TECHNICAL SERVICES GROUP (TSG) North, NEW KOT LAKHPAT

LAHORE

TECHNICAL AUDIT / INSPECTION OF

220kV GRID STATION NTDC MANSEHRA
Team Supervisor:

Engr. Muhammad Bakhsh Mahaar

Addl. Chief Engineer (TL&TA)
Team:
Engr. Ahmad Waqas Deputy Manager (TL&TA)

Engr. Nasir Abbas Deputy Manager (TL&TA)

Engr. Muhammad Faheem Akram Assistant Manager (TL&TA)

Mr. Muhammad Waseem Tahir Assistant Manager (TL&TA)

Technical Audit carried out W.E.F. 04.07.2019 to 10.07.2019

 Technical Audit / Inspection report of 220kV Grid Station NTDC Mansehra

1. Auto Transformers T-1, T-2 & T-3 (220/132kV, 250MVA)

Maximum Load along with date Minimum Load along with date and
Auto Transformers
and time time

Auto Transformer T1 700A (28/06/2019 at 21:00Hrs) 30A (02/11/2018 at 13:00Hrs)

Auto Transformer T2 690A (26/06/2019 at 21:00Hrs) 30A (02/11/2018 at 13:00Hrs)

Common observations and recommendations regarding Auto Transformers are as under:

S No. Observation / Inspection Recommendation

Functional tests of (OLTC) On Load Tap Changer Functional tests should be

1. 1. buchholz relay has not been performed for auto performed for mentioned
transformers T1 and T2. protection.
Stability test of the
Stability test of the auto transformers (T1 & T2) has not
2. 2. transformers should be
been performed.
performed.
It should be provided to check
Impact recorder data has not been made available at
3. 3. any damages / fault during
site.
transportation.
Winding resistance test for HV to LV has not been
4. 4. It should be performed.
performed for both transformers T1 and T2.
It should be the first test to be
performed as Site (as it is the
SFRA (Sweep Frequency Response Analyzer) has not
5. 5. last test at factory) to check if
been performed in SAT.
there has been any damages /
fault during transportation.
Automatic Voltage Regulator (AVR) is installed but not AVR should be commissioned
6. 6.
commissioned. as per SOP.

All tests should be performed

7. 7. No tests has been performed for Tertiary Bushing CT.
as per SOP.
The Nitrogen Injection and Explosion prevention system
has been set to Out of service. So much expensive It should be commissioned
8. 8.
protection system has not been commissioned properly.
properly.

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 Technical Audit / Inspection report of 220kV Grid Station NTDC Mansehra

Oil level vs Temperature graph for oil level of Mentioned graph should be
9. 9.
conservator was not available on transformers T1 & T2. provided on the transformers.
There has been seepage of oil from oil pots of OLTC and Oil seepage should be
10. 10.
Main Conservator breathers. addressed.
Approach ladder / stand have not been provided for the Approach ladder / stand
11. 11. main cubical cabinet and motor drive unit cubical of the should be provided for
transformers. mentioned boxes.
Cable sheath of control cables of Motor Drive Unit Cable sheath should be
12. 12.
cubical are not grounded properly. grounded.
Some of the ground connecting loops of auto
Missing loops should be
13. 13. transformers found missing (e.g. Coupling pipe for
provided.
radiators).
Duct covers of cable ducts are missing in the Duct covers should be placed
14. 14. transformer cubical cabinet and some cable ducts are properly and broken cable
broken. ducts should be replaced.
Cable dressing in the transformer cubical cabinet and
Cable dressing should be done
15. 15. Motor drive unit cubical has not been done properly.
properly.
Also spare cores are lying open in cubical cabinet.
Vermin proofing is required in the main cubical cabinet
Vermin proofing should be up
16. 16. of the transformer, motor drive unit cubical and
to the mark.
Nitrogen cylinder cabinet.
Actuator wiring has been removed from the nitrogen
17. 17.
cylinder box.
Mentioned issues should be
No cable glands have been used in Nitrogen Cylinder resolved.
18. 18. box. Inappropriate cable glands have been used in the
transformer cubical cabinet.
The transformer neutral is grounded with 02 points but
It should be mentioned
19. 19. the points have not been differentiated that which
properly.
point is of earth electrode and which is of earth mesh.
The OGST (Oil Gas Separator Tank) have not been It should be bolted properly
20. 20.
bolted with foundation. with foundation.
Missing cable tags should be
Some of the cable tags in Transformer cubical cabinet
provided and cable tags
and motor drive unit cubical are missing. Cable tags
should be used inside the
21. 21. have been provided outside the transformer cubical
cubical cabinet of the
cabinet, due to this cable tags will become rusty and
transformer to avoid rust and
will deteriorate quickly.
deterioration.
Inappropriate cable ties have been used for binding
Appropriate cable ties should
22. 22. cable tags with control cables in transformer cubical
be used.
cabinet and motor drive unit cubical.

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 Technical Audit / Inspection report of 220kV Grid Station NTDC Mansehra

1.1 Auto Transformer T-1 Make: CHINT, China (220/132kV, 250 MVA)

Date of commissioning April 04, 2018.

S No. Observation / Inspection Recommendation

Winding resistance test results of FAT and SAT were

compared and found that winding resistance values for
HV-N have been almost increased 02 times in SAT and
for LV-N these have been almost 60 times decreased in
SAT but for tertiary these values have remained
constant for Transformer T1 whereas for transformer T2
no considerable change has occurred for the said values.
Tap Phase SAT FAT Remarks

1 0.6366Ω 0.3437Ω
HV-N
14 (Red 0.5775Ω 0.3111Ω
Phase)
27 0.6393Ω 0.3436Ω
SAT
1 0.6361Ω 0.3436Ω
HV-N results
are 2 The issue should be taken up
14 (Yellow 0.5771Ω 0.3113Ω with the manufacturer as the
times the
Phase) transformer is within
1. 27 0.6378Ω 0.3437Ω FAT
23. warranty and corrective
results
measures should be taken on
1 0.6364Ω 0.3439Ω
HV-N emergent basis.
14 (Blue 0.5774Ω 0.3118Ω
Phase)
27 0.6386Ω 0.3442Ω
LV-N
N/A 0.0036Ω 0.1816Ω SAT
(Red)
results
LV-N
N/A 0.0036Ω 0.1818Ω are much
(Yellow)
lower
LV-N than FAT
N/A 0.0036Ω 0.1826Ω
(Blue)
Tertiary
N/A 3.6mΩ 3.7mΩ
(R-Y) But here
Tertiary SAT are
N/A 3.59mΩ 3.78mΩ
(B-Y) same as
Tertiary FAT.
N/A 3.61mΩ 3.78mΩ
(R-B)

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 Technical Audit / Inspection report of 220kV Grid Station NTDC Mansehra

Comparison of Oil and winding temperatures are:

Control /
Temperature Switchyard Relay
Room The difference should be
minimized by proper
Oil Temperature 1 44℃ 43℃
calibration of temperature
24. 2.
Oil Temperature 2 43℃ 41℃ gauges / indicators. Winding
Temperature should not be
Winding
43℃ 45℃ less than Oil temperature.
Temperature 1
Winding
46℃ 46℃
Temperature 2

DES test should be

25. 3. DES (Dielectric Strength Test) has not been performed.
performed as per SOP.

Temperature settings on the temperature gauges is as

under:
Fan Fan Spare
Gauge Alarm Trip
1 2 Fan Setting of temperature
Oil 1 should be verified and
55℃ 65℃ 85℃ 95℃ 95℃
Temp. approved setting from
26. 4. Oil 2 Protection and Control
55℃ 65℃ 85℃ 95℃ 95℃ should be implemented.
Temp.
Alarm and Trip settings can’t
Winding be same.
65℃ 75℃ 95℃ 105℃ 105℃
1 Temp.
Winding
65℃ 75℃ 95℃ 105℃ 105℃
2 Temp.

Light issue should be set

27. 5. Light is not working in Motor Drive Unit cubical.
right as per SOP.

28. 6. Silica gel of main conservator breather is deteriorated. Silica gel should be replaced.

Oil seepage has been observed from the radiator tube

This oil seepage should be
29. 7. coupling pipe (bottom side) towards HV side of the
addressed.
transformer.

The ampere meter for measuring the current of HV The meter problem should
30. 8.
Winding temperature gauge CT is not working properly. be addressed.

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 Technical Audit / Inspection report of 220kV Grid Station NTDC Mansehra

1.2 Auto Transformer T-2 Make: XD, China (220/132/11kV, 160 MVA)

Date of Commissioning May 02, 2018

S No. Observation / Inspection Recommendation

During C&DF test correction factor of “1.00” has been

31. 1. used whereas the temperature recorded for Oil was DF (Dissipation Factor) value
28℃ and DF value corrected to 20℃. must be corrected to 20℃
properly for future
During C&DF test no correction factor has been used for comparison and reference.
32. 2.
the correction of DF value at 20℃.
Comparison of Oil and winding temperatures are:
Control
Temperature Switchyard / Relay The difference should be
Room minimized by proper
Oil 1 Temperature 47℃ 46℃ calibration of temperature
33. 3.
gauges. Also Oil temperature
Oil 2 Temperature 41℃ 40℃ should be low as compared
to the winding temperature.
Winding 1 Temperature 45℃ 44℃

Winding 2 Temperature 47℃ 44℃

Temperature settings on the temperature gauges is as

under:
Setting of temperature
Fan Fan Spare
Gauge Alarm Trip should be verified and
1 2 Fan approved setting from
Oil 1 Temp. 55℃ 65℃ 85℃ 95℃ 95℃ Protection and Control
should be implemented.
34. 4.
Oil 2 Temp. 55℃ 65℃ 85℃ 95℃ 95℃ Alarm and Trip settings can’t
be same. It is worth to
Winding 1 mention here that for WTI-1
65℃ 75℃ 95℃ 110℃ 105℃
Temp. Alarm settings are greater
Winding 2 than the trip settings.
65℃ 75℃ 95℃ 105℃ 105℃
Temp.

Oil seepage should be

addressed. These welded
pipes will have oil seepage
Oil seepage has been observed from the Nitrogen problems time and again as it
35. 5. Injection pipe. Moreover welded pipes from joints have was in the case of 220kV grid
been used for Nitrogen injection. station Gujrat where same
pipes were eventually
replaced to remove the
recurrent oil seepage issues.

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 Technical Audit / Inspection report of 220kV Grid Station NTDC Mansehra

Earth mesh riser for grounding of nitrogen cylinder

36. 6. cabinet has not been bolted with the cabinet (i.e. Lying It should be properly bolted.
open).

2. POWER TRAFO (T-3) Make: CHINT (132/11kV, 10/13MVA)

Date of commissioning April 06, 2018.

S No. Observation / Inspection Recommendation

Functional tests of (OLTC) On Load Tap Changer Functional tests should be

46. 1. buchholz relay has not been performed for auto performed for mentioned
transformers T1 and T2. protection.

Temperature settings on the temperature gauges is

as under:
Fan Fan
Gauge Alarm Trip
1 2 Setting of temperature should
Oil 1 be verified and approved
2. 50℃ 55℃ 85℃ 95℃ setting from Protection and
47. Temp.
Control should be
Oil 2
50℃ 55℃ 85℃ 95℃ implemented.
Temp.
Winding
60℃ 65℃ 96℃ 105℃
Temp.

Comparison of Oil and winding temperatures are:

Control
The difference should be
Temperature Switchyard / Relay
minimized by proper
Room
calibration of temperature
48. 3. Oil 1 Temperature 44℃ 45℃
gauges. Also Oil temperature
Oil 2 Temperature 42℃ 42℃ should be low as compared to
the winding temperature.
Winding Temperature 42℃ 45℃

Stability test of the

Stability test of the power transformer (T3) has not
49. 4. transformer should be
been performed.
performed.

It should be provided to the

No FAT (Factory Acceptance Test) report was
50. 5. grid staff for future
available for Power Transformer T3.
comparison and reference.

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 Technical Audit / Inspection report of 220kV Grid Station NTDC Mansehra

It should be tightened
The earth mesh riser for grounding of core for the emergently and necessary
51. 6. power transformer is not grounded properly (i.e. lose tests should be performed to
connection). analyze the transformer
condition.

02 out of 03 fans were not working when switched Fans problem should be
52. 7.
ON manually. addressed.

Cable sheath of control cables in Motor Drive Unit Cable sheath should be
53. 8.
cubical are not grounded properly. grounded.

Duct covers of cable ducts are missing in the Duct covers should be placed
54. 9. transformer cubical cabinet and some cable ducts properly and broken cable
are broken. ducts should be replaced.

Cable dressing in the transformer cubical cabinet and

Cable dressing should be done
55. 10. Motor drive unit cubical has not been done properly.
properly.
Also spare cores are lying open in cubical cabinet.

Vermin proofing is required in the main cubical Vermin proofing should be up

56. 11.
cabinet of the transformer, motor drive unit cubical. to the mark.

Motor drive unit cubical has been grounded through It should be grounded directly
57. 12.
body. from earth mesh.

Silica gel of the breather of main conservator is The silica gel should be
58. 13.
deteriorated. replaced.

Approach ladder / stand have not been provided for Approach ladder / stand
59. 14. the main cubical cabinet and motor drive unit cubical should be provided for
of the transformer. mentioned boxes.

Main cubical cabinet of the transformer has not been

60. 15. It should be grounded.
grounded.

Supporting structure for the 11kV cables have not It should be grounded
61. 16.
been grounded properly (i.e. grounding cable lose). properly.

3. 220kV SWITCHYARD

S No. Observation / Inspection Recommendation

Cable tag should be on each

Some cables have not been tagged in almost all the
62. 1. and every cable in the
cubical boxes of the switchyard.
switchyard.

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 Technical Audit / Inspection report of 220kV Grid Station NTDC Mansehra

Appropriate (i.e. with two

Inappropriate thimble (i.e. with single bolt) is used bolts) should have been used
63. 2. for grounding of supporting structure and gantries to for grounding of supporting
the earth mesh in switchyard. structure and gantries with
earth mesh in switchyard.

Inappropriate cable ties have been used for binding

Appropriate cable ties should
64. 3. cable tags with control cables in switchyard cubical
be used.
boxes (e.g. CB, CT, CVT, MK and DS).

Check nuts have not been used for in the supporting

65. 4. Check nuts should be used.
structure of CBs , CTs and Isolators etc.

Cable dressing is not upto the mark in the cubical

Mentioned problems should be
66. 5. boxes of (CB, CT, DS and CVT). Some of the cable
addressed.
ducts have no cover.

Some of the cable ducts have been broken (e.g. Broken cable ducts should be
67. 6.
especially in CVT and CT junction box). replaced.

Vermin proofing is required in CT, CVT, DS and CB Vermin proofing should be up

68. 7.
boxes especially. to the mark.

There should be name of circuit

The name of circuit breaker has not been mentioned
69. 8. breaker properly mentioned
on the MKs in 220kV switchyard.
(i.e. with paint) on the MKs.

Fans and heater problem

70. 9. Some fans and heaters in MKs are not working.
should be addressed.

The MCBs should be turned ON

Some MCBs found tripped / off in cubical boxes (e.g. and their contacts / indications
71. 10.
D2Q1 Blue pole F2 MCB and D2Q3 MK F07 MCB). should be verified in control
room (i.e. on indication blocks).

4. 220KV CIRCUIT BREAKERS

S No. Observation / Inspection Recommendation

Functional tests of SF-6 Gauge have not been Functional tests of SF-6 gauge
72. 1. performed for any circuit breaker. Alarm & lockout should be performed as per
verification has not been carried out. SOP.

Timing test should be

No record has been found regarding the timing tests
73. 2. performed as early as possible
of any 220kV circuit breaker.
for all circuit breakers.

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 Technical Audit / Inspection report of 220kV Grid Station NTDC Mansehra

Contact resistance test has been performed for

220kV circuit breakers of bay D2, but the results of
FAT and SAT having a huge difference. It is worth to
mention here that SAT results of other bays (i.e. D1
& D3) results were comparable with FAT. Some
results are given for example:
Phase Phase SAT FAT

R 11.23µΩ The contact resistance in SAT

has been reduced to a
Y D2Q1 11.36µΩ minimum of 2 times, which
makes testing procedure /
74. 3. B 9.21µΩ testing set doubtful. The test
should be performed again
R 6.72µΩ
with another test set to verify
24µΩ the results.
Y D2Q2 9.81µΩ
32µΩ
B 8.13µΩ

R 11.02µΩ

Y D2Q3 9.33µΩ

B 10.12µΩ

The said test should be

75. 4. Minimum voltage trip test has not been performed.
performed as per SOP.

Anti-Pumping feature & Pole discrepancy feature of The said tests should be
76. 5.
Circuit Breakers has not been tested. performed as per SOP.

Close / open operation verification of circuit

The DC Voltage values should
breakers has been performed at site but the values
77. 6. be as per operating DC
of maximum / minimum voltage are used by taking
Voltage.
110V DC as reference but not 220V DC.

Missing cable tags should be

There is no cable tagging in CB Box and some cable
provided and cable tags
tags are missing in CB Junction box. Cable tags have
should be used inside the
78. 7. been provided outside the CB and CB junction box,
cubical cabinet of the
due to this cable tags will become rusty and will
transformer to avoid rust and
deteriorate quickly.
deterioration.

Approach ladder / stand have not been provided for Approach ladder / stand
79. 8.
the main cubical box of all the circuit breakers. should be provided.

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 Technical Audit / Inspection report of 220kV Grid Station NTDC Mansehra

The glass covers / window boxes for the position of

These glass covers / window
80. 9. circuit breaker, spring charging status and operation
boxes should be replaced.
counter have lost their transparency.

There is no gland used for the entrance of SF6 gauge There should be proper cable
81. 10. cable in the junction box / CB box of the circuit gland for this very sensitive
breaker. cable.

Terminal blocks should be

The tightening of terminal blocks needs attention in
82. 11. tightened where loose to
D3Q2 CB MK (Marshaling Kiosk).
avoid any untoward situation.

5. 220kV ISOLATORS

S No. Observation / Inspection Recommendation

All tests as per SOP should be

No test has been performed for isolator D2Q21 and
83. 1. performed on mentioned
earth switch D2E10.
isolator and earth switch.

Contact resistance test has been performed for

220kV isolators but the results of FAT and SAT
having a huge difference. Some results are given for
example:
Phase Phase SAT FAT

R 11.01µΩ 73µΩ
The contact resistance in SAT
Y D3Q22 11.01µΩ 71µΩ has been reduced to a
minimum of 7-8 times, which
B 10.67µΩ 72µΩ makes testing procedure /
84. 2.
testing set doubtful. The test
R 10.97µΩ 72µΩ should be performed again
with another test set to verify
Y D3Q10 71.61µΩ 71µΩ
the results.
B 12.81µΩ 73µΩ

R 12.45µΩ

Y D2Q10 11.67µΩ

B 12.11µΩ

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 Technical Audit / Inspection report of 220kV Grid Station NTDC Mansehra

Opening and closing time test of isolators has been

Testing results clearly shows
performed but no testing report (i.e. printed from
that proper testing procedure
85. 3. test set) has been attached. And value of opening
has not been adopted or may
and closing time is exactly fixed 5.00 sec for all
have not been properly tested.
isolators.

Functional tests of 220kV isolators have not been Functional tests should be
86. 4.
performed. performed.

Interlocking of isolators with circuit breakers has not Interlocking should be verified
87. 5.
been checked / verified. with circuit breaker.

Mechanical interlocking has not been verified of all Mechanical interlocking should
88. 6.
isolators. be verified.

Open / close operation of isolators has only been

It should be checked and
89. 7. checked manually but not from motor (i.e. Local
verified.
from switchyard and Remote from Control room).

Lights should be arranged and

Lights are not working in cubical boxes (e.g. D3Q20,
90. 8. installed in mentioned cubical
D2Q10 and D2Q12).
boxes.

Internal door of the cubical box of most of the

91. 9.
isolators is not opening / closing properly.
Mentioned problems of door
should be addressed.
Main door of the cubical box of D3Q10 is not
92. 10.
opening / closing properly.

Earthing pads for isolators in switchyard have not These pads should be bolted
93. 11.
been bolted with foundation. properly.

Thermostat / heater are not working properly of Thermostat / heater should be

94. 12.
D3Q32 and D3Q21. made functional.

6. 220kV CURRENT & VOLTAGE TRANSFORMERS

S No. Observation / Inspection Recommendation

No record in commissioning results has been found

CT circuit verification should
95. 1. regarding CT circuit verification for 220kV current
be performed as per SOP.
transformers.

Applied voltage has not been mentioned in the ratio Applied voltage should be
96. 2.
test of the Voltage transformers. mentioned.

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 Technical Audit / Inspection report of 220kV Grid Station NTDC Mansehra

Temperature has not been recorded for C&DF test

Temperature recording is
performed for Current transformers and Voltage
97. 3. necessary for comparison
transformers; Therefore, correction factor cannot be
purpose in future.
applied.

Doors for Junction boxes of Current Transformers

Mentioned issues should be
98. 4. and Voltage transformers are having closing issues
addressed.
and their gaskets are deteriorated mostly.

Spare cores as well as terminated wires / cores in the

The dressing should be up to
99. 5. CT and CVT junction box have not been properly
the mark.
dressed.

No cable glands have been used in the CVT

100. 6. Secondary box. Some cable glands in CT and CVT Cable glands should be used.
junction boxes are lose.

Secondary box of CTs (e.g. D3CT3, D3CT2 etc.) have

Proper cable tags should be
101. 7. no cable tags. Cable tags in some junction boxes are
provided for all cables.
missing.

In CT Junction box space heater has been provided Corrective measures should
102. 8. very close to control cables, which are also not be taken to address the
dressed properly (i.e. lying out of the cable duct). problem.

Light should be made

103. 9. Light is faulty in the cubical box of D3 CVT 10.
functional.

Door of D3CT2 Junction box door hinge is not Mentioned problem should be
104. 10.
working properly. addressed.

7. 132kV SWITCHYARD

S No. Observation / Inspection Recommendation

Appropriate (i.e. with two

Inappropriate thimble (i.e. with single bolt) is used for bolts) should have been used
105. 1. grounding of supporting structure and gantries to the for grounding of supporting
earth mesh in switchyard. structure and gantries with
earth mesh in switchyard.

Cable tag should be on each

Some cables have not been tagged in almost all the
106. 2. and every cable in the
cubical boxes of the switchyard.
switchyard.

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 Technical Audit / Inspection report of 220kV Grid Station NTDC Mansehra

Inappropriate cable ties have been used for binding

Appropriate cable ties should
107. 3. cable tags with control cables in switchyard cubical
be used.
boxes (e.g. CB, CT, CVT, MK and DS).

Check nuts have not been used for in the supporting

108. 4. Check nuts should be used.
structure of CBs , CTs and Isolators etc.

Cable dressing is not upto the mark in the cubical

Mentioned problems should be
109. 5. boxes of (CB, CT, DS and CVT). Some of the cable
addressed.
ducts have no cover.

Some of the cable ducts have been broken (e.g. Broken cable ducts should be
110. 6.
especially in CVT and CT junction box). replaced.

Vermin proofing is required in CT, CVT, DS and CB Vermin proofing should be up

111. 7.
boxes especially. to the mark.

Thermostat / heater in MK (Marshaling Kiosk) of T3 Thermostat / heater should be

112. 8.
(E1Q1) are not working properly. set right.

There should be name of circuit

The name of circuit breaker has not been mentioned
113. 9. breaker properly mentioned
on the MKs in 132kV switchyard.
(i.e. with paint) on the MKs.

The door of some MKs in 132kV is not being properly The door problem should be
114. 10.
closed. set right.

Cable sheath of some cables in MK (E7Q1) have not Cable sheath should be
115. 11.
been grounder properly. grounded properly.

8. 132KV CIRCUIT BREAKERS

S No. Observation / Inspection Recommendation

Functional tests of SF-6 Gauge have not been Functional tests of SF-6 gauge
116. 1. performed for any circuit breaker. Alarm & lockout should be performed as per
verification has not been carried out. SOP.

Timing test should be

No record has been found regarding the timing tests
117. 2. performed as early as possible
of any 132kV circuit breaker.
for all circuit breakers.

Dew point test has been performed but some circuit These values should have been
breakers having a value of temperature recorded as recorded with attention and
118. 3.
+51℃ rather than negative (e.g. E5Q1 and E8Q1 these values needs proper
having a value of +51℃). verification.

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Mentioned tests should be

119. 4. Minimum voltage trip test has not been performed.
performed as per SOP.

Close / open operation verification of circuit

breakers has been performed at site but the values The DC Voltage values should
120. 5.
of maximum / minimum voltage are different from be as per FAT.
FAT.

Mentioned feature should be

121. 6. Anti-pumping feature have not been tested.
tested as per SOP.

There should be proper cable

There is no gland used for the entrance of SF6 gauge
122. 7. gland for this very sensitive
cable in the CB box of the circuit breaker.
cable.

Lights and heaters in Cubical Boxes of some Circuit

Lights and heaters should be
123. 8. Breakers were non-functional (e.g. E8Q1, E9Q1 and
made functional.
E10Q1).

9. 132KV ISOLATORS

S No. Observation / Inspection Recommendation

Contact resistance test has been performed for

132kV isolators but the results of FAT and SAT
having a huge difference. Some results are given as
example:
Phase Phase SAT FAT

R 6.72µΩ 61µΩ
The contact resistance in SAT
Y E0Q11 9.82µΩ 66µΩ has been reduced to a
minimum of 7-8 times, which
B 6.73µΩ 62µΩ makes testing procedure /
124. 1.
testing set doubtful. The test
R 6.35µΩ 54µΩ should be performed again with
another test set to verify the
Y E4Q10 5.28µΩ 52µΩ
results.
B 8.9µΩ 60µΩ

R 6.35µΩ 39µΩ

Y E6Q11 5.28µΩ 40µΩ

B 7.47µΩ 42µΩ

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Opening and closing time test of isolators has been

Testing results clearly shows
performed but no testing report (i.e. printed from
that proper testing procedure
125. 2. test set) has been attached. And value of opening
has not been adopted or may
and closing time is exactly fixed 5.00 sec for all
have not been properly tested.
isolators.
Interlocking of isolators with circuit breakers has not Interlocking should be verified
126. 3.
been checked / verified. with circuit breaker.
Mechanical interlocking has not been verified of all Mechanical interlocking should
127. 4.
isolators. be verified.
Open / close operation of isolators has only been
It should be checked and
128. 5. checked manually but not from motor (i.e. Local
verified.
from switchyard and Remote from Control room).
Internal door of the cubical box of some of the Mentioned problems of door
129. 6.
isolators is not opening / closing properly. should be addressed.
Thermostat / heater of E1Q12, E9Q10, E9E10,
The thermostat / heater
130. 7. E10Q10, E10Q11, E10Q12, E9Q11, E9Q12 and
problem should be resolved.
E10E10 were not working properly.
The isolators should be
The switch of E1Q12 was set to manual which
131. 8. operated through motor and
indicate that it may have been operated manually.
from remote.
Lights found non-functional in cubical boxes (e.g.
Lights should be arranged
132. 9. E1Q11, E3Q11, E4Q11, E9Q10, E9E10, E10Q10,
where missing / non-functional.
E10Q11, E10Q12, E9Q11, E9Q12 and E10E10).

Earthing pads for isolators in switchyard have not These pads should be bolted
133. 10.
been bolted with foundation. properly.

10. 132kV CURRENT & POTENTIAL TRANSFORMERS

S No. Observation / Inspection Recommendation

No record has been found regarding 132kV current

134. 1.
transformers testing. CT testing and CT circuit
verification should be
No record in commissioning results has been found performed as per SOP.
135. 2.
regarding CT circuit verification.

Temperature has not been recorded for C&DF test

Temperature recording is
performed for Current transformers and Voltage
136. 3. necessary for comparison
transformers; Therefore, correction factor cannot
purpose in future.
be applied.

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Applied voltage has not been mentioned in the ratio Applied voltage should be
137. 4.
test of the Voltage transformers. mentioned.

Vermin proofing in the CT secondary box have not Vermin proofing should be
138. 5.
been done properly. done.

Light and heater was not functional in the junction Light and heater should be
139. 6.
box of CT (E10Q1). functional.

Doors for Junction boxes of Current Transformers

Mentioned issues should be
140. 7. and Voltage transformers are having closing issues
addressed.
and their gaskets are deteriorated mostly.

11. TRANSMISSION LINE LOSSES

Monthly statement record for different months regarding T/L Losses checked and found that
the losses of the 220kV transmission lines are within limits.

12. 220/132 KV PROTECTION AND CONTROL SYSTEM

S No. Observation / Inspection Recommendation

The scheme has been amended without proper The scheme along with
approval for Over fluxing protection relay due to components should be
141. 1.
which Auto transformer T-1 has been tripped 02 approved from Protection and
times on over fluxing relay. Control, NTDC.

There should be backup energy

No backup energy meters are installed on auto
142. 2. meters installed as it is CDP
transformers (T1 & T2).
(i.e. Common Delivery Point).

Functional verification of “AR Block on Circuit

Mentioned feature should be
143. 3. Breaker Failure” for auto reclosures has not been
verified.
performed.

Busbar protection auxiliary relay (Micom P742) has

only been tested at one injected current / point. Mentioned problems should be
144. 4.
Proper pickup / drop off verification along with verified / tested properly.
other features have not been verified.

220kV breaker failures of D1-BF2, D2-BF1, D2-BF-2

Operating time should have
145. 5. and D2-BF3 operating time has not been recorded
been recorded.
for stage 2.

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Operating time of over current installed on all 220kV

146. 6.
transmission lines has not been recorded.

220kV T/Line ISPR (MICOM P443) has been tested It should have been tested
147. 7.
with default settings but not actual settings. with actual settings.

Functional tests of Binary Inputs (BI), Binary Outputs

Mentioned functional tests
(BO) and LEDs have not been performed for most of
148. 8. should be performed for all
the protection relays installed on 220kV and 132kV
protection relays.
protection relays.

Synch check scheme should be

Synch check scheme has not been commissioned
commissioned properly and
149. 9. properly. Moreover, synch check relay is in “OFF /
synch check relay should be
De-energized” state.
tested properly.

220kV Busbar protection relay has not been tested It should be tested thoroughly
150. 10.
properly. Only pickup test has been performed. including busbar stability test.

Circuit breaker trip test from overcurrent protection

Mentioned verification / tests
151. 11. and verification of indications on control / relay
should be performed.
panels have not been performed.

It should be powered ON and

Screen recorder installed in energy meter panel is
152. 12. tested and commissioned
not working. (“Even not powered ON”)
properly.

No record has been found for testing of Event Event and fault recorders
153. 13.
recorders and fault recorders. should be tested.

The additional features of Distance relay i.e. VT The additional features of

154. 14. Failure, VT MCB Trip, SOTF and STUB etc. have not distance protection relays
been tested. should be tested as per SOP.

Time synchronization has not been done for all Time synchronization should
155. 15.
relays. be done.

Said scheme should be

156. 16. Tele-protection scheme has not been implemented. implemented after testing /
verification.

Timing test has not been performed for 11kV Circuit Timing test should be
157. 17.
breakers. performed as per SOP.

VIDAR test should be

158. 18. VIDAR test has not been performed for 11kV.
performed.

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11kV energy meters should be

159. 19. 11kV energy meters have not been tested.
tested as per SOP.

Indications (e.g. VT MCB trip, VT Failure, AC/DC Trip As there are no backup energy
etc.) regarding primary energy meters of auto meters, indications regarding
160. 20.
transformers have not been made available in primary meters should be
control room. wired up to the control panels.

Carrier OK signals are missing in 220kV ISPR-I and

161. 21.
220kV ISPR-II Transmission lines set II panels.

Relay panel (E6RP3) is having an indication “NIC No Mentioned issues should be

162. 22.
response”. addressed.

163. 23. Trip circuit supervision-II is unhealthy on E7RP3.

Communication problem of the

mentioned relays should be
132kV busbar protection panel (E0RP6-2) having
addressed as communication
164. 24. indication “Fiber Comm Error” on Auxiliary busbar
error on any auxiliary / master
relay (MICOM P742) of (E8Q1, E9Q1 and E10Q1).
relay makes 132kV Busbar
protection out of circuit.

Front panel buttons of 132kV auxiliary busbar

The said protection relay
165. 25. protection (MICOM P742) installed on E11Q1 are
should be replaced.
not working.

“CB Status alarm” has been observed on 132kV

auxiliary busbar protection (MICOM P742) of E13Q1,
The mentioned problems
166. 26. E12Q1 and E9Q1. And “Q1 Status Alarm” and “Q2
should be rectified.
Status alarm” observed on auxiliary busbar
protection (MICOM P742) of E9Q1.

Mentioned indications /
Following indications has been observed on 132kV problems of 132kV busbar
busbar protection (Common Unit i.e. MICOM P741) common unit should be
167. 27. “Fiber Comm Error”, Circuit Fault Alarm Zx”, “Circuit removed / addressed. And if
Fault Alarm Lock Zx”, “PU Error Alarm Zx”, “PU Error necessary the said relay should
Lock Zx”. be tested again as the relay is
not working properly.

Door of 132kV busbar protection panel (E0RP6-3) Door problem should be

168. 28.
was not closing properly. addressed.

Cable tags should be on each

Some cables have not been tagged in almost all the
169. 29. and every cable in the relay
relay and control panels.
and control panels.

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Tap changer operations from control room (Local as Tap changer operations should
170. 30.
well as from AVR) are not configured properly. be configured properly.

Manual control verification of fan groups of the Control of fan groups should
171. 31. transformers (i.e. Local and Remote) has not been be verified from all available
performed. points.

Inappropriate cable-ties have been used for binding

Appropriate cable ties should
172. 32. cable tags with control cables in relay and control
be used.
panels.

Cable dressing is not upto the mark in the relay and

control panels. Some of the cable ducts have no Mentioned problems should be
173. 33.
cover. Specially, cable dressing in 220kV control addressed.
panels is in extremely bad condition.

Vermin proofing is required in most of the relay and Vermin proofing should be up
174. 34.
control panels. to the mark.

Spare cables / cores have not been dressed properly These spare cores should be
175. 35.
and these are lying open outside the cable ducts. dressed properly.

Some of the cable glands in the relay and control The issue of cable glands
176. 36.
panels are not of proper size. should be resolved.

Lights are non-functional in some of the control and

177. 37. relay panels (e.g. D2R6, D2R1, D1R2, D1R1, E4RP3,
E7RP3, E9RP3 and E10RP3).
Light and heater problem
should be addressed.
Heater / thermostat found non-functional in some
178. 38. relay and control panels (e.g. D3R6, E4RP3, E7RP3,
E9RP3 and E10RP3).

Missing trench covers should

Some of the trench covers are rusty in control and
be provided and rusty trench
179. 39. relay room. Moreover, some trench covers are
covers should be replaced /
missing.
painted properly.

Over current protection (MICOM P122) installed on It should be checked and

180. 40.
11kV panels is showing zero (0A) current. verified.

Instrument meters installed on 220kV and 132kV

Instrument meters should be
181. 41. control panels and 11kV panels have not been
tested as per SOP.
tested.

Some indications have been recorded on the control

panels (e.g. “D0C6 supervision operated”, “E7CP31 These indication problems
182. 42.
CBQ0 Trip circuit II faulty” and “CB MK DC Supply should be addressed.
fail”).

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No record has been found for the testing of 11kV 11kV protection relays should
183. 43.
protection relays. be tested as per SOP.

Trip circuit supervision and DC Supervision installed

184. 44. on 220kV and 132kV relay panels have not been
tested. Mentioned relays should have
been tested as per SOP.
Trip relays / Slave relays installed on 220kV and
185. 45.
132kV control panels have not been tested.

Terminal protection glass (on terminal blocks) is Terminal protection glass

186. 46. missing in most of the 220/132/11kV control and should be properly fixed on
relay panels. terminal blocks.

13. EARTHING MESH

S No. Observation / Inspection Recommendation

Earth mesh integrity should be

Earth mesh integrity test has not been performed for
187. 1. performed for 132kV
132kV switchyard.
switchyard also.

Some lightening arrester rods were missing on the

Mentioned problems should be
188. 2. roof of control house building. And some rods
addressed.
supporting structure has not been bolted properly.

14. LIGHTENING / SURGE ARRESTORS

S No. Observation / Inspection Recommendation

Surge counters have not been tested as the surge

Surge counters must be
189. 1. counter readings of most of the surge arresters
tested.
(220kV and 132kV) installed are reading zero or one.

C&DF test has not been performed for all surge C&DF test should be
190. 2.
arresters. performed as per SOP.

Insulation resistance (IR) test of the following surge

arresters has not been performed (Auto transformer Insulation resistance test of
191. 3. 02 HV & LV side, 220kV transmission lines Allai mentioned surge arresters
Khuwar I & Allai Khuwar II and 132kV Power should be performed.
Transformer T3)

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LCM test should be performed

192. 4. LCM test has not been performed.
as per SOP.

Corona ring and grading potential ring has not been

These should have been
193. 5. provided / installed for 132kV surge arresters.
provided.
(Mentioned in Wapda specifications P181 [3.3]).

15. STATION BATTERY

S No. Observation / Inspection Recommendation

There should be proper

Pilot cell has not been marked in any of the battery
194. 1. marking of Pilot cell in all
banks neither in 220V nor in 110V DC.
battery banks.

Capacity test should be

Capacity test of 220V DC battery bank 2 has been
completely performed and
performed but was incomplete and Cell voltage of
195. 2. those cells which fail during
some cells after 5 hours have been dropped below the
capacity test should be
end voltage level i.e. 1.85V.
replaced.

Temperature correction has not been applied to the It should be applied for proper
196. 3.
specific gravity reading of the cells. analysis and comparison.

These batteries should be

197. 4. 48V DC Telecom batteries have not been provided.
provided.

16. BATTERY CHARGER / RECTIFIER

S No. Observation / Inspection Recommendation

When switched to boost, 220V DC Charger A has

198. 1.
supplied 266V DC to battery and 238V to the load.
The chargers should be
When switched to boost, 220V DC Charger B has calibrated as no calibration
199. 2. report of chargers has been
supplied 265V DC to battery and 238V to the load.
provided.
When switched to boost, 110V DC Charger A has
200. 3.
supplied 131V DC to battery and 114V to the load.

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When switched to boost, 110V DC Charger A has

201. 4.
supplied 133V DC to battery and 124V to the load.

The status of DC battery banks is as under:

S Battery Voltage Voltage Voltage

No. Bank (+,-) (+, Gnd) (-, Gnd)

220V
1 236V 113V 122V There is DC Grounding present
Bank A
202. 5. in the 110V DC should be
220V
2 236V 112V 122V rectified as early as possible.
Bank B
110V
3 118V 2V 114V
Bank A
110V
4 118V 59V 58V
Bank B

17. AUXILIARY VOLTAGE (400VAC, 110V & 220VDC) PANELS

S No. Observation / Inspection Recommendation

Proper scheme testing should

203. 1. Scheme testing of AC/ DC panels has not been done.
have been performed.

Some of the ampere meters installed in CHB (Control

House Building) electrification panels are not working
204. 2.
(e.g. 1ST Floor DB-D1, DB-D4, DB-L2, Ground Floor DB-
D2, DB-P2 and DB-L1).

Name tags of MCBs in CHB Electrification panels are

205. 3. Mentioned problems should be
not proper.
addressed.
Some of the MCBs and ampere meters have not been
206. 4.
properly fixed (e.g. DB-L2 at 1st floor).

Phase selector switch of DB-P3 (1st floor) is not

207. 5.
working.

Main MCB (FE-160) of DB-P2 (Ground Floor) operating The MCB should be replaced
208. 6. lever is broken / damaged. And supply is also not and supply should be made
available in the said panel. available in the panel.

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18. STATION TRANSFORMERS

S No. Observation / Inspection Recommendation

FAT reports should be provided

No FAT (i.e. Factory Acceptance Tests) reports have
209. 1. for future comparison and
been available for both station transformers.
reference.

19. GENERAL POINTS

S No. Observation / Inspection Recommendation

As per BOQ and Layout

Fire Hydrants in Control House Building (CHB) have drawing of CHB, Fire Hydrants
210. 1.
not been installed. should have been installed in
CHB.

As built drawings and other relevant material

These should be provided as
211. 2. regarding the testing, commissioning and
early as possible.
maintenance has not been provided.

There should be a proper shed

212. 3. There is no shed for the backup generator (100kVA). for the generator if not
separate room.

As per BOQ there should be a Parking area to

accommodate 10 vehicles to be constructed near CHB It should be constructed as per
213. 4.
but it has been constructed only to accommodate 6 BOQ.
vehicles.

Keeping in view that there is

There is no space available in Control House Building no MSB (Mechanical Services
214. 5. (The only building available at Grid Station) to place Building), a C-Type store may
the spares which will be received as per BOQ. be constructed to for the safe
placement of spares.

There should be security

There are no security cameras installed at the grid
215. 6. cameras installed at the grid
station.
station.

The boundary wall of the grid station is damaged from The boundary wall should be
216. 7. many places and there are no security check posts repaired and check posts
constructed. should be constructed.

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Lighting system should be in

Lighting system for the switchyard and approach road
217. 8. working condition as early as
is incomplete.
possible.

Sand buckets and sand drums are not available in the Sand buckets and sand drums
218. 9.
switchyard. should be arranged.

There are nests found in the exhaust fan housing in

11kV room should be cleaned
219. 10. 11kV room. And cleanliness of 11kV room was not up
properly.
to the mark.

There is acute shortage of technical, non-technical and Shortage of staff should be

220. 11.
security staff. addressed.

Spares and T&P have not been handed over to Grid Spares and T&P should be
221. 12.
station staff. handed over to grid staff.

Keeping in view the

emergency duty of the grid
Residential Colony has not been constructed at the
222. 13. station residential colony
grid station.
should be constructed as early
as possible.

Engr. Muhammad Bakhsh Mahaar

Addl. Chief Engineer (TL & TA)
o/o CE (TSG) North NTDC, Engr. Ahmad Waqas
NKLP Lahore. Deputy Manager (TL&TA),
o/o CE (TSG) North, NTDC,
Engr. Tehseen Ali Khan NKLP, Lahore.
Deputy Manager,
220kV Grid Station,
NTDC, Mansehra. Engr. Nasir Abbas
Deputy Manager (TL & TA)
o/o CE (TSG) North NTDC,
NKLP Lahore.
Engr. Muhammad Kamran
Assistant Manager (P&I)
220kV Grid Station, Engr. Muhammad Faheem Akram
NTDC Mansehra. Assistant Manager (TL&TA),
o/o CE (TSG) North, NTDC,
NKLP, Lahore.
Engr. Zia Ur Rehman
Assistant Manager (M)
220kV Grid Station, Mr. Muhammad Waseem Tahir
NTDC Mansehra. Assistant Manager (TL & TA)
o/o CE (TSG) North NTDC,
NKLP Lahore.

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