Friday 23 October 2015

General Introduction of Electrical Sub-Station arrangment and maintenance

 Maintenance, erection and Operation of An Electrical substations

Importance:

The EHT Electrical sub-Stations are most important to transmit the power by transmission line to the load center without more deviation of the quality of the Power supply i.e to avoid voltage drop, Power loss due to high currents.
Aim:
Transmission of the power supply from generating stations to Load centers for long distances also without much voltage drop and power loss, with optimum quality to the consumer.

Requirement:

The LT voltage useful at consumer end is 3Ø 415 to 440V  or 1Ø 220 to 250V, But the generating stations are generating the power with 3h. 11KV which is to be transmitted to the far away to load centers. Due to high load current of the 11KV/440V Sub-Stations directly under the generating stations, the I2R i.e heat loss is more and voltage drop is very high. The consumer end voltage may drop very high level order of 40%. The devices of the consumer may not be operative. Hence the 11KV Power generated up to 400KV, to be transmitted and step down to deferent voltage levels [e.g 220KV à132KVà33KVà11KVà415 to440V] as per the distances and variation of the load or demand at various areas. Hence it is required to construct the electrical sub-stations at various voltage levels to transmit the power by lines.

Electrical sub-station: the electrical sub-station mainly consists of Transformers for step up at generating station and step down the voltage at load centers and in between. The transformers feeds the number of feeders with secondary voltage with the LV current=Ratio XHV current. Here Mainly Transformers step down the voltage without much change its input power to output power and frequency with small transformer losses i.e about 0.3% of copper and Iron or no load loss out of its input power.

**[Important note: The DC voltage transmission is not possible by any transformer as it does not works with zero frequency. The transformer works with the principle of Faraday's loss of electromagnetic induction i.e rate of change of electromagnetic flux which not possible in DC i.e without frequency.]

Brief explanation of EHT Sub-stations [220/132KV and 132/33K Sub-Stations

EHV (Extra High Voltage) Sub-Station forms an important link between Transmission network and Distribution network. It has a vital influence of reliability of service. Apart from ensuring efficient transmission and Distribution of power, the sub-station configuration should be such that it enables easy maintenance of equipment and minimum interruptions in power supply. Flexibility for future expansion in terms of number of circuits and transformer MVA Capacity also needs to be considered while choosing the actual configuration of the substation.EHV Substation is constructed as near as possible to the load centre. The voltage level of power transmission is decided on the quantity of power to be transmitted to the load centre. Generally, the relation between EHV Voltage level and the power to be transmitted is as follows:

1)                  Up to 80MVA to 132KV/33KV.2) From 100MVA to 300MVA 220KV/132KV.) 300 MVA to 1000 MVA 400 KV/220KV.


*SIGNIFICANT NOTES TO BE  CONSIDERED  DURING  LAYING OUT OF THE EHT  SUBSTATION*

Substations are important part of power system. The continuity of supply depends to a considerable extent upon the successful operation of sub-stations. It is, therefore, essential to exercise utmost care while designing and building a substation. The following are the important points which must be kept in view while laying out a sub-station

It should be located at a good extendable site for future expansions as the demand increases day by day. As far as possible, it should be located at the centre of gravity of load.

It should provide reliable and safety arrangement likes firefighting equipment, first aid arrangements, hospitality. For safety, consideration must be given to the maintenance of proper clearances between HT element to ground and other equipment with highly solid earthing of the body of the EHT equipment. The Facilities for carrying out repairs and maintenance, abnormal occurrences such as possibility of explosion or fire etc. for reliability must be given for good design and construction, and the provision of suitable protective switch gear etc.

·         It should be easily operated and maintained.

·         It should involve low capital cost.

·         It should be out of polluted area as the metal parts like supporting CPL and tower structures rust, dielectric level of the insulators may decrease.

·         The site should be selected for future expansion as every year the load demand increases by 15% of the previous year demand.
·         The transportation facility like road, rail should consider as heavy electrical equipment like power transformers and breakers to be transported to the site and repair centers during the construction and replacement of the failed equipment.
·         The site should suitable for using optimum floor area.

      Schematic Diagram of 132KV/33KV Sub-Station 


conclusion
Transmission and distribution stations exist at various scales throughout a power system. In general, they represent an interface between different levels or sections of the power system, with the capability to switch or reconfigure the connections among various transmission and distribution lines. The major stations include a control room from which operations are coordinated. Smaller distribution substations follow the same principle of receiving power at higher voltage on one side and sending out a number of distribution feeders at lower voltage on the other, but they serve a more limited local area and are generally unstaffed. The central component of the substation is the transformer, as it provides the effective interface between the high- and low-voltage parts of the system. Other crucial components are controlling panels, Relays, circuit breakers and instrument transformers act as protective devices that open the faulty section of the circuit automatically in the event of a fault, that is, when a protective relay find excessive secondary current according to the primary current of the current transformer connected in EHT line or equipment. An important difference between circuit breakers and switches is that breakers are designed to interrupt abnormally high range of currents i.e. from 0Amps to few Kilo Amps, whereas regular switches are designed to be operable under no loads at high voltage levels ­>11KV, and with small currents at voltage levels <11KV.  Breakers are placed on both the high- and low-voltage side of transformers to arrange internal and external protection of the transformers. . Finally, substations may also include capacitor banks to provide lagging Mvar control further small voltage improvement.

Continue with explanation of all equipment erection, maintenance, precautions and safety.

Saturday 10 October 2015

Protection

Battery Bank.
Rating of batteries: 80AH, 220V generally for 132/33KV Level Sub-stations, 200AH to 250AH with 220V DC and above for 220/132KV voltage levels and above.





                                                   Fig: 220V, 200AH  Battery set.

Importance of batteries in EHT sub-stations: The batteries are used for protection of the sub-station equipment from internal faults like Transformer internal faults [Electrical Internal faults, Thermal faults of the Transformers] and external faults like line faults [i.e earth fault, over load faults] and back up protection of the equipment. The batteries are simply can say the heart of the Sub-station, no electrical sub-station can be commissioned without batteries along with charger. The batteries are using along with 3ø Ac/DC FC/BC Charger for protection of  the sub-station total equipment from external and internal faults even in the condition of Station LT supply to charger failed as batteries can feed DC sufficiently for 4 to 6hrs with previous charging.
  
80AH to 250AH, EXIDE, AMARRAJA, STANDARD, electroflo and Ub-Mech make batteries are used for all EHT sub-stations..
Maintenance: The batteries should be clean to avoid self discharge on [+ve terminal to –ve terminal].Inspection of voltages, sp. Gravities, level of the float of battery and connection between the battery terminals to avoid failure of DC as the batteries are connected in series to obtain 220V DC.

Recently the VRLA Maintenance free batteries are used for EHT Sub-Stations rather than Lead acid cells. But the maintenance free battery set makes an open circuit, if one of the cells in battery bank opens. This leads to failing of the 220V DC supply to the protection system.[relays, breakers of the Sub-station].


[precaution: 1]The protection of the sub-station cannot be run with on 220V DC charger supply in the condition of battery DC fails as no reliability of station Transformer LT 440V LT supply.
[precaution: 2]Even though continues availability of the AC supply from station Transformer supply, the bus voltage of LV Bus [33KV] may decreased suddenly due heavy fault current flow due to any external fault simultaneously, the 3Ø LT AC voltage of station transformer out put falls to a great extent and further the charger DC Output also decreases fails the total protection of the sub-station.
Precaution: 3] No one battery or battery bank should not allow short circuit and monitoring the DC leakage current [in mA maximum of 50mA] of the battery bank. If dc leakage observed on either of +ve or –ve terminal, should check out the leakage and disconnect the leakage path in the load circuit.


The DC Leakage circuit;

   
Process of  commissioning of the batteries of different make and capacities;
Sl. .No.
Particulars
Standard
Emco
Ub-mek
Electro flo
80AH
200AH
80AH
200AH
80AH
200AH
80AH
200AH
A
Initial filling of the batteries








1
Electro lyte sp. Gravity
1.19 0 @27oC
1.19 0 @27oC
1.19 0 @27oC
1.19 0 @27oC
2
Soaking time
12 to 16hrs.
12 to 16hrs.
12 to 16hrs.
12 to 16hrs.
B
First charge
But not >24Hrs.
But not >24Hrs.
But not >24Hrs.
But not >24Hrs.
1
Initial charging duration
100Hrs.
80Hrs.
50Hrs.
100Hrs.
2
Rating of charging
4A for 60hrs.
10A for 60hrs.
3.2A for 10hrs.
8.0A for 80hrs.
6.0A for 50hrs.
15.0A for 50hrs.
4A for 60hrs.
10A for 60hrs.
Rest for 4Hrs.
--

Rest for 4Hrs.
3.
4A for 40hrs.
10A for 40hrs.
4A for 40hrs.
10A for 40hrs.
4.
Maximum permissible temperatures
50oC
50oC
50oC
50oC
50oC
50oC
50oC
50oC
5.
During charging readings [Voltage]
2.55V
2.55
2.40
2.40
2.40
2.40
2.5
2.6
6.
At the end of the charging [Sp.Gravity @27o]
1200+0.05
1200+0.05
1200+0.05
1200+0.05
1200+0.05
1200+0.05
1200+0.05
1200+0.05
C]
Capacity /discharge  test








1
Discharge current
8A
20A
8A
20A
8A
20A
8A
20A
2
Test procedure :
After completion of the 1st charge, allow the battery to stand on open circuit for not less than 12hrs. butnot more than 24Hrs. discharge the battery through a variable resistor  or acetated water load at constant current equal to I=0.1C, the discharge shall be stopped when the closed circuit voltage of each battery falls to 1.85V, and specific gravity falls to 1.130 obtained in the duration of 10Hrs, maximum.
D]
Recharging








1.
Normal  recharge








2.
Current and end voltage of  the cell
8A up to 2.35V to 2.4V
20A up to 2.35V to 2.4V
11.2A up to  2.4V
28A up to  2.4V
8A up to  2.4V
20A up to  2.4V
8A up to  2.4V
20A up to  2.4V
3.
Finishing charge  Current and end voltage per cell
4A up to 2.55V to 2.65V
10A up to 2.55V to 2.65V
5.6A  up to 2.40 full Volts.
14A  up to 2.40 full Volts.
4A up to full charge
10A up to full charge
4A up to  2.65V
10A up to  2.6V
4.
End sp.gravity of the cell at 270C
1.200+0.05
1.200+0.05
1.200+0.05
1.200+0.05
1.200+0.05
1.200+0.05
1.200+0.05
1.200+0.05
5.
Maximum charging range
12A
30A
16A
40A
18A
45A
12A
30A
Note:Temperature correction: if cell temperature is different form 270C, correction to specific gravity is to applied is 0.0007 per each Degree variation of the below or above the 270C
Maintenance of the batteries:
a] Keep the battery room dry and well ventilated.
b] Keep the battery and its surrounding dry.
c] Keep the battery top surface clean and dry forever.
d] Ensure the tightness of the all battery connector erminals.
e] All battery terminals should be cleaned and covered with thin layer of the petroleum jelly.
f] Traces of corrosion to be removed properly and to be cleaned the terminals with distilled water.
g] Metal kettles should not be used for topping up of distilled water to maintain float level of the each battery.
h] care to be taken when work with metal tools on battery bank to avert short circuit of the battery terminals.
i] When handling electrolyte or concentrated acid, safety measures to be taken like wearing of apron and glows.

j] like bare lights, smoking of cigarette which creates sparks  should be avoided in the battery room.  
Connected Battery Charger:

k] very weak or discharged battery cells should be recharged separately to avert over charging of  remaining batteries in the battery bank..
l] at least once in a 15 days,battery bank should be discharged [i.e kept off the float charger in the load condition of the battery bank] for 1:00 Hrs. to 1Hrs.:30Mins.
m] Check the each battery cell voltage and specific gravity in the load condition to ensure the healthiness of the  each battery cell.
n] ensure the perfect continuity of the batteries by taking voltage of the each cell with voltmeter/multi meter from other adjacent cells terminals as below.
              The voltmeter connectors connected at +ve terminal of the 108th cell and –ve terminal of the 100th Cell i.e the volt meter measures the voltage of the 109th cell including voltage drop due to contact resistances of  connecting bars ‘a’, ‘b’ and internal resistance of the cell. If any loose contact between cells from +ve of 108th cell to –ve of 100th cell, the voltmeter shows above 2+0.02 V or abnormal voltage. Sometimes Heat dissipation may be observed due to lose contact resistance I2R loss. The float charger is to be kept on immediately to reduce the load on the battery bank and tight the battery terminals with safety precautions. [i.e the float charger feeds the load in especially in the cases of continues load of EHT sub-stations protection and auxiliaries.

Distilled water or demineralized water  Topping up
Topping up of Distilled water or de mineralized water [as per IS 1069] is necessary up to sufficient level of float of each battery. Distilled water should not be filled above the float red mark which leads to lower the specific gravity of the battery cell.


Topping up of  Distilled water or demineralized water [as per IS 1069] is necessary up to sufficient level of float of each batter is mostly suggestible just before the battery bank boost charging.


Battery trouble

cause
Remedy
       over  charging
         Excessive gassing and buckling of plates, filling of active material on +ve plates, increasing of the temperature.
      Reduce the float or boost charging voltage to a value which attains the specific gravity of electrolyte is 1.200.
      Or add distilled water if level is near or below to red mark.
       Ensure the accuracy of the voltmeter on FC/BC charger if necessary to avoid over or low charging of the batterys.
Under charging
        Low specific gravity of electrolyte,
        Reversal of voltage, light colour plates, buckling of the plates.     
      Put the battery bank in the boost condition which increases the voltage 2.16 V to 2.2/each cell attains specific gravity 1.200 of  electrolyte.
      Carefully check leaking of the electrolyte from cell if found arrest the same. Ensure that no earth leakage in the battery circuit or load circuit in the field which lead unwanted discharging of the battery bank.
       Corrosion of the  plates                         
         Impure electrolyte  
         Disconnect the battery from the circuit, remove the electrolyte, flush with distilled water and refill with fresh electrolyte. Further separately charge   the cell up to 1.200+0.005 specific gravity and 2.00+5% V and reconnect the cell in the circuit.
     Flaking of active      mterial
        Charging done at high rate, material impurity applied on plates.
      Charging and discharging limits should be limited between 2.4V to 1.85V
       Lose of voltage,  battery voltage falls too on discharging condition
        Excessive sulphation, loose connections,
       Corroded terminals.
sulphation at initial stage can be rectified by low rate of repeated charging and discharging of the cells.
       Continues lowering of the electrolyte level
       Loss  of  water in the electrolyte due to evaporation by too high float voltage or over charging.
       Leakage of electrolyte.
      Corroded parts should be cleaned with warm distilled and cover with thin layer of patrollium gelly or vasaline.
      Check  and arrest the leakage.
       Over flowing of the electrolyte level  even without the addition of the distilled water
      Due to humid atmosphere in the battery room causing condensation on the cell top surface.
       Replace container incase of any leakage.
       Improve ventilation in the battery room.

DC Chargers:

            Main Input AC supply is fed from AC Distribution Board-3h. 33KV/415V, 100KVA Station Transformer for 132/33KV sub-stations connected to 33KV bus side and feeds to AC Distribution Board. The Float cum/Boost Trickle Charger connected to 3Ø AC Supply on AC Distribution panel. The AC supply converted in to 220V to 245V DC and feeds battery bank, relays and auxiliaries. The Float cum boost 220V battery charger is very important to maintain the batteries healthy charge condition. If the discharging time is more during the line clears/interruptions on 33KV Bus or 33KV Station transformer, the boost charger is used to boost the batteries up to good level i.e specific gravity should be around 1.2+5% and voltage around 2.0 volts + 10% in next load condition. Example: FC/BC Charger Make: HEE 220V Dc, 200AH Float Current: 8 Amps, Boost Current: 16 Amps 
     
Float charging: the charger supplies 220V to 235V to load as well as batteries to light charging to hold full charge [i.e compensate to self discharge and backup during protection operated times]. The charging current is order of 0.2A to 0.5A only.

Boost Charger: the charger is utilized for boost the batteries by supplying 235V to 290V DC, current is maximum of 8A for 80AH batteries and 20A for 200AH batteries. During the boost charging, the entire battery set doesn’t connect across the load as the boost voltage more than system operating voltage i.e >220+10%. It causes failure of protective relays, contractors, and trip, close coils in the breakers. Hence the load is connected from 1to84th cell of the battery bank to reduce the load voltage up to rated voltage. Entire battery bank connected to boost charger to obtain full charging with DC voltage from 235V to 290V.

Float cum boost charging; This type of battery charging isolates the load and feeds the load on float charging mode. The station batteries are fed through boost mode separately. This type of charging is used when the batteries discharged condition up to thresh hold limit [i.e Voltage <1.9/each cell]. It will improves charge of the station batteries quickly with 235V to 290V can be varied by course voltage tapes of the boost transformer [i.e connected in 3ph. AC supply to feed boost