bushing. Magnetic balance test
and measurement of IR value, magnetizing current and transformer earthing
performed on 19.08.11 were also satisfactory.
3.0 Failure of 16.67 MVAR, single phase, 400 kV Bus Reactor (Y-phase) at
400 kV Amreli substation, Gujarat
15 Sequence of events/ :
Description of fault
-5-
All control cables for Y-phase Bus Reactor were found burnt and damaged.
HV bushing of the reactor blasted and fire took place. Radiator bank was
found de-shaped and collapsed due to heat. Emulsifier pipe line for reactor
got damaged. Post Insulator connected adjacent to the reactor also got
damaged. LA connected in Y-phase was flamed and its surge counter was
damaged.
B-phase reactor’s WTI, OTI with cable and breather and emulsifier pipe line
got damaged and top portion of HV bushing got flamed.
R-phase reactor’s top plate gasket got damaged and minor oil leakage was
found. Its neutral bushing was found intact but its cable and collar were found
damaged. Associated 400 kV LA’s bottom portion was found damaged.
17 Conclusion/recommendations :
Last test results of Oil DGA, capacitance and tan delta prior to the fault do not
indicate any abnormality in the oil, winding or bushing. IR value and
Polarization index of Y-phase reactor measured on 02.04.11 were also
satisfactory.
Operation of REF, bucholz and PRV indicates occurrence of fault inside tank.
LV tests (magnetizing current test, magnetic balance test, and turn ratio test
etc.) may be carried out on reactor after replacing the damaged bushings,
cables and LA. Oil may be tested for DGA and BDV.
Internal inspection may be carried out at site and its condition may be
assessed. If possible, the reactor may be repaired at site as per prevailing
practices and periodic maintenance schedule may be continued.
-6-
3 Faulty Equipment : Power Transformer
15 Sequence of events/ :
Description of fault
160 MVA transformer & 125 MVA transformer-I were charged on the same
day at 22:16 hrs and 22:18 hrs respectively and they stood OK.
At 02:45 hrs 132 kV railway traction-I feeder was charged and it stood OK.
At around 08:30 hrs, bucholz alarm and trip arrived in 220kV control panel of
this transformer. It is to mention here that the transformer was off (out of
circuit) at that time. After the rain stopped, shutdown was taken on the
transformer. While trying to release the air/gas from bucholz relay, it was
observed that there was vacuum inside it and it was sucking air from outside.
Its conservator was also empty. Approximately 800 1trs oil was topped up in
the transformer. At 02:50 hrs on 02/01/2012 this transformer was charged
from 220kV side and it tripped with differential trip indication.
16 Details of Tests done after : Oil BDV test, insulation resistance test,
failure ratio test, magnetic balance test,
magnetizing current test and FRA
17 Conclusion/recommendations :
-8-
5.0 Failure of 220 kV SF6 Current Transformer at Meramundali substation,
Odisha
4 Rating : 220 kV
5 Make : Siemens
15 Sequence of events/ :
Description of fault
16 Details of Tests done after : Visual inspection, IR test, ratio test and
failure secondary continuity test were done.
Results of tests found satisfactory.
17 Conclusion/recommendations :
It is assumed that SF6 loss alarm would have been left open accidentally
because of which no alarm signal was heard by operating staff in the control
room. Continuous monitoring of SF6 gas is required and periodical
maintenance should be done.
On 21/02/12, Kopli Unit IV machine was synchronized with the grid at 16:30
hrs. The unit was generating at 49 MW load as per schedule. But the machine
tripped at 20:02 hrs with the following fascia indications:
1. GT A phase bucholz alarm
2. GT A phase bucholz operated
3. Excitation Equipment Stage I
The unit was kept under shutdown for detailed investigations since tripping.
On 22.02.12, both the generator transformers of Phase-A & C were
disconnected from bus duct (11kV side) and HV side.
16 Details of Tests done after : Oil BDV test, insulation resistance test,
failure ratio test and magnetizing current test
17 Conclusion/recommendations :
This GT has failed for the first time since its commissioning in year 1988. It
has served for about 24 years without giving any trouble.
There is no oil and water differential pressure gauge in the cooler line, which
had been removed by NEEPCO due to its malfunctioning and which may have
allowed the water to enter in the oil line and consequently damaged the
windings. It is recommended that the same be reinstalled.
Water being used for the cooling system has very low PH value and because
of this corrosion takes place in the water tubes and metal parts of the heat
exchanger resulting in tube failure. Periodical maintenance is recommended
for heat exchanger tubes.
- 11 -
Repairing may be done, if found economical on the basis of benefit cost
analysis.
15 Sequence of events/ :
Description of fault
In CVT connected in 230 kV Neyveli feeder, heavy sound and smoke was
- 12 -
detected at about 18:45 hrs on 30.03.12. On inspection, the CVT got flashed
over and loop jumper between CVT and wave trap got released from CVT
point and hung near by the wave trap support insulator without tripping the
feeder. Oil leakage in CVT was also noticed.
16 Details of Tests done after : CVT burst out so it was not possible to
failure conduct any test after failure.
17 Conclusion/recommendations :
5 Make : HBB
16 Details of Tests done after : CVT burst out so it was not possible to
failure conduct any test after failure.
17 Conclusion/recommendations :
9.0 Failure of 16.67 MVAR, single phase, 400 kV Bus Reactor (B-phase) at
400 kV Amreli substation, Gujarat
15 Sequence of events/ :
Description of fault
All control cables for B-phase Bus Reactor were found burnt and damaged.
HV bushing of the reactor blasted and fire took place. Emulsifier pipe line for
reactor got damaged. Post Insulator connected adjacent to the reactor also got
damaged. Surge counter of LA connected in Y-phase was damaged.
17 Conclusion/recommendations :
Last test results of Oil DGA, capacitance and tan delta prior to the fault does
not indicate any abnormality in the oil, winding or bushing. However, IR
value in B-phase showed decrease in value from 2945 MΩ measured on
02.04.11 to 1270 MΩ measured on 07.12.11. IR value in B-phase was
registered 1460 MΩ on 29.02.12.
- 15 -
Operation of REF, bucholz and PRV indicates occurrence of fault inside tank.
LV test may be carried out on reactor after replacing the damaged bushings,
cables and LA. Oil may be tested for DGA and BDV.
Internal inspection may be carried out at site and its condition may be
assessed. If possible, the reactor may be repaired at site as per prevailing
practices and periodic maintenance schedule may be continued.
15 Sequence of events/ :
Description of fault
15 Sequence of events/ :
Description of fault
- 17 -
220 kV CT was connected in B-phase of HV side of 50 MVA, 220/66 kV
Transformer-I. At 01:15 hrs on 26.07.11, B-phase CT suddenly burst out.
Load was shifted to other transformer.
17 Conclusion/recommendations :
17 Conclusion/recommendations :
4 Rating : 220 kV
- 19 -
13 Details of previous : Information not available
maintenance
15 Sequence of events/ :
Description of fault
17 Conclusion/recommendations :
4 Rating : 400 kV
17 Conclusion/recommendations :
15 Sequence of events/ :
Description of fault
At 23:13 hrs, pole-I & II of converter breaker and tie breaker were tripped on
AC bus differential protection and AC bus overcurrent protection. Hence,
inspection of AC yard was carried out. During inspection, Y-phase CT of tie
bay was found blasted from secondary core terminal box with oil spreading
around the CT in AC yard.
17 Conclusion/recommendations :
15 Sequence of events/ :
Description of fault
17 Conclusion/recommendations :
M/s CGL is of the opinion that Y phase winding has been damaged.
Formation of acetylene gas in excess of threshold value indicates generation
of very high temperature which may be due to arcing in the tank. Operation of
differential relay, bucholz relay, AC supervision relay and PRV also indicates
occurrence of internal fault in transformer. LV tests also point towards internal
fault. M/s CGL is of the opinion that the transformer is not repairable at site.
Need for repairing may be evaluated on the basis of benefit cost analysis,
considering the fact that the transformer would need to be transported to
manufacturer’s works. It is noted that the transformer is 26 years old.
Periodic condition monitoring with the use of various diagnostic tools is
recommended for all substation equipment.
4 Rating : 400 kV
15 Sequence of events/ :
Description of fault
- 24 -
16 Details of Tests done after : Information not available
failure
17 Conclusion/recommendations :
Upon physical inspection, it was found that each stack diaphragm was opened
and leakage current monitor was burst.
Periodic condition monitoring with the use of diagnostic tools is
recommended.
5 Make : M/s WS
15 Sequence of events/ :
Description of fault
Oil leakage from CVT was noticed on 08.08.12 at 10:45 hrs during normal
- 25 -
maintenance. CVT was thoroughly examined and bushing was found
dislocated from the metal part of the CVT. Mild air crack was also noticed at
the bottom of the bushing and in metal part.
17 Conclusion/recommendations :
It is difficult to pin point any particular reason for failure of CVT. Since CVT
was in service for about 29 years, ageing may be one of the reasons for failure.
Periodic condition monitoring with the use of various diagnostic tools is
recommended for all substation equipment.
- 26 -
19.0 Summary of Failures of substation equipment in Tamil Nadu during 2011 to 2012 (September) for which brief information was
provided by Sh. B. Abdul Rahim, SE, TANTRANSCO during Meeting held on 30.10.12.
Sl. Name of the Equipment detailsMake & Sl. Date/Year of Date & Time Details of failure and action
No. Substation/ feeder No. Manufacturing/ of Failure taken
Commissioning
1. 230/110 kV 100 MVA, 230/110 NGEF YOM: 1999 28.12.2011 ‘W’ phase IV winding of the
Thudialur S/s kV, Auto 6800000180 DOC: 15.12.1999 23:34 Hrs transformer was found faulty.
Transformer DGA test result of oil taken on
13.05.2011 and BDV value of oil
taken from OLTC chamber on
07.07.11 were found satisfactory.
The transformer was replaced on
29.02.12.
2. 230 kV Kavanoor- 230 kV CVT (Y CGL YOM: 1995 13.10.2011 Y phase CVT burst out with huge
SIPCOT feeder phase) 8347 DOC: 07.02.2005 23:08 Hrs sound. B phase CVT petticoats
were also damaged. Feeder was
put into service with R phase CVT
alone on 14.10.11.
3. 230/110 kV 230 kV Main Bus CGL Not Available 10.01.2012 R phase PT burst out. Replaced
Alagarkoil S/s PT II (R phase) 11960 20:17 Hrs with new BHEL make PT on
31.01.12.
4. 230 kV 230 kV SF6 TELK YOM: 1988 29.02.2012 Y phase limb had not cleared the
Checkkanurani- Breaker (Y phase) 860028-2 DOC: 22.03.1990 08:05 Hrs fault in time even after opening of
TTPS-I feeder other limbs resulting in activation
of LBB protection. Overhauling
was done in Y phase limb and put
into service on 21.08.12.
5. 230 kV Kavanoor 230 kV Bus CVT CGL YOM: 1997 30.03.2012 B phase CVT failed and other 2
- 27 -
S/s (B phase); CVTs in 10054, 10055, DOC: 15.09.1997 13:15 Hrs phase CVTs were isolated from
all 3 phases 10057 the service due to high tan delta
replaced value. New CVTs commissioned
on 10.04.12.
6. 230 kV Theni- 230 kV PT TELK YOM: 1988 15.04.2012 PT burst out with heavy sound and
Moozhiyar (Metering) 730037-2 DOC: 27.03.1989 18:05 Hrs the spurt out oil caught fire.
interstate feeder at Internal fault and ageing is
230 kV Theni S/s suspected. New PT commissioned
on 18.04.12.
7. 230 kV Theni- 230 kV Wave Trap WSI YOM: 1988 15.04.2012 WT burnt out due to the oil spurt
Moozhiyar DOC: not 18:05 Hrs out from PT which burst at the
interstate feeder at available same time. New WT
230 kV Theni S/s commissioned on 18.04.12.
8. 230/110 kV 230 kV bus PT-II CGL Not available 05.06.2012 PT burst out with heavy sound
Alagarkoil S/s 11966 05:36 Hrs from the bottom side. New PT
commissioned on 14.06.12.
9. 230 kV Sembatty 230 kV SF6 TELK YOM: 1988 16.07.2012 Due to sluggish operation of
feeder at Breaker 860028-10 DOC: not 18:12 Hrs breaker limb and ageing, the fault
Checkkanurani S/s available was not cleared. 1 No defective
limb was rectified using the spares
available from the released failed
breaker limb and the breaker was
put into service on 24.07.12.
10. 230 kV Sembatty Bus II 230 kV CVT CGL YOM: 1995 21.07.2012 CVT burst out with heavy noise
S/s (B phase) 8443 DOC: not 19:52 Hrs due to internal fault. New CVT
available commissioned on 27.07.12.
11. 230 kV Sembatty Bus II 230 kV CVT CGL YOM: 1995 13.08.2012 CVT burst out with heavy noise
S/s (R phase) 8442 DOC: not 18:20 Hrs due to internal fault and ageing.
available
- 28 -
12. 230 kV Unjanai 230 kV CT TELK YOM: not 18.02.2011 Cause of failure is not known.
feeder in 400 kV 23014409 available 07:19 Hrs Failed CT to be devoluted into
K.R. Thoppur S/s DOC: 23.03.88 store as scrap. Replaced on
22.02.11.
13. 400 kV K.R. 230 kV Bus ‘B’ PT TELK YOM: not 12.10.2011 Cause of failure is not known.
Thoppur S/s (Y phase) 7300338 available 19:45 Hrs Failed PT to be devoluted into
DOC: 11.08.1988 store as scrap. Replaced on
23.10.11.
14. 230 kV Salem- 230 kV Breaker HBB YOM: not 04.11.2011 Cause of failure is not known.
K.R.Thoppur feeder 113150342 available 16:30 Hrs Failed breaker to be devoluted into
in 230 kV Salem DOC: 23.03.1989 store as scrap. Replaced on
S/s 23.11.11.
15. 230 kV Gobi feeder 230 kV CT Alstom YOM: not 05.12.2011 Cause of failure is not known.
in 400 kV K.R. 20051129 available 08:30 Hrs Failed CT to be devoluted into
Thoppur S/s DOC: 01.06.2007 store as scrap. Replaced on
16.12.11.
16. 400 kV 230 kV LA (R CGL YOM: 1999 25.08.2012 No associated tripping occurred at
Sriperumbudur S/s phase) 4853 DOC: 30.06.2002 16:46 Hrs the substation or at other
connected substations at the time
of the failure. No abnormality
observed in previous tests. Failure
is attributed to internal fault.
17. 230 kV Udayathur 230 kV CT Alstom YOM: not 02.12.11 CT burst out with heavy noise and
feeder in 230 kV 20051022 available 08:17 Hrs fire due to suspected internal fault.
Kayathar S/s DOC: 12.03.2007 Replaced on 04.02.11.
18. 230/110 kV 230 kV LA (B CGL YOM: 1999 22.11.2011 230 kV HV II & 110 kV LV II
Pudukkottai S/s phase) connected 4887 DOC: 16.10.2000 16:04 Hrs breaker tripped due to differential
with Auto relay acted in Auto transformer II.
Transformer-II On inspection LA was found failed
- 29 -
and surge monitor charred. Failure
is attributed to weak stacks in LA.
New LA commissioned on
23.11.11.
19. 230 kV Karaikudi 230 kV CT (R & Y TELK YOM: 1979 29.10.2011 CT connected in R phase of 230
feeder in 230/110 phase) 230068-10 & DOC: 25.10.1980 00:06 Hrs kV Karaikudi feeder burst out
kV Thiruvarur S/s 230068-9 suddenly and oil spurt out with fire
surrounding it. The porcelain
petticoats were broken into pieces
which eventually damaged
adjacent Y phase CT also. All 230
kV breakers tripped. Failure may
be attributed to ageing. New CTs
in both the phases commissioned
on 30.10.11.
Submitted by
- 30 -
MINUTES OF MEETING OF THE STANDING COMMITTEE OF EXPERTS
TO INVESTIGATE THE FAILURE OF 220 KV AND ABOVE VOLTAGE
CLASS SUBSTATION EQUIPMENT HELD ON 30-10-2012 IN CEA, NEW
DELHI IN CONNECTION WITH REPORTED FAILURES FROM OCTOBER
2011 TO SEPTEMBER 2012 AT VARIOUS SUBSTATIONS IN THE
COUNTRY
-------------------------------------------------------------------------------------------------------
The list of participants is enclosed as Annexure-1.
Dr. Prabhat Mohan, Chief Engineer-I/C (SETD) and Chairman of the Standing
Committee of Experts to investigate the failure of 220 kV and above voltage class
substation equipment, welcomed the participants. He expressed concern about very
low attendance in the meeting. No representative from MSETCL, GETCO, NEEPCO,
CSPTCL & OPTCL, who were Owners of the substations where equipment failure
had occurred, attended the meeting. Most noted was the absence of representative of
MSETCL which had reported six incidents of equipment failure. The regular
members of the Committee, viz. representatives of PGCIL, CPRI & IIT, were also not
present.
The Chairman of the Committee requested DTL to give their views on the
possible causes of failure of power transformers at Rohini and Indraprastha
substations. DTL representatives informed that the transformer at Rohini was slightly
overloaded for the last 4 years. They also informed that since the transformer had
completely burned, it was not possible to perform any test after failure. DTL informed
that regular maintenance and testing is performed as per prevailing practices. Latest
DGA, Oil BDV and capacitance & tan delta measurement tests were found
satisfactory. The Committee was of the view that operation of differential, bucholz
and master trip relay indicates towards internal fault which caused failure and burning
of the transformer. However, the absence of any fire fighting system at the substation
(in fact at most of the substations of DTL as informed by their representatives) was a
cause of concern to the Committee. The Committee was of the view that DTL must
install High Velocity Water Spray System or Nitrogen based Fire Protection System
at their substations as soon as possible. DTL informed that at new/existing substations,
Nitrogen based Fire Protection System was being provided, but due to a court case
there was some delay.
DTL informed that the transformer at Indraprastha also did not have any
history of failure. This transformer had served for about 26 years and ageing could be
one reason for failure. Last two DGA tests of oil were satisfactory except rising trend
in formation of CO2 which may be due to overheated cellulose. Last tan delta and
capacitance test before failure carried out on 03.03.10 also did not show any
abnormality. LV tests and DGA were performed after failure and acetylene was found
above its threshold value. Operation of differential, bucholz & AC supervision relay
and PRV indicate towards internal fault.
DTL informed that at many substations the power transformers are overloaded
from April to July and the high temperature of the transformer over several months
might be one reason for failure.
- 31 -
The Committee also suggested that DTL make changes, if required, in the
power transformer specifications to avoid frequent failures. DTL might ask
manufacturers for a longer warranty period.
Sh. Satbir Singh, SE, SRPC, informed that in Southern Region protection
audit of important substations was being done. This was appreciated by the
Committee.
The Committee was of the view that various diagnostic tools as suggested in
Central Electricity Authority (Technical Standards for Construction of Electrical
Plants and Electric Lines) Regulations, 2010, should be used regularly for periodic
maintenance and condition based maintenance of substation equipment.
- 32 -
Annexure - I
LIST OF PARTICIPANTS
TANTRANSCO, Tamilnadu
- 33 -