Failure Report October 11 To September 12 PDF

REPORT
ON
FAILURE OF
220 KV AND ABOVE VOLTAGE CLASS
SUBSTATION EQUIPMENT
CENTRAL ELECTRICITY AUTHORITY

MINISTRY OF POWER
GOVERNMENT OF INDIA
NEW DELHI
NOVEMBER, 2012
TABLE OF CONTENTS
Subject Pages
Introduction 2
Substation equipment failures reported between October 3-26

2011 and September 2012
Summary of Substation equipment failures reported 27-30

during meeting held on 30.10.2012
Minutes of meeting of Standing Committee held on 31-33

30.10.2012
Order constituting Standing Committee 34-35
-1-
1.0 Introduction
In order to investigate the failure of 220 kV and above substation equipment

and recommend measures to avert recurrence, a Standing Committee under
Section 73, Clause(1) of the Electricity Act, 2003, comprising experts in the
field of design and operation of EHV Substations from CEA, various power
utilities and research/academic institutes was constituted. As part of such
activity, CEA has received between October, 2011 and 30th September, 2012,
failure reports in respect of following equipments from various utilities:
a) 100 MVA, 220/66/11 kV Power Transformer at 220 kV Rohini

substation, Delhi
b) 16.67 MVAR, single phase, 400 kV Bus Reactor (Y-phase) at 400 kV
Amreli substation, Gujarat
c) 125 MVA, 220/132 kV Power Transformer at Bhatapara substation,
Raipur (C.G.)
d) 220 kV SF6 Current Transformer at 400/220/132 kV Meramundali
Substation, Odisha
e) 20 MVA, single phase, 11/220/√3 kV Generator Transformer of 4x50
MW Kopili Hydro Power Station of NEEPCO, Assam
f) 230 kV Capacitor Voltage Transformer (Y-phase) at 230 kV Cuddalore
substation, Tamilnadu
g) 230 kV Capacitor Voltage Transformer (Y-phase) at 230 kV Trichy
h) 16.67 MVAR, single phase, 400 kV Bus Reactor (B-phase) at 400 kV
Amreli substation, Gujarat
i) 220 kV Current Transformer (B-phase) at 220 kV Warora substation,
Maharashtra
j) 220 kV Current Transformer (B-phase) at 220 kV Warora substation,
Maharashtra
k) 220 kV Lightning Arrester (R-phase) at 220 kV Wardha substation,
Maharashtra
l) 220 kV Coupling Capacitor (B-phase) at 220 kV Butibori TSS,
Maharashtra
m) 400 kV Lightning Arrester (B-phase) at 400 kV Chandrapur substation,
Maharashtra
n) 400 kV Current Transformer at 500 kV HVDC Terminal station
Chandrapur, Maharashtra
o) 100 MVA, 220/33 kV Power Transformer at 220 kV Indraprastha
substation, Delhi
p) 400 kV Lightning Arrester (B-phase) at 400 kV Alamathy substation,
Chennai, Tamil Nadu
q) 230 kV Capacitor Voltage Transformer (B-phase) at 230 kV
Villupuram substation, Tamilnadu
Salient features of each of the substations and analysis of failure of equipment

are detailed in pages 3 to 26, incorporating the views of the Standing
Committee noted in its meeting held on 30th October, 2012. During the
meeting TANTRANSCO, Tamil Nadu, submitted brief information on 19
-2-
more cases of substation equipment failure of 220 kV and above. A summary
statement on these 19 failures is contained in pages 27 to 30. The minutes of
the meeting are at pages 31-33. The analysis of some failures remains partial
due to non-submission of details by the respective utilities or absence of the
utilities in the meeting of the Standing Committee.
2.0 Failure of 100 MVA, 220/66/11 kV Power Transformer-III at 220 kV

Rohini substation, Delhi
1 Name of Substation : 220 kV Rohini substation, Delhi
2 Utility/Owner of substation : Delhi Transco Ltd. (DTL)
3 Faulty Equipment : Power Transformer-III
4 Rating : 100 MVA, 220/66-33/11 kV
5 Make : Crompton Greaves Ltd. (CGL)
6 Sr. No. : BH8930/1
7 Year of manufacturing : 2003
8 Year of commissioning : 2004 (31st March)
9 Date and time of : 17.10.11; 18:45 Hrs.

occurrence/discovery of fault
10 Information received in CEA : October 2011
11 Fault discovered during : Operation
12 Present condition of : Replaced

equipment
13 Details of previous : Last measurements of capacitance and
maintenance tan delta of bushings and windings of
transformer were carried out on 24.11.10
and results were found satisfactory.
Last DGA test of oil was carried out on
17.03.11 and no abnormality was
observed; BDV was 70 kV.
Magnetic balance test and measurement
of magnetizing current, IR value and
transformer earthing resistance were
performed on 19.08.11 and results were
found satisfactory.
14 Details of previous failure : None
15 Sequence of events/ :
-3-
Description of fault
On 17.10.11 at 18:45 hrs transformer –III tripped alongwith operation of

following protection systems:
a. Differential protection (87)

b. Bucholz trip (30A)
c. Bucholz alarm (30D)
d. Master relay (86A & 86B)
On-duty operation staff rushed to the yard and found fire at 100 MVA
transformer-III. The staff used all available fire extinguishers to put down the
fire but fire could not be controlled because of very high intensity. The fire
was brought under control by fire tenders used by fire brigade personnel.
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.
16 Details of Tests done after : As the transformer had completely

failure burned, tests could not be performed
after failure.
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.
Operation of differential protection, master relay and bucholz relay indicates

occurrence of fault inside tank. It is understood that the transformer-III has
completely been damaged due to fire and is beyond repair.
Most substations of DTL are running overloaded. It is recommended to reduce

the load as a short term measure and provide additional transformation
capacity as a long term measure. DTL must install High Velocity Water Spray
System or Nitrogen based Fire Protection System at their substations as soon
as possible.
3.0 Failure of 16.67 MVAR, single phase, 400 kV Bus Reactor (Y-phase) at
400 kV Amreli substation, Gujarat
1 Name of Substation : 400 kV Amreli substation, Gujarat
2 Utility/Owner of substation : Gujarat Energy Transmission Corp. Ltd.

(GETCO)
-4-
3 Faulty Equipment : Bus Reactor (Y-phase)
4 Rating : 16.67 MVAR, single phase, 400 kV
6 Sr. No. : 24527
8 Year of commissioning : Reactor was earlier commissioned at

Jetpur as line reactor on Asoj line. It was
re-commissioned at Amreli as bus
reactor on 21.12.2000.

10 Information received in CEA : 26.12.11
12 Present condition of : Awaiting repair/replacement

equipment
13 Details of previous : Periodical maintenance (i.e.

maintenance measurement of IR value, cleaning of
bushings and clamp connectors, bucholz
trip test, WTI/OTI alarm/trip test,
replacement of silica gel, observing oil
level of bushing and conservator tank
etc.) was being carried out since
commissioning.
Thermo graphical inspection for clamps
& connectors of reactor was carried out
on 19.11.11 and no hot spots were
observed.
Last measurements of capacitance and
tan delta of bushings and windings of
reactor were carried out on 07.12.10 and
results were found satisfactory. DGA
test of oil was carried out on 20.09.10
and no abnormality was observed.
IR value and PI were measured on
02.04.11 and found satisfactory.
14 Details of previous failure : No history of faults
-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.
Following protection systems had operated:

a. Restricted Earth Fault (REF) protection
b. Bucholz trip (R,Y & B phase)
c. Pressure Relief Valve (PRV) trip (Y-phase)
High winding and oil temperature was recorded in Y-phase Reactor.
16 Details of Tests done after : Information not available

failure
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.
4.0 Failure of 125 MVA, 220/132 kV Power Transformer at Bhatapara

substation, Raipur (C.G.)
1 Name of Substation : 220/132/33 kV Bhatapara substation,

Raipur, Chhattisgarh
2 Utility/Owner of substation : Chhattisgarh State Power Transmission

Company Ltd.
-6-
3 Faulty Equipment : Power Transformer
4 Rating : 125 MVA, 220/132/11 kV; YNyao11
5 Make : Bharat Heavy Electricals Ltd. (BHEL),

Bhopal
6 Sr. No. : 600447
8 Year of commissioning : 1984 (14th April)


equipment
13 Details of previous : On 05.11.11, IR value & PI test, Oil

maintenance BDV test, Oil DGA, magnetizing
current test and magnetic balance test
were conducted and found OK.
14 Details of previous failure : Did not fail; however, transformer

tripped many times during its service
life (differential tripping -9 nos., bucholz
tripping-3 nos., overcurrent indication
HV side-11 nos.; LV side 3 nos.,
earthfault tripping-6 nos., Oil surge
Relay tripping-2 nos., without
indication-4 nos.)
At 220kV S/S Bhatapara, on 31/12/2011 at 21:35 hrs. 40MVA, 132/33 kV

transformer tripped on differential relay operation. Alongwith, following three
nos. 220/132 kV transformers of this S/S also tripped from 132 kV side:
(a) 125 MVA transformer-I(BHEL make): 132 kV side B phase overcurrent

relay operated
(b) 125 MVA transformer-II (GEC make): 132kV side R phase overcurrent
relay operated
(c) 160 MVA transformer: 132 kV side R phase overcurrent relay operated
These trippings were associated with bursting of B-phase 132 kV Lightning

-7-
Arrester and Y pole of 132 kV Circuit Breaker of 40MVA transformer bay.
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 02:40 hrs on 01/01/2012, R phase LA of 132 kV Akaltara feeder burst

causing tripping of the feeder with indication R-N Zone-1 in Distance relay.
Simultaneously, 132 kV Railway Traction –I feeder tripped with E/F
indication and 125 MVA transformer-I tripped from both side after bucholz
alarm & Trip relay on 220 kV side and master relay on 132 kV side operated.
It was raining heavily and atmosphere temperature was down to 15oC.
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.
Complete testing of the transformer was carried out after this.
Abnormalities observed in B-phase in Magnetizing Current Test, Magnetic

Balance Test, Frequency Response Analysis and Turns Ratio Test. The
transformer was declared defective.
16 Details of Tests done after : Oil BDV test, insulation resistance test,
failure ratio test, magnetic balance test,
magnetizing current test and FRA
Transformer body and all accessories are intact. Excessive magnetizing

current in B-phase, abnormal results in magnetic balance test and turns ratio
test indicate some internal problem in B-phase HV winding. The transformer
has served for 27 years and 8 months. Due to ageing winding insulation might
have deteriorated and some surge got through to the winding after bursting of
LA. The test reports were forwarded to BHEL for examination. As per their
opinion also there is some problem in B-phase winding. Layer type winding
design was adopted by BHEL for this transformer manufacture and this design
has now become obsolete; facilities for repairing the winding are not
available.
-8-
5.0 Failure of 220 kV SF6 Current Transformer at Meramundali substation,
Odisha
1 Name of Substation : 400/220/132 kV grid substation,

Meramundali, Odisha
2 Utility/Owner of substation : Orissa Power Transmission Corporation

Ltd.
3 Faulty Equipment : SF6 Current Transformer (CT) in 220

kV Kaniha-I bay (bay-15)
4 Rating : 220 kV
5 Make : Siemens
6 Sr. No. : 10509002
8 Year of commissioning : 2010 (16th March)

12 Present condition of : Replaced with new oil filled CT of

equipment Areva make
13 Details of previous : Nil

maintenance
14 Details of Previous failure : Nil
On 15.02.12 at 17:13 Hrs 220 kV Meramundali-Kaniha ckt-I tripped

alongwith tripping of 315 MVA, 400/220kV ICT-II and 220 kV Kaniha ckt-
II. Then at 18:20 Hrs on same day charging of 220 kV Kaniha ckt-I was
attempted from Meramundali end but the line did not hold.
During inspection of the equipments in Kaniha ckt-I feeder, it was observed

that SF6 gas inside the R-phase CT of the feeder had leaked out by rupturing
the top diaphragm. SF6 pointer in density monitor was at maximum level.
Since SF6 loss alarm was found open, there was no alarm, after leakage of
gas, in the control room. Blacking was found at earth flat connection point.
-9-
Faulty CT was replaced with a new CT and the feeder was charged
successfully on 23.02.12 at 17:03 Hrs.
16 Details of Tests done after : Visual inspection, IR test, ratio test and
failure secondary continuity test were done.
Results of tests found satisfactory.
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.
6.0 Failure of 20 MVA, single phase, 11/220/√3 kV Generator Transformer of

4x50 MW Kopili Hydro Power, Assam
1 Name of Substation : 4x50 MW Kopili Hydro Power Station

Switchyard, Dima Hasao, Assam
2 Utility/Owner of substation : North Eastern Electric Power

Corporation Ltd. (NEEPCO)
3 Faulty Equipment : Generator Transformer (GT)
4 Rating : 20 MVA, single phase, 11/220/√3 kV
6 Sr. No. : 24115
8 Year of commissioning : 1988


equipment
13 Details of previous : Insulating oil was tested in CPRI on

maintenance 25.10.2011 and was found OK.

- 10 -
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 following relays operated:

1. Trip relay 86A, 86B, 86C
2. GT ‘A’ phase bucholz trip realy 83GTX
3. GT differential ‘A’ Ph 87 GTA
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.
On checking Phase-A of GT, the following were observed:

(a) Accumulation of gas was observed in bucholz relay
(b) Oil level in conservator dropped to almost empty mark
(c) Oil leakage from two nos. of heat exchanger cooler tube
16 Details of Tests done after : Oil BDV test, insulation resistance test,
failure ratio test and magnetizing current test
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.
Operation of differential relay indicates internal fault in GT and operation of

bucholz relay indicates formation of gases inside GT. Results of tests done
after failure indicate deterioration of insulation resistance and insulating oil.
Since the GT was commissioned in 1988, ageing may also be one of the
reasons for insulation deterioration. GT may be opened after consultation with
manufacturer and its condition from inside may be assessed for whether it
could be repaired.
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.
If windings are to be replaced at site, the same needs to be done as per

manufacturer’s recommended practices.
Periodic maintenance of Generator Transformer using diagnostic tools is

recommended.
7.0 Failure of Y-phase, 230 kV Capacitor Voltage Transformer (CVT) at 230

kV Cuddalore substation, Tamilnadu
1 Name of Substation : 230/110 kV Cuddalore substation,

Tamilnadu
2 Utility/Owner of substation : Tamilnadu Transmission Corp. Ltd.

(TANTRANSCO)
3 Faulty Equipment : CVT (Y-phase)
4 Rating : 230 kV/110 V
6 Sr. No. : 9701/1997
8 Year of commissioning : 1998 (28th February)

12 Present condition of : Replacement under process

equipment
13 Details of previous : Megger value was ≥ 500 MΩ measured

maintenance on 12.03.12
14 Details of previous failure : Nil
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.
Since no protection operated, it is difficult to pin point any particular reason

for failure of CVT. However, ageing may be one of the reasons. Periodic
condition monitoring with the use of various diagnostic tools is recommended
for all substation equipment.
8.0 Failure of Y-phase, 230 kV Capacitor Voltage Transformer (CVT) at 230

kV Trichy substation, Tamilnadu
1 Name of Substation : 230/110 kV Trichy substation,

Tamilnadu

(TANTRANSCO)
3 Faulty Equipment : CVT (Y-phase)
4 Rating : 230 kV/110 V
5 Make : HBB
6 Sr. No. : IB048299
7 Year of manufacturing : Information not available
8 Year of commissioning : 1984 (9th March)


equipment
13 Details of previous : Information not available

maintenance
14 Details of previous failure : Information not available

- 13 -
230 kV CVT was connected in Trichy-Alundur-II feeder. On 28.02.12,CVT

suddenly burst out and oil spurt out with fire surrounding it. The porcelain
petticoats were broken into pieces. No protection operated and no tripping
took place. The associated breaker was hand tripped at both ends since the
feeder was in tied condition. The faulty CVT was removed and feeder was
charged without CVT.
16 Details of Tests done after : CVT burst out so it was not possible to
Since no protection operated, it is difficult to pin point any particular reason

for failure of CVT. Since CVT was in service for about 28 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.
9.0 Failure of 16.67 MVAR, single phase, 400 kV Bus Reactor (B-phase) at
400 kV Amreli substation, Gujarat
1 Name of Substation : 400 kV Amreli substation, Gujarat
2 Utility/Owner of substation : Gujarat Energy Transmission Corp. Ltd.

(GETCO)
3 Faulty Equipment : Bus Reactor (B-phase)
4 Rating : 16.67 MVAR, single phase, 400 kV
6 Sr. No. : 24530
8 Year of commissioning : Reactor was earlier commissioned at

Jetpur as line reactor on Asoj line. It was
recommissioned at Amreli as bus reactor
on 21.12.2000.


- 14 -
equipment
13 Details of previous : Periodical maintenance (i.e.

maintenance measurement of IR value, cleaning of
bushings and clamp connectors, bucholz
trip test, PRV trip test, WTI/OTI
alarm/trip test, replacement of silica gel,
observing oil level of bushing and
conservator tank etc.) was being carried
out since commissioning.
Last measurements of capacitance and
tan delta of bushings and windings of
reactor and DGA test of oil were
carried out on 01.03.12 and results were
found satisfactory.
Top cover gasket, HV bushing, damaged
cables, WTI & OTI were replaced; oil
was filtered and all routine tests and
tripping tests were carried out on
05.03.12.
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.
Following protection systems had operated:

a. Restricted Earth Fault (REF) protection
b. Bucholz trip (R,Y & B phase)
c. Pressure Relief Valve (PRV) trip
High winding and oil temperature was recorded in B-phase Reactor.

failure
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.
10.0 Failure of B-phase, 220 kV Current Transformer (CT) at 220 kV Warora

substation, Maharashtra
1 Name of Substation : 220 kV Warora substation, Maharashtra
2 Utility/Owner of substation : Maharashtra State Electricity

Transmission Co. Ltd. (MSETCL)
3 Faulty Equipment : CT (B-phase) in Warora-Chandrapur

feeder
4 Rating : 220 kV; 1200-600/1 A
5 Make : M/s Universal Magnoflux Ltd., Indore
6 Sr. No. : 12768
8 Year of commissioning : Information not available


equipment

maintenance
220 kV CT was connected in Warora-Chandrapur feeder. At 18:39 hrs on

08.02.12, B-phase CT suddenly burst out with fire surrounding it. All 10 core
- 16 -
control cables from R,Y&B phase CT to CT marshalling box got damaged
due to fire.
16 Details of Tests done after : CT burst out so it was not possible to

No additional information was provided by the utility in spite of reminders.

Hence no concrete reason may be ascertained for failure. However, periodic
11.0 Failure of B-phase, 220 kV Current Transformer (CT) at 220 kV Warora

1 Name of Substation : 220 kV Warora substation, Maharashtra

3 Faulty Equipment : CT (B-phase) associated with 50 MVA,

220/66 kV Transformer-I
4 Rating : 220 kV; 800-400/1-1-1-1-1 A
5 Make : M/s ABB
6 Sr. No. : ID 220820


equipment

maintenance
- 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.


12.0 Failure of R-phase, 220 kV Lightning Arrester (LA) at 220 kV Wardha

1 Name of Substation : 220 kV Wardha substation, Maharashtra

3 Faulty Equipment : LA (R-phase) associated with 50 MVA,

220/66 kV Transformer-I
4 Rating : 220 kV; 1200-600/1 A
5 Make : M/s Elpro
6 Sr. No. : A-0428-83-1895
8 Year of commissioning : 1975


equipment

maintenance

- 18 -
At 07:17 hrs on 05.10.11, R-phase LA associated with 50 MVA, 220/66 kV

Transformer-I burst. Simultaneously, 220 kV feeders CBs not tripped at
Wardha end but remote end CBs tripped.
16 Details of Tests done after : LA burst out so it was not possible to


Hence no concrete reason may be ascertained for failure. However, since CVT
was in service for about 36 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.
13.0 Failure of B-phase, 220 kV Coupling Capacitor at 220 kV Butibori TSS,

Maharashtra
1 Name of Substation : 220 kV Butibori substation, Maharashtra

3 Faulty Equipment : Coupling Capacitor (B-phase)
4 Rating : 220 kV
5 Make : M/s CGL
6 Sr. No. : 114821


equipment
- 19 -
maintenance
B-phase coupling capacitor of 220 kV TSS-Butibori circuit burst at TSS end at

20:02 hrs.
16 Details of Tests done after : No test could be done after failure as
failure coupling capacitor had burst.

14.0 Failure of B-phase, 400 kV Lightning Arrester (LA) at 400 kV

Chandrapur substation, Maharashtra
1 Name of Substation : 400 kV Chandrapur substation,

Maharashtra

3 Faulty Equipment : LA (B-phase)
4 Rating : 400 kV
5 Make : M/s Elpro International, Hyderabad
6 Sr. No. : 54 ABCD


equipment
- 20 -
maintenance
15 Sequence of events/ : Information not available


failure

15.0 Failure of 400 kV Current Transformer (CT) at 500 kV HVDC Terminal

Station Chandrapur, Maharashtra
1 Name of Substation : 500 kV HVDC Terminal Station,

Chandrapur, Maharashtra

3 Faulty Equipment : CT (Y-phase) (tie breaker bay)
4 Rating : 400 kV; 2000/1 A; 7 core
5 Make : M/s Universal Magnoflux Ltd., Indore
6 Sr. No. : Information not available


equipment
- 21 -
maintenance
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.


16.0 Failure of 100 MVA, 220/33 kV Power Transformer at 220 kV substation

Indraprastha, Delhi
1 Name of Substation : 220 kV Indraprastha Substation, Delhi
2 Utility/Owner of substation : Delhi Transco Ltd. (DTL)
3 Faulty Equipment : Power Transformer
4 Rating : 100 MVA, 220/33 kV
5 Make : M/s Crompton Greaves Ltd.
6 Sr. No. : 24669
8 Year of commissioning : 1986 (at GTPS); recommissioned in Dec

2009 at 220 kV IP S/s

- 22 -
equipment
13 Details of previous : Last DGA test of oil was carried out on

maintenance 24.02.12 and CO2 gas concentration was
on higher side.
Tan delta & capacitance measurement of
bushing were carried out on 03.03.10
and no abnormality was observed.
On 24.07.12 at 06:25 hrs, transformer tripped off on differential protection

relay, bucholz relay, AC supervision relay and PRV.
Later on the same day, magnetic balance test and measurement of

magnetizing current, voltage ratio, and DC resistance were performed by
centralized testing lab of DTL which were not found in order as compared
with previous values. Transformer oil DGA was also done which shows
excessive presence of gases including high amount of Acetylene.
No external abnormality in transformer was observed during physical

inspection. Internal inspection was carried out by representative of M/s CGL
and some copper granules were found on top of HV side Y-phase winding.
16 Details of Tests done after : Magnetic balance test and measurement

failure of magnetizing current, voltage ratio, IR
value, and DC resistance and DGA were
performed.
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.
Most substations of DTL are running overloaded. It is recommended to reduce

the load as a short term measure and provide additional transformation
- 23 -
capacity as a long term measure. DTL must install High Velocity Water Spray
System or Nitrogen based Fire Protection System at their substations as soon
as possible.
17.0 Failure of B-phase, 400 kV Lightning Arrester (LA) at 400 kV Alamathy

1 Name of Substation : 400 kV Alamathy substation, Tamilnadu

(TANTRANSCO)
3 Faulty Equipment : LA (B-phase) associated with 400/110

kV Auto transformer
4 Rating : 400 kV
5 Make : M/s CGL
6 Sr. No. : 26188
8 Year of commissioning : 2006 (16th June)


equipment
maintenance
14 Details of previous failure : Nil
HV & LV side breakers of auto transformer tripped with following

indications:
- Transformer protection 87T-Hi Set
- Back impedance 21T –Start C, Start N
- Auxiliary Relay: Group relay 86A & 86B
- Multiplier: 86 AX, 86BX
- 24 -
failure
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.
18.0 Failure of B-phase, 230 kV Capacitor Voltage Transformer (CVT) at 230

kV Villupuram substation, Tamilnadu
1 Name of Substation : 230/110 kV Villupuram substation,

Tamilnadu

(TANTRANSCO)
3 Faulty Equipment : CVT (B-phase)
4 Rating : 230 kV/110 V
5 Make : M/s WS
6 Sr. No. : 780110
8 Year of commissioning : 1983 (24th January)

11 Fault discovered during : Maintenance

equipment

maintenance
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.
16 Details of Tests done after : Megger test on CVT was performed.

failure However, the kV rating of the megger is
not known.
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.
- 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
(Dr. Prabhat Mohan)

Chief Engineer-I/c (SETD) &
Chairman, Standing Committee to investigate the failure
of 220 kV & above substation equipment
- 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.
Failure of equipment at substations in Tamilnadu was discussed with Shri B.

Abdul Rahim, S.E., TANTRANSCO. He informed that faulty CVTs at Cuddalore,
Trichy and Villupuram have been replaced. Since no protection operated in case of
failure at Cuddalore and Trichy, it was difficult to pin point any particular reason for
failure. Sh. Rahim pointed out that all periodic testing of substation equipment is done
by a separate testing wing. He also informed that service life of CVT is generally
considered to be 15 years. CVTs at Cuddalore, Trichy and Villupuram had served for
14 years, 28 years and 29 years respectively. As the CVTs at Trichy and Villupuram
had served for 28 and 29 years respectively, so ageing may be the reason for their
failure. Not much information was available with the Committee in respect of failure
of 400 kV LA at Alamathy substation. Sh. Rahim agreed to provide more information
through E-mail to the secretariat of the Committee.
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.
The meeting ended with thanks to the chair.
- 32 -
Annexure - I
LIST OF PARTICIPANTS
Central Electricity Authority, New Delhi
1. Dr. Prabhat Mohan, Chief Engineer-I/C (SETD)

2. Shri Y.K.Swarnkar, Deputy Director (SETD)
3. Shri S. Chandrasekhar Rao, Deputy Director (SETD)
Southern Regional Power Committee, Bengaluru
Shri Satbir Singh, S.E.
Delhi Transco Ltd., Delhi
1. Shri S. Sutradhar, 220 kV O&M VII

2. Shri T.R.Tuteja, 220 kV I
3. Shri S.S.Gupta, 220 kV S/S Rohini
4. Shri Sunil Varshney, 220 kV S/S Rohini
5. Shri Deepak Mehdiratta, 220 kV S/S Shalimar Bagh
6. Shri Hari Gopal, 220 kV S/S Indraprastha
TANTRANSCO, Tamilnadu
Shri B. Abdul Rahim, S.E., Villupuram
- 33 -

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REPORT

220 KV AND ABOVE VOLTAGE CLASS

CENTRAL ELECTRICITY AUTHORITY

Substation equipment failures reported between October 3-26

Summary of Substation equipment failures reported 27-30

Minutes of meeting of Standing Committee held on 31-33

Order constituting Standing Committee 34-35

In order to investigate the failure of 220 kV and above substation equipment

a) 100 MVA, 220/66/11 kV Power Transformer at 220 kV Rohini

Salient features of each of the substations and analysis of failure of equipment

2.0 Failure of 100 MVA, 220/66/11 kV Power Transformer-III at 220 kV

1 Name of Substation : 220 kV Rohini substation, Delhi

2 Utility/Owner of substation : Delhi Transco Ltd. (DTL)

3 Faulty Equipment : Power Transformer-III

4 Rating : 100 MVA, 220/66-33/11 kV

5 Make : Crompton Greaves Ltd. (CGL)

6 Sr. No. : BH8930/1

7 Year of manufacturing : 2003

8 Year of commissioning : 2004 (31st March)

9 Date and time of : 17.10.11; 18:45 Hrs.

10 Information received in CEA : October 2011

11 Fault discovered during : Operation

12 Present condition of : Replaced

14 Details of previous failure : None

On 17.10.11 at 18:45 hrs transformer –III tripped alongwith operation of

a. Differential protection (87)

16 Details of Tests done after : As the transformer had completely

Operation of differential protection, master relay and bucholz relay indicates

Most substations of DTL are running overloaded. It is recommended to reduce

1 Name of Substation : 400 kV Amreli substation, Gujarat

2 Utility/Owner of substation : Gujarat Energy Transmission Corp. Ltd.

4 Rating : 16.67 MVAR, single phase, 400 kV

5 Make : Crompton Greaves Ltd. (CGL)

6 Sr. No. : 24527

7 Year of manufacturing : 1985

8 Year of commissioning : Reactor was earlier commissioned at

9 Date and time of : 07.12.11; 02:57 Hrs.

10 Information received in CEA : 26.12.11

11 Fault discovered during : Operation

12 Present condition of : Awaiting repair/replacement

13 Details of previous : Periodical maintenance (i.e.

14 Details of previous failure : No history of faults

Following protection systems had operated:

High winding and oil temperature was recorded in Y-phase Reactor.

16 Details of Tests done after : Information not available

4.0 Failure of 125 MVA, 220/132 kV Power Transformer at Bhatapara

1 Name of Substation : 220/132/33 kV Bhatapara substation,

2 Utility/Owner of substation : Chhattisgarh State Power Transmission

4 Rating : 125 MVA, 220/132/11 kV; YNyao11

5 Make : Bharat Heavy Electricals Ltd. (BHEL),

6 Sr. No. : 600447

7 Year of manufacturing : 1982

8 Year of commissioning : 1984 (14th April)

9 Date and time of : 01.01.12; 02:40 Hrs.

11 Fault discovered during : Operation

12 Present condition of : Replaced

13 Details of previous : On 05.11.11, IR value & PI test, Oil

14 Details of previous failure : Did not fail; however, transformer

At 220kV S/S Bhatapara, on 31/12/2011 at 21:35 hrs. 40MVA, 132/33 kV

(a) 125 MVA transformer-I(BHEL make): 132 kV side B phase overcurrent

These trippings were associated with bursting of B-phase 132 kV Lightning

At 02:40 hrs on 01/01/2012, R phase LA of 132 kV Akaltara feeder burst