MAIN COMPONENTS OF ELECTRICAL SUBSTATION

Incoming Line:
Incoming line is normally 33/11KV depending on load. Higher voltages 66 to 400KV may be applicable to large
subsations. Incoming line can be overhead line or cable as per local situations.

Lightning/Surge Protection:
When the lightning strike in transmission line or place near it will generate large voltage. The lightning arrester is used
as protective shield against the surge of the lightning.
Metal Oxide and varistors type arrests are the two main types of surge arrester which use in electrical industry.
Normally metal oxide arrester is much popular, and this also provide great over voltage protection for electrical
transformer which is connected to the power system.
Main purpose of the lightning arrester is the current form the surge is diverted around the protect insulation to earth.
Lighting arrester are also known as surge arrester in electrical engineering. Apart from protect high voltage
transmission lines, theses arrester are sue to protect electrical equipments from lightning and surges.
High voltage occurs due to lightning may cause insulation failure in transformers and other electrical devices in
transmission system.

Metering Cubicle:
The metering cubicles is installed electrically in between the incoming supply point and the step down transformer of
consumer's installation. The general arrangement of the cabinet manufactured by us are as per the Electricity Board
approved specification.
The cubicles are made from 2/2.5 mm Hot rolled, mild steel.
The Metering cubical are available in bottom cable entry The cubical are divided into two parts The front compartment
for energy meter and the larger rear compartment for the current and voltage transformers. The cubical are dust proof
and pilfer resistant. Space Heaters are provided
The powder coated finish involves a two-stage preparation, consisting of degrease, iron phosphate etch and rinse
followed by an electro- statically applied polyester powder coat (80 microns thick), ensuring anti-rust conditioning,
superior finish and lasting strength.

Metering cubicles shall be provided with following components suitably mounted:

• 3 No.s 11/22/33kv class current transformers
• 3 No.s 11/22/33kv class potential transformers
• Tinned copper busbars totally covered by resin casting
• The secondary wires from the terminals of C.T.s and P.T.s in the CT/PT compartment shall be covered by resin
cast blocks and the secondary wires shall be brought in the metering compartment through rubber bush and
shall be left open duly crimped with suitable pin type copper lugs
• Resin cast bushing boards with arrangement to receive Reychem and equivalent type of cable terminations
for incoming and outgoing supply points.
• Adequate number of PVC cable glands to receive purchaser’s incoming and outgoing cables

Isolation and protection for Transformer:

This arrangement veries greatly depending on the size
• Generally, up to the rating of 400KVA rating pole mounted switch fuse is used
• Above 400KVA a VCB or SF6 breaker is used.
• For underground cable system RMU (Ring Main Unit) may be used

Protection of transformer is also depending on rating of transformer

Generally, up to the rating of 400KVA only fuses are used as protection
For tranformer rating up to 2000KVA following protections are provided
• Over-current, Short Circuit and Earth fault protection
• Over and under volatge protection, Phase reversal protection
• buchholz relay, Oil and winding temperature
For Higher rating transformers Restricted earth fault and Differential Protection can be provided.
Pole mounted Substation
Vacuum Circuit Breaker
Package Transformer

Dry type Transformer

Requirements of Transformer Installations in India
Outdoor

• Minimum clearance between supplier's and consumer's 11 kV structures shall be 3

m. If it is 5 m or more they should be braced together both at top and middle.

• Minimum size of RSJ poles shall be 175 x 85 mm. Channels shall be of minimum 75
x 50 mm.

• Phase to phase and phase to earth clearances at AB switch shall be minimum 915
mm and 610 mm respectively.

• Minimum size of 11 kV jumpers shall be Number '0' SWG copper.

• Maximum length of unsupported 11 kV jumpers shall be 2.44 m for solid conductors

and 1.5 m for stranded conductors.

• Minimum safety working clearance of 2.6 m shall be maintained for bare conductors
and live parts.

• Lightning arrestors shall be provided between AB switch and D.O. / H.G. fuse.

• Group control AB switch shall be provided for multiple transformer installations.

• The minimum clearance from ground to the 11 kV bushings of the transformers shall
be 2.6 m

• AB switch operating handle shall be fixed at 1 m to 1.25 m from ground level.

• 11 kV AB switch shall be three insulator type.

• Fencing with a height of 2.5 m shall be provided, keeping a minimum clearance of

1.5 m from the transformer body.

• Minimum clearance between 11 kV up and down jumpers shall be 75 cm.

• Outdoor transformer is not permitted in corporation areas and at the premises of

high-rise apartment buildings. However outdoor transformers with cable end boxes
at both sides and indoor breaker/SFU at primary side may be permitted judiciously.

• Indoor transformer is recommended for rating above 630 kVA

• If more than one transformer, having more than 2000 litres of oil, are installed side
by side, baffle walls of minimum 4 hr fire rating shall be provided in between
transformers.
Indoor

1. Only dry type transformers shall be installed inside residential/commercial buildings

(Rule 64(2)(e)(iv)).

Oil filled transformers are permitted outside residential and commercial buildings subject to
the following conditions.

(a) Only indoor type transformers are permitted in Corporation areas and at the
premises of residential buildings.

(b) There shall be free access for fire engines to the transformer stations.

(c) The building in which transformer is installed shall have minimum clear distance
of 1.5 m from the residential/commercial buildings.

(d) The substation building shall be of weatherproof and fire proof construction. Walls
shall be of 355 mm thick brick or 230 mm thick RCC. If there is any window/door
opening towards the residential/commercial building, there shall be a fire resistant
wall between the substation building and residential/commercial building keeping a
minimum clear distance of 1.5 m from both the buildings.

(e) Transformers may be installed outdoor, keeping a minimum distance of 6 m from

commercial buildings in areas other than corporation areas.

(f) If the transformer is installed outdoor with in 6m from commercial buildings, there
shall be a fire resistant wall in between the transformer and the building keeping a
minimum distance of 1.5m both from the building and the transformer.

2. Only dry type transformer shall be installed in cellars and above ground floor. Indian
Electricity Rules, 1956 (Rule 64(2) (f) (iii))

3. ABSF unit/VCB shall be provided at primary side. The 11 kV ABSF unit shall have CPRI
test certificate and brand certification. At hospital premises breaker shall be recommended.

4. Minimum size of cable at 11 kV side shall be 150 sq.mm XLPE (Aluminium). But size
may be 70 sq.mm XLPE (Aluminium) if back up fuse is provided.

5. Fire separation walls shall be provided in between oil filled transformers. Thickness of
the wall shall be minimum 30 cm (Brick) or 20 cm (RCC)

6. Oil filled transformers shall be segregated from HT and MV switchgears using fire
separation wall

7. Oil drainage facility/soak pits shall be insisted for oil filled transformers if quantity of oil is
more than 2000 litres.

8. All-round clearance shall be provided for indoor transformers. It shall be minimum 1.25m
if walls are provided at 4 sides.

9. Transformers shall be installed at the periphery of the building for getting easy access
and adequate ventilation.
10. Doors and windows of transformer room shall be of non-inflammable materials.

11. Minimum 50 cm headroom clearance shall be provided for the transformer.

12.
a). If dry type transformers are installed above ground level, emergency switching off
facility shall be provided at ground floor.

b). Structural fitness certificate from a competent structural engineer shall also be
furnished.

13. Minimum phase to phase and phase to earth clearance of bus bars in 11 kV panel
shall be 130 mm and 80 mm respectively.

14. Minimum 1.0 metre clear space shall be available in front of HT panel in breaker drawn
out position.

Distribution Transformer : Erection & Commissioning

Checkpoints
Introduction
A distribution transformer is an important link between any utility’s
distribution network and the power supply delivered to customer. It is
therefore most vital asset in any electrical distribution network and needs
special attention right from erection, commissioning and maintenance of
these transformers.
Let us examine some important aspects related to erection, commissioning of
Distribution Transformer.
Checkpoints before Transformer installation
Before the transformer is lifted from the warehouse / maintenance workshop
and taken to the site where it is to be installed, following physical
inspection/checks should be done:
1. Check the transformer bushings thoroughly for any signs of cracks /
damages

2. Check the oil level in the transformer and check for any signs of oil leakage
through bushings, gaskets or welded joints

3. Test the Insulation Resistance (IR) values using a 1000 V Megger unit for
various sections such as – HV to LV, LV to Earth, HV to Earth.

4. For a rated voltage of winding between 11 kV up to 6.6 kV the minimum

safe IR value should be in the range of 200 mega Ohms to 400 mega Ohms

5. In case if the above values are not obtained then it is necessary to dry out
the transformer completely by filtration procedure
6. Check whether tests are carried out for – Ratio Tests, % impendence voltage
test and rate voltage withstand tests
Transformer Installation
During installation of Transformer on a Pole mounting structure, following
checks should be made:
1. Ensure that the base channel of transformer is at height complying to IEC
Standards:
a) Height of top of HV bushing from ground for pole mounted transformer
should be 4.572 meters minimum (15 Ft)
b) Height of top of HV bushing from ground for plinth mounted transformer
should be 2.75 meters minimum (8 Ft)

2. Ensure that base channel is horizontally leveled

3. Avoid jerky movement of the transformer while lifting it upwards during

installation

4. During installation ensure that the HV bushings of the transformer are on

the DO unit (or HG fuse unit) side of the structure

5. After installation of transformer, also check that other allied equipments

such as AB switch, Horn Gap fuse units, DO Fuse sets, Lightening arrestor etc.
are fitted at appropriate positions as per the applicable drawing issued by the
utility.

6. Use PVC unarmoured cable (3 ½ core) of appropriate size and length for LV
side. Ensure that the lugs are appropriately crimped at the ends.
Earthing of Distribution Transformer
Earthing of transformer is an important aspect of Distribution Transformer
installation. As per IE rules: 61 (1) (a) and 61 (2), the neutral bushing of the
transformer and the body of the transformer should be earthed by not less
than two separate and distinct connections with a minimum of two different
earth electrodes.
In order to comply with above rule it is a customary practice to excavate three
earth pits (usually 8 feet deep) arranged to form an equilateral triangle. One
pit is used for connecting lightening arrestors. The transformer neutral
earthing is connected to another pit while the body earthing is connected to
third pit.
These three earth electrodes are connected to each other to form earth bus at
one feet below the ground. The earth resistance of these interconnected
electrodes should not exceed 2.5 ohms.
Commissioning of Distribution Transformer
Before actually charging the transformer the following points should be
checked:
1. Transformer should be inspected by authorized electrical inspector and get
permission to energize the same

2. Insulation resistance and continuity of the winding should be checked by

1000V Megger

3. Check dielectric strength of the transformer oil by taking out sample

4. Check oil level in conservator tank, colour of silica gel in the breather and oil
level at the bottom of the breather

5. Make MCCB/Main Switch in the distribution box OFF and charge the
transformer on no load by using DO fuse elements of suitable capacity

6. Wait until noise of the transformer stabilizes then measure the secondary
voltages phase to phase and phase to neutral

7. Apply load on the transformer (preferably a 3 phase motor) and check

direction of rotation of motor. If the motor rotates in reverse direction, then
the phase sequence of connections is wrong and needs to be rectified. To
rectify this, interchange the cable connections at the MCCB / Main switch e.g.
R&Y or Y&B or B&R phase connections. The phase sequence will then be
rectified.