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1.0 Introduction:
Deregulation in power sector has abolished the age-old concept of supplier-wise licensed area
and has given option to the electricity consumers to choose the suppliers. As a result, foreseeing
the strong competition, the utilities are now taking all out measures to improve power quality and
reduce selling price to the extent possible to keep them geared up. The utilities, therefore, are
now forced to improve power quality by taking measures to reduce breakdown outages and
increase the mean time between failure (MTBF) and cut cost at all corners, of course, without
endangering steady supply of electricity to the demanding customers. Capital-intensive
replacement is being judiciously taken by extending as much life as possible of the existing old
equipment which have crossed their normal designed life. Hence close health monitoring and
taking corrective measures at the right time for the right plant are the vital needs of the day.
Further, in almost every utility, numerous equipment, currently in operation, have reached a
considerable age well beyond 30 years; might be close to their nominal end of life. A failure of the
equipment means not only cost for repair / replacement but also considerable extra costs for lost
sales of energy and environmental damages.
These are the reasons why continuous Condition Monitoring (CM) for incipient fault detection
and ageing assessment of equipment is an important part of a modern maintenance strategy.
Change-over to (i) condition based maintenance from time based maintenance and (ii) condition
based replacement from conservative replacement are also taking place as a cost economy
measures.
The primary assets of concern in a T&D network are Transformer, Switchgear / Circuit Breaker,
Cables / Transmission Line, Yard equipment like CT, PT, LA, Isolator etc. and last but not the
least, Battery.
Beside the age-old condition monitoring techniques like measurement of Insulation Resistance for
solid insulation, Electric Strength (BDV) for liquid insulation, Specific Gravity for Battery-Cell etc,
many new techniques have come up over the years increasing the ambit of monitoring for
different equipment. Condition monitoring techniques now being widely used by the leading
utilities are as given in the Table-1. Out of them the most dividend-paying techniques are:
Partial Discharge (PD) Monitoring: PD activity accounts for the largest percentage of disruptive
failures of electrical equipment. Early detection of PD activity provides an early warning of
problems and can prevent failure of equipment.
A. Ultrasound Detection Technique: Arcing, tracking and corona all produce some form of
ionization which disturbs the air molecules around it and produce high frequency noise. The
Ultrasound equipment translates the high frequency noise into the audible ranges. Electrical
discharges are heard as a frying or buzzing sound.
B. TEV measurement: When the PD occurs, electromagnetic waves propagate away from the
discharge site. Very small quantity (pico-coulombs) of electrical charge is transferred (in a few
nanoseconds) capacitively from the high voltage conductor system to the earthed metal-
cladding. At an opening in the metal cladding such as the gasketted joints, the
electromagnetic wave propagate out into free space. The wave then generates a transient
earth voltage on the metal surface.
Strong odor of Ozone, presence of whitish to bluish green powder due to formation of nitrous acid
from ionization, colour fading and dark tracks on insulation near conductors, usually with a
"treeing" pattern are common effects of PD.
3.0 Prevailing Condition Monitoring Practices in CESC:
CESC, as one of the leading Indian utility, is also practicing condition monitoring in some of the
important areas since long. It may be shared with the young engineers that checking trip circuit
healthy in switchgear along with taking hourly load reading of Incomers / Feeders is a laid down
practice in CESC since time immemorial, in all manned Stations. Monitoring of power transformer
through routine oil sampling for determining electric strength, moisture content, acidity etc is an
established practice over 2 decades. DGA monitoring of power transformer is in practice since
1997. Thermo-graphic scanning of outdoor yard has been introduced in 1994-95. Condition
monitoring activities, so far practiced in CESC, are as highlighted (yellow) in the above chart.
CESC has introduced FRA (Frequency Response Analysis) for power transformers since 2009-
10. New transformer during long transportation may get accidental shock and transformer in
service may experience short circuit which may cause winding deformation. FRA is a recent
technology now being used by the utilities for assessing mechanical healthiness of the winding.
33 kV Swbd. at 6 kV / 11 kV 6 kV / 11 kV Sw at 6 kV / 11 kV RMU at 6 kV / 11 kV
S/S and D/S Swbd at D/S downstream of D/S downstream of D/S Dist. Transf.
9 41 29 20 13
Condition monitoring activities, newly introduced in CESC, are as highlighted (green) in the above
chart.
However, in view of large number of operations, dusty environment and absence of suitable non-
intrusion CM techniques for assessing the operating mechanism in the circuit breaker, time-based
maintenance (at cycle based on experience) is essential for ensuring their reliability.
History: The transformer tripped through buchholz and differential protection on 22/9/09. On
inspection no accumulation of gas was found in the buchholz relay and also no abnormality was
detected in the subsequent LV / HV tests. But the post-tripping DGA result indicated high
concentration of key gases, specially C2H2 and H2. The DGA results were indicating high
temperature arcing in the oil. It was then kept in charged condition (without load) till Durga-Puja
end (for meeting exigency during Puja days, if any) and was under close DGA monitoring. DGA
results of samples taken on different dates are:
The transformer was re-commissioned on the same day in fixed tap after temporary repair of the
damaged leads and put on load. On 10/10/09, another shutdown was taken for carrying out
proper repair of the damaged leads and the normalcy was restored on the same day.
Oil filtration carried for purging out the dissolved gases after ensuring no further abnormal
generation of gases inside the transformer. Post repair DGA results are as above.
Routine IR Thermography of outdoor yards, carried out in last summer has detected quite a few
cases of high resistant joints of varying abnormalities. The defects are being rectified
progressively as per their severity and availability of shutdown for the equipment / circuits.
Excerpt from the report of above scanning, incorporating the finding in each case, is as given in
the chart for reference.
3 New Ballyg. Transf. T2 206 CSE to Pipe 47 52 349 35 Pipe bus clamp
(E) D/S Bus Flex. joint found loose
Connector
5 Sukchar D/S Transf. T2 146 CSE Terminal 43 41 172 36 Joint found loose
Pad Joint due to severe
rusting of the
hardware
During PD monitoring (through acoustic detector) at Dhakuria D/S on 6/5/09, 35 dB noise along
with acidic smell was detected from the circuit breaker chamber and VT chamber of the 11 kV
panel for transformer T2.
Internal inspection was carried out on 18/5/09, when the following was observed:
1) Surface degeneration of resin-cast components inside the panel like supporting insulators, CT
and VT.
3) Surface degeneration of one fibre-glass support holding the VT fuses of all three phase.
Defective resin-cast components, barrier boards and fibre-glass VT fuse support replaced. Post
work noise measurement indicated removal of the causes for noise in the referred panel.
Continuous knowledge updating and induction of available new techniques in the related fields
are of vital need of the day to enhance the coverage of condition monitoring drives and assess
equipment health more accurately. Induction of techniques like moisture estimation in paper
insulation in transformer, furan analysis of oil for estimation of degeneration of paper insulation in
transformer, DCRM for circuit breaker, in future, will facilitate more precise health monitoring of
the network equipment.
8.0 Conclusion:
In todays competitive age, utilities are faced with what seems to be an impossible situation
maintaining or improving network reliability while working with reduced staffing and declining
maintenance budgets. Engineers are showing themselves to be remarkably resourceful in
developing or locating monitoring systems that provide the key data required to schedule
maintenance in a more cost effective manner. As the industry continues to restructure and evolve,
utility personnel will continue to use advanced technologies to deliver reliable power to their
customers.
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