CIMFR Animesh Report Final Nbhg-1
CIMFR Animesh Report Final Nbhg-1
ON
ELECTRICAL DISTRIBUTION SUBSTATION
At
CSIR-Central Institute of Mining and Fuel Research ,
Barwa Road, DHANBAD.
Vocational Training
During the period from 24th December, 2023 to 22nd January, 2024
By
ANIMESH CHAKRABORTY
Roll no: 2001021
Registration no: 20030450017
Sindri-828123
District - Dhanbad, Jharkhand
Under Supervision of
I take this opportunity to express my profound gratitude and record our sense of
obligation to the individuals who helped me directly or indirectly in accomplishing my
training on (ELECTRICAL DISTRIBUTION SUBSTATION) at the CSIR-Central
Institute of Mining and Fuel Research, Dhanbad(Jharkhand), from 24th December 2023
to 22nd January 2024.
I am grateful to Prof. Arvind Kumar Mishra, Director, CSIR - CIMFR and Mr. Dilip
Kumbhakar, Chief Scientist and Head, HRD CIMFR, Dhanbad for permitting us to do
a project at this institute.
At the very outset, I would like to express my sincere gratitude to Mr. Virendra kumar,
Executive Engineer(Electrical), CSIR – CIMFR for his guidance and support. He took
his time off from work and explained about the practical aspects of the project. His
valuable guidance has helped me and my team patch this project and make it full proof
success. His suggestions and instructions have served as the major contributor towards
the completion of the project. This work would be incomplete without his involvement.
I would also express my gratitude to staff of Electrical Maintenance and Generator
section, who were very helpful throughout this training period.
INDEX
Sl. no Topic Page no
[1] Introduction 01
[2] Substation and its classification 02 – 04
[3] Indoor Substation 05
[4] Main Indoor Substation 06
[5] Basic features and components of Main Indoor Substation 07 – 19
A. 11 KV incoming line 07
B. Isolators 07
C. Insulators 08
D. Circuit Breakers 08 – 10
E. Transformer ( type, rating and selection) 11 – 18
F. Power Distribution Board 19
[6] Brushless AC Diesel Generator 20
[7] Automatic Transfer Switch 21 – 22
[8] Technological Block Indoor Substation 23
[9] Basic features and components of Technological block 24 – 27
Indoor substation
A. 11 kV incoming line 24
B. Oil Circuit breaker 24 – 25
C. Transformer 25 – 26
D. Power Distribution Board 26 – 27
[10] Pole Mounted Substation 28
[11] Basic features and components of Pole Mounted Substation 29 – 40
A. 33/11 kV transmission line 29
B. Double Pole structure 29
C. Foundation of Poles 30
D. Cross arm 30
E. Isolators (AB Switch) 31
F. Lightning arrester 31
G. Horn gap fuse 31
H. Circuit Breaker 31 – 32
I. Transformer 32 – 33
J. Insulators 33 – 34
K. Cables 34 – 37
L. Earthing 38
M. Metering unit 39
N. Power Distribution panel 39 – 40
O. Danger notice plate 40
[12] Scope of Improvement 41
[13] Conclusion 42
[14] References 43
LIST OF FIGURES
Sl no Figure Page no
1 General layout of distribution of power in substation 1
2 Layout of indoor substation 5
3 Main Indoor substation 6
4 I. Double pole structure of incoming 11kV 7
II. Types of insulators 8
III. a. Four HT OCB in 11kV main distribution panel 9
b. Main OCB for 11 kV incoming 10
c. Low tension OCB of 400/440V 10
IV. a. Layout of Transformer 11
b. Transformer core 11
c. Transformer windings 12
d. Transformer tank 12
e. Transformer oil 12
f. Bushing and terminals 12
g. Conservator tank 13
h. Buchholz relay 13
i. Chart of kVA rating of transformer 14
j. Image of Transformer 1 16
k. Name plate of transformer 1 16
l. Image of transformer 2 17
m. Name plate of transformer 2 17
V. Power Distribution panel 19
5 Brushless AC Diesel Generator 20
6 Automatic Transfer switch 21
7 Technological block indoor substation 23
8 I. 11kV distribution panel of main substation 24
II. 11kV high tension Oil Circuit Breaker 24
III. 11000/415 V indoor substation transformer 25
IV. a. Power distribution panel 27
b. DG set panel 27
c. Automatic transfer switch 27
9 I. Pole mounted substation near gate no 2 28
II. Layout of pole mounted substation 28
10 I. Double pole structure 29
II. Structural layout of pole mounted substation 30
III. Cross arm 30
IV. AB switch 31
V. Lightning Arrester 31
VI. Horn gap fuse 31
VII. 3 phase core type pole mounted transformer 32
VIII. Types of insulators 34
IX. a. 3 core 11kV XLPE cables 35
b. 3 core cable 35
c. 4 core 11kV cable 35
d. size and current rating chart of cables 36
X. Earthing in pole mounted substation 38
XI. Distribution board 40
XII. Danger notice board 40
INTRODUCTION
Substations are important part of power system and form a link between generating stations,
transmission systems and distribution systems. It is an assembly of electrical components such
as bus-bars, switchgear apparatus, power transformers etc. Their main functions are to receive
power transmitted at high voltage from the grid substations and reduce the voltage to a value
suitable for distribution. Some substations provide facilities for switching operations of
transmission lines, others are converting stations.
Substations are provided with safety devices to disconnect equipment or circuit at the time of
faults. Substations are the convenient place for installing synchronous condensers for the
purpose of improving power factor and it provide facilities for making measurements to
monitor the operation of the various parts of the power system.
The substations may be classified in according to service requirements and constructional
features. According to service requirements it is classified in to transformer substations,
switching substations and converting substations. The present-day electrical power system is
A.C. as well as D.C .
The electric power is produced at the generating station, which are located at favourable
places, generally quite away from the consumers. It is delivered to the consumer through a
large network of transmission and distribution. At many places in the line of power system, it
may be desirable and necessary to change some characteristic (e.g., Voltage, ac to dc,
frequency, power factor etc.) of electric supply. This is accomplished by suitable apparatus
called sub-station for example, generation voltage (11KV) at the power station is stepped up
to high voltage for transmission of electric power. Similarly, near the consumer's localities, the
voltage may have to be stepped down to utilization level. This job is again accomplished by
suitable apparatus called sub-station.
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SUBSTATION
A Substation is an assembly of apparatus which is installed to control Transmission and
Distribution of electrical power.
It is also used to step up/ step down of voltage levels, AC (Alternating Current) to DC (Direct
Current) conversion or vice versa, metering, frequency and power factor improvement of
electric supply.
The generating electricity is step up by generation substation which is then supplied to
transmission substation that goes to the double pole set up by JSEB (Jharkhand State Electricity
Board) afterwards it goes to the double pole set up by building authority which is then passed
to the area substation. The area substation receives 11KV voltage. It is further stepped down
using the transformer to 440V. The 440V is then supplied to the main panel of the building in
three phases. Through the main panel of the building, it is passed to each floor distribution
panel in single phase. There are two distribution board in each floor. One distribution board is
used for light, fan and 5A points and other distribution board is used for AC points.
Substations may be owned and operated by an electrical utility, or may be owned by a large
industrial or commercial customer. Generally, substations are unattended, relying on SCADA
for remote supervision and control.
a. Step up substation-
➢ Also known as Switchyard .
➢ It is linked with generating station as generation is achieved in low voltage.
➢ Economical transmission of electrical energy over greater distance.
➢ Ex:- 11/132 KV substation.
a. Converter Substation-
➢ It is used in conversion of AC to DC voltage or vice versa and also used in change in
frequency.
➢ Used for Electrical Traction, battery charging etc.
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b. Switching Substation-
➢ Used for switching of power line without altering the voltage as they are placed
between Transmission lines.
➢ Isolate fault occurrence and de-energise fault equipment.
d. Collector Substation-
➢ It is used to collect power from various sources of energy where power flow is
collected and distributed by stepping up the voltage.
➢ Used in distributed power generated project.
a. Outdoor Substation-
➢ It is constructed in open area with voltage level of 132/66 KV, 132/11 KV or
11KV/440V.
➢ All the equipment in outdoor substation is within view, so fault location is easier.
➢ More space is required for its construction.
b. Indoor Substation-
➢ Apparatus is installed within the substation building or shade.
➢ It is not easily affected by environmental factor such as low lightning effect.
➢ Generally, it is used for 11KV/415V .
➢ High maintenance and much safer than outdoor substation.
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➢ Transformer used in this substation is D/⅄ connected.
➢ Used for low voltage power distribution to domestic consumers.
d. Mobile Substation-
➢ It provides temporary power supply to industry and in such area which does not have
its own power grid.
➢ Easy mobility.
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INDOOR SUBSTATION
In these electrical sub-stations, equipment like transformers and switchgear are installed inside
the building. These are generally made of capacity up to 117 and 500 kVA. Still, where
impurities (conducting dust, smoke, metallic corrosive gases) are found in the surrounding
environment, the sub-stations are made of 11kV, 33kV and 66kV.
Indoor type substations have several subdivisions, including control subdivision, protection
subdivision, main bus-bar subdivision, circuit breaker, operating mechanism subdivision, and
current-transformer and cable-seal box subdivision. The switchgear at the supply or primary
side only houses the circuit breaker. High voltage is supplied to the primary side of the
transformer with the help of a circuit breaker. The feeders are connected to the bus bar. The
isolating switch and circuit breaker are installed in the feeder panel. The main reason for
installing an indoor substation is that the possibility of fire can be reduced by installing a fire-
resistant wall and fire extinguishers. Carbon dioxide is mainly used to extinguish fires. The
layout of the indoor type sub-station is shown below:
Indoor substations have high capital cost than outdoor substation, high maintenance, less
lighting effect, and faults are easily caught.
In CSIR – CIMFR, there are two 11kV/440V indoor substations:
o Main indoor substation in main building
o Technological building indoor substation
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MAIN INDOOR SUBSTATION
It is situated in the main administration building of CSIR – CIMFR, Dhanbad. This substation
is used to delivers power to whole institution. All the apparatus are installed within a closed
room in the main building. The incoming voltage of this substation is 11kV and outgoing
voltage is 440V.
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Basic features and components of main indoor substation are:
A. 11kV incoming line :-
11 KV lines are used in residential areas and feeds the local transformer which
distributes power in that area.
In CSIR – CIMFR, 11kV line is incoming in a double pole structure which is placed
outside main building. In this Double Pole structure, metering is also done and it has
one AB switch for protection purpose.
B. Isolators :-
Isolator refers to disconnecting switches which is used to isolate different component
or sections of a substation’s electrical system for maintenance, repair, or safety purpose.
There are two common types of isolators used in substation:
• Busbar isolator
These isolators are used to isolate sections of a substation busbar system. The
busbar is conductive bars that carry electrical power between various
component within a substation. This provides a means to disconnect a specific
section of the busbar from the rest of the system, allowing maintenance work or
repairs to be carried out on the section without affecting the rest of the system.
• Line isolator
This are used to isolate transmission or distribution lines from the substation.
These disconnectors are installed at the points where the lines connect to the
substation. They provide a way to disconnect the lines from the substation
equipment such as transformer or switchgear, for maintenance or repair
purpose.
In this institute, Line isolator of 11kV is installed in main incoming Double Pole
structure (AB switch) and Busbar isolator of 11KV is installed in 11kV distribution
panel of main substation.
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C. Insulators :-
In CSIR – CIMFR, generally three types of insulators are used:
o Pin insulator: It is a device that isolates a wire from a physical support such as
a pin on a telegraph or a utility pole. It is a single layer shape that is made out
of a non-conducting material usually porcelain or glass.
o Disc insulator: In suspension insulator, no of insulators are connected in series
to form a string and the line conducted is carried by the bottom most insulator.
Each insulator of suspension string is called disc insulator because of its disc
like shape.
o Shackle insulator: Shackle insulators are mainly used in low-voltage
distribution lines. The shackle insulators can be used either in a horizontal
position or in a vertical position. The shackle insulators can be directly fixed to
the pole at the cross arm and the line conductor in the grove is bounded by a
soft binding wire.
D. Circuit Breakers :-
A circuit breaker is an essential component in a substation's electrical system. It is a
protective device designed to automatically interrupt or break the electrical circuit when
it detects a fault or abnormal condition, such as an overload or short circuit. The primary
function of a circuit breaker in a substation is to protect the electrical equipment,
transmission lines, and distribution systems from damage due to excessive current flow.
Here are some key features and functions of circuit breakers in substations:
o Fault Detection and Interruption: Circuit breakers continuously monitor the
electrical current flowing through a circuit. If the current exceeds a predefined
threshold, indicating a fault or abnormal condition, the circuit breaker trips and
interrupts the flow of electricity, effectively isolating the faulted section of the
electrical system.
o Load Protection: Circuit breakers provide protection against overloads, which
occur when the current flowing through a circuit exceeds its rated capacity.
When an overload is detected, the circuit breaker trips to prevent overheating
and potential damage to the equipment and conductors.
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o Short Circuit Protection: Short circuits occur when there is an unintended
connection or low-resistance path between two points in a circuit. Circuit
breakers are designed to rapidly interrupt the circuit in response to a short
circuit, preventing excessive current flow and potential damage to the
equipment.
o Coordination with Protection Systems: Circuit breakers in substations are
coordinated with other protection devices, such as relays and protective relaying
schemes, to ensure selective tripping. Selectivity ensures that only the circuit
breaker nearest to the fault operates, minimizing the impact on the rest of the
electrical system and enabling faster fault location and restoration.
Circuit breakers play a crucial role in maintaining the reliability, safety, and efficient
operation of substations by protecting equipment and preventing damage during
abnormal electrical conditions.
It is of two types-
a) LT (Low Tension) Circuit Breaker
o MCB (Miniature Circuit Breaker)
o MCCB (Moulded Case Circuit Breaker)
o ELCB (Earth Leakage Circuit Breaker)
o RCCB (Residual Current Circuit Breaker)
o ACB (Air Circuit Breaker)
b) HT (High Tension) Circuit Breaker
o VCB (Vacuum Circuit Breaker)
o OCB (Oil Circuit Breaker)
o S𝐹6 CB (Sulphur Hexafluoride Circuit Breaker)
o ABCB ( Air Brake Circuit Breaker)
In main indoor substation, there are total 5 HT OCB and 2 LT OCB. A primary High
Tension Oil circuit Breaker of 11 kV, 400Amp is set up next to 11kV incoming line
and 4 HT OCB is installed in 11kV distribution panel next to isolator. The 2 low tension
OCB of 400/440V is for the two transformers installed in the substation.
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Fig 4.III.b:- Main OCB for 11kV incoming line Fig 4.III.c:- Low tension OCB of 400/440V
Type HN3
Volts 400/440V
Amps 800A
Cycles 50 ~
No 60/06
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E. TRANSFORMER :
Transformer is a static device which transfers electrical energy form one electrical
circuit to another electrical circuit through magnetic fields without change in frequency.
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II. Transformer Windings
Copper winding is used in transformer and it
is wound in transformer core. Each turn in
Transformer winding is insulated to avoid
short circuit. The type and arrangement of
winding used for transformers depend upon
the current rating, short circuit strength,
temperature rise, impedance, and surge
voltages.
Fig 4.IV.c: Transformer windings
III. Transformer Tank
There are two main function of transformer tank
• Protects the core and the windings from the
external environment.
• Serves as a container for oil and support for
all other transformer accessories.
Tank bodies are made by fabricating rolled steel
plates into containers. They are provided with lifting
hooks and cooling tubes. In order to reduce weight
and stray losses, aluminium sheets are also used
instead of steel plates. However, aluminium tanks are Fig 4.IV.d:- Transformer tank
costlier than steel ones.
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VI. Conservator Tank
The oil conservator is moved on top of the
transformers and is located well above the tank and
bushings. The transformer oil expands and contracts
with an increase and decrease in temperature. The
oil conservator provides adequate space for oil
expansion. It is connected to the main tank through
a pipe. A level indicator is fitted to the conservator
to indicate the oil level inside. Fig 4.IV.g: Conservator Tank
❖ Transformer ratings
Transformer ratings is measured in KVA (Kilo Volt Amperes), MVA (Mega Volt
Amperes).
Loads are measured in KW (Kilo Watt).
The range of all the transformer rating of distribution transformer is from 16 KVA to
1000KVA ( 16, 30, 37.5, 45, 75, 112.5, 150, 225, 300, 315, 500, 1000 KVA).
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The chart of KVA rating of transformer with voltage and current rating is shown
below:
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❖ Selection of the Transformer on the basis of power required for a
building/plant/load-
Let us suppose a building has 100 people.
Power consumed by individual person:
o Lighting – (100 – 400)W
o Appliances and electronics – (300 – 1500)W
So, at an average individual consumption 1 person = 1500W =1.5kW
Total consumption of 200 people = 1.5kW × 100 = 150kW
Power Factor: It is the ratio of true power (Active Power, measured in KW) to apparent
power (measured in KVA). For distribution of power, power factor is 0.8.
150 𝑘𝑊
Load in kVA = = 187.5 KVA
0.8
Diversity Factor: The ratio of the sum of individual maximum demands to the
maximum demand on the power station is known as a diversity factor. Diversity factor
can be used to estimate the total load required for a facility or to size the transformer.
The knowledge of diversity factor is vital in determining the capacity of the plant
equipment. Diversity factors have been developed for main feeders supplying a number
of feeders, and the typical values are given below.
➢ Residence consumer - 1.2 to 1.3
➢ Commercial load - 1.1 to 1.2
➢ Power and lighting loads - 1.50 to 2.0
Let the diversity factor be 1.2.
So, Transformer rating (in kVA) = 187.5 kVA × 1.2 =225kVA
Taking 25% margin for future safety,
Transformer rating = 225kVA × 1.25 = 281.25 kVA
So, we select transformer rating of 300 kVA or 315 kVA.
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In main substation, there are two 11kV/440V transformer of 350kVA rating which are
connected in parallel.
➢ Transformer 1
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Transformer To. BSS121/1969
Type of cooling ON (Oil Natural)
Impedance Volts 5.23%
Year of manufacture 1961
Oil 925 L
Weight of oil 802 kg
Core and windings 1006 kg
Total weight 2620 kg
➢ Transformer 2
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The detailed information of transformer 2 is shown below:
Maker’s Sl no. TQ139/1592
Type Indoor
Maker’s name G.E.C. (The General electrical Co.
of India Limited)
K.V.A. 350kVA
Volts at no load (HV) 11000 V
Volts at no load (LV) 415 V
Amperes (HV) 18.37 A
Amperes (LV) 488 A
Phase (HV) 3
Phase (LV) 3
Frequency 50 Hz
Vector symbol DY11
Diagram Drg no. DN712
Transformer To. BSS171/1959
Type of cooling ON (Oil Natural)
Impedance Volts 5.24%
Year of manufacture 1961
Oil 925 L
Weight of oil 802 kg
Core and windings 1006 kg
Total weight 2620 kg
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F. Power Distribution Board :
A power distribution board is one of the essential components used for electrical
wirings in households and office buildings. The power distribution board is usually
installed where the input current from the primary energy supply line enters the
household wiring system.
Depending on the amperage, usage, and location, power distribution boards can be
several types. Power distribution boards used for urban households usually range from
transfer switches, main breaker panels, and sub-panels. Uses of power distribution
boards Power distribution boards are of vital importance for electrical distribution and
protection at the household level. –
o Electrical distribution: As the name suggests, the power distribution board is
primarily responsible for evenly distributing the electrical supply from the main
supply line throughout the house. The electrical flow is divided by the power
distribution board upon entering the household wirings from the main supply
line. It is evenly transferred to the subsidiary connections and miniature circuits
across the line.
o Electrical protection: The other vital purpose served by the power distribution
line is electrical protection to the subsidiary electrical lines and miniature
circuits in the house. The power distribution board is equipped with fuses and
miniature circuit breakers (MCBs and MCCBs) that prevent permanent
electrical damages to connected devices and wirings from risks like circuit
overloads and power surges during electrical anomalies.
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❖ For backup, a Diesel Generator of 600kVA is installed near Gate no 2 for supply
of 3 phase, 440V A.C. supply in this institution.
KW 480 Ambt. C 40
Hz 50 Sae/Disc 1/14’’
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II. Power load: Power load are non-essential components are those components
which does not need continuous power supply. Air Conditioners, Pumps and
some equipment come under non-essential components. These components are
not connected to DG Set. Non-Essential components are not connected to ATS
(Automatic Transfer Switch). Solar power supply is connected to only this kind
of Non-Essential Component. Solar Power source from ACDB (3 Phase) comes
to Bus Bar of Non-Essential Component.
Two input supply is received into ATS, one is the Main Supply and other is standby
(Generator supply). The transfer of power from Main to Standby and vice versa goes
automatically into ATS. There is a single output cable which goes into the BUSBAR
for distribution into the required rooms.
Function of ATS is to –
▪ Primary and Secondary Power Sources: An ATS typically connects two power
sources, a primary source (often the utility power grid) and a secondary source
(such as a backup generator or an alternate power supply). The primary source
is the normal power supply, while the secondary source is used as a backup or
alternative power source.
▪ Power Monitoring: The ATS continuously monitors the primary power supply.
If it detects a loss of power, voltage drop, or other predefined conditions that
indicate an interruption or degradation of the primary power source, it initiates
the transfer process.
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▪ Transfer Mechanism: The ATS employs mechanical or electronic mechanisms
to automatically switch the electrical load from the primary power source to the
secondary power source. It ensures a swift and seamless transition to the backup
power supply, minimizing downtime and maintaining power to critical loads.
▪ Transfer Time: The transfer time of an ATS refers to the time it takes for the
switch to transition from the primary source to the secondary source. Modern
ATS systems can achieve transfer times within a few milliseconds, resulting in
minimal disruption to connected equipment.
▪ Manual and Automatic Operation: ATS devices can be configured for automatic
operation, where the transfer occurs automatically without any human
intervention, or manual operation, allowing operators to manually initiate the
transfer process if desired.
▪ Monitoring and Control: ATS systems often provide monitoring and control
features, allowing operators to monitor the status of power sources, load
conditions, and transfer events. Some ATS devices can also integrate with
building management systems or remote monitoring systems for centralized
control and monitoring.
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TECHNOLOGICAL BLOCK INDOOR SUBSTATION
It is situated in Technological Block building of CSIR – CIMFR, Dhanbad. This substation is
used to delivers power to Technological block, Mining gallery, old workshop furnace and
others. All the apparatus are installed within a closed room in ground floor of Technological
building. The incoming voltage of this substation is 11kV and outgoing voltage is 440V.
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Basic features and components of Technological Block indoor substation are:
A. 11 kV incoming line:-
11 KV lines are used in residential areas and used to feed the local transformer which
distributes power in that area.
In Technological block indoor substation, 11 kV comes from 11kv distribution panel
of main indoor substation with the help of 11 kV underground cables.
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Rating of HT Oil Circuit Breaker is given below:
Type VL
Volts 11000 V
Amps 200A
Cycles 50 ~
Phase 3
Sl no 61/01
C. Transformer:-
Transformer is a static device which transfers electrical energy form one electrical
circuit to another electrical circuit through magnetic fields without change in frequency.
In Technological block indoor substation, it has core type transformer of incoming
voltage 11kV and outgoing voltage of 415V. The high voltage side of transformer is
delta connected of 11000V rating and low voltage side is star connected ( 3 phase wire
and one neutral wire) of 415V rating.
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The structural description of this transformer is given below:
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circuit when an overload, short circuit, or other fault condition occurs. This helps to
protect the equipment and prevent damage.
The main trunk busbar is used to delivers power to technological block. This supply is
connected to ATS (Automatic Transfer switch) which is used to deliver power to light load
components in emergency situations by the help of diesel generator.
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POLE MOUNTED SUBSTATION
Pole Mounted Substation provides the energy supply for the local area in which the line is
located. The main function of the substation is to collect the energy transmitted at high voltage
from the generating station and then reduce the voltage to an appropriate value for local
distribution and gives facilities for switching.
Two poles with seating channels and associated angles create an H type configuration. Pole
mounted Substations receive HT 11KV supply and produces 3-phase, 4-wire 400V LT
distribution voltage by last step-down transformation. On H structure, control and protection
is mounted at 2440mm (8ft) height from the ground level.
The initial and maintenance cost of pole mounted substation is low. These pole-mounted
substations are the cheapest and smallest form of substations. This arrangement needs about 3
meters by 2 meters space (on ground) around the H Pole structure to locate Distribution box
and other components.
In CSIR-CIMFR, a Pole Mounted Substation is located near Gate no 2 which has a core type
Transformer of 315 KVA rating. Its incoming voltage is 11 KV and outgoing voltage is 433V.
Fig 9.I:- Pole mounted substation near gate Fig 9.II: Layout of pole mounted substation
no 2
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Basic features and components of Pole Mounted Substation are:
A. 33/11 KV transmission line:
11 KV lines are used in residential areas and feeds the local transformer which
distributes power in that area.
33 KV are used to distribute power from one small substation to other.
So, 33 KV is delivered in Dhanbad Substation which gives an output voltage of 11 KV
to main panel in CSIR-CIMFR. Through the main panel situated in main building, an
incoming of 11 KV is provided to Pole Mounted Substation present near Gate no 2.
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C. Foundation of poles:
Total length of pole- 9m (7.5 m above ground and 1.5 m below ground, grouting length
is one-sixth of total length of pole).
Total width- 8 feet
o Above 1.5 m from ground, Transformer is connected and bolted.
o Above 5m from ground, Horn gap fuse is connected.
o Above 6.7m from ground, Lightning arrestor is connected.
o Above 7.3m from ground, AB switch is connected.
D. Cross arm:
It is horizontal element used on distribution lines to support
insulator, transformer and many other equipment.
Earlier, wooden cross arm is used, but nowadays composite
crossarm (made up of angel steel) are used which has larger
strength.
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E. Isolators:
In CSIR-CIMFR, AB Switch is used as an isolator.
It is an isolator which is an off-load switch that isolate
equipment for maintenance and transfer load from one
bus to another.
It is a long rod which has a handle and by bringing it
down, we can directly disconnect HT from the source.
AB Switch is known as Air-Break Switch. Their
contacts open in the air and quenching of an arc is
achieved by compressed air.
Fig 10.IV: AB SWITCH
F. Lightning Arrester:
It is a protective device which is used to discharge
overvoltage to earth during lightning strokes.
In Pole mounted Substation, generally electrolytic type
LA is used. And three lightning arrester is used in three
lines (one LA in one phase).
H. Circuit Breaker:
It is a switching device which isolates power supply of system in case of any fault or
short circuit occurred in system.
It is of two types-
c) LT (Low Tension) Circuit Breaker
o MCB (Miniature Circuit Breaker)
o MCCB (Moulded Case Circuit Breaker)
o ELCB (Earth Leakage Circuit Breaker)
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o RCCB (Residual Current Circuit Breaker)
o ACB (Air Circuit Breaker)
d) HT (High Tension) Circuit Breaker
o VCB (Vacuum Circuit Breaker)
o OCB (Oil Circuit Breaker)
o S𝐹6 CB (Sulphur Hexafluoride Circuit Breaker)
o ABCB ( Air Brake Circuit Breaker)
It is not necessary to use Circuit Breakers in Pole Mounted Substation, but in some
places, OCB is used of rating 440/400V for easy maintenance.
I. Transformer:
Transformer is a static device which transfers electrical energy form one electrical
circuit to another electrical circuit through magnetic fields without change in frequency.
In CSIR-CIMFR, the pole mounted substation has core type transformer of incoming
voltage 11KV and outgoing voltage of 433V.
The high voltage side of transformer is delta connected of 11000V rating and low
voltage side is star connected ( 3 phase wire and one neutral wire) of 433V rating.
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The structural description of this transformer is shown below:
J. Insulators :
In CSIR – CIMFR, generally two types of insulators are used.
o Pin insulator: It is a device that isolates a wire from a physical support such as
a pin on a telegraph or a utility pole. It is a single layer shape that is made out
of a non-conducting material usually porcelain or glass.
o Disc insulator: In suspension insulator, no of insulators are connected in series
to form a string and the line conducted is carried by the bottom most insulator.
Each insulator of suspension string is called disc insulator because of its disc
like shape.
o Shackle insulator: Shackle insulators are mainly used in low-voltage
distribution lines. The shackle insulators can be used either in a horizontal
position or in a vertical position. The shackle insulators can be directly fixed to
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the pole at the cross arm and the line conductor in the grove is bounded by a
soft binding wire.
K. Cables :
Earlier HT cables and LT cables were the two most common type of cables used in
distribution substations. But nowadays XLPE is the mostly recommended because of
its vast advantages over normal power cables.
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In CSIR – CIMFR, 3 core XLPE cables are used as a High-Tension cable for
distribution of 11KV voltage from main building to pole mounted substation.
At first In XLPE (cross connected synthetic resin insulated atomic number 13 conductor
armoured) cable stranded atomic number 13 conductor is screened within the variety
of semi-conductor extrusion that gives a sleek conductor surface that prevents
formation of cavities at the surface of conductors after they area unit subjected to
bending. The insulation is any screened with layer of non-metallic semiconductor and
on high of that with a non-magnetic metal like screen within the variety of copper or
atomic number 13 tape is applied. The area feature of the XLPE insulation is that long
molecular chains of synthetic resin area unit cross connected to every different by
means that of a method almost like processing of rubber and therefore forming a 3
dimensional-network structure with robust bond.
Fig 10.IX.b:- 3 core, 11kV cable Fig 10.IX.c:- 4 core 1.1kV cable
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The size and current rating chart of power cable are as follows:
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The rating chart of XLPE insulated cables is shown below -
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L. Earthing :
Earthing system provides a surface of uniform ground or nearly zero potential under
and around the substation. The Earthing System is designed such that in both normal
and abnormal conditions there is no danger of shock to persons. Earthing limits rise of
potential on metallic supports during occurrence of abnormal conditions or insulation
failure. In case of a fault directly to earth, Earth Fault Current will flow back to its
source (i.e., the Primary substation). Earthing provides a low impedance path to fault
currents to ensure prompt and consistent operation of protective devices during ground
faults.
A total three no of earthing will be provided for DP structure, one earth will be
connected to the lightning arrester, another earthing will be connected to the
transformer neutral and third earthing will be connected to all the parts of the DP
structure. All the earthing is also interconnected to each other.
• For Earthing three earth pits in Triangular formation at a distance of 6.5 meters from
each other to be provided.
• Earth pit should be digged for 45cm*45 cm size and 5ft depth.
• 3 number of 40 mm diameter and 2.9mm thickness and 3meter(10ft) length of earth
pipe should be used for earthing.
In CSIR – CIMFR, plate earthing and pipe earthing is used.
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M. Metering unit :
This meter keeps record of the total energy consumption of the campus. It takes
approximately 10 minutes to show all 13 different parameters. For electric bill payment,
the technician takes the reading from this meter itself.
Rating of the meter installed: 3 phase 4-wire Watt Hour Meter
Frequency- 50 Hz
Base Current (𝐼𝑏 ) – 5A
Maximum Current (𝐼𝑚𝑎𝑥 ) – 10A
CT / PT Metering:
This box contains a step-down transformer. Its function is to reduce the voltage for
meter so that it is easier for the meter to take the reading. Generally, it is not easy to
take reading for such a high voltage (11KV). So first all the parameters are reduced and
then measured. After the lowered value is measured the reading is displayed in the
Reading Box installed near HT Pole.
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The output power from Pole mounted substation in CSIR – CIMFR is distributed
to Pump House, Guest House, Committee centre, Director house and others.
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SCOPE OF IMPROVEMENT
There are several areas where improvements can be made in an 11 kV substation to enhance
its efficiency, reliability, and safety. Here are some potential areas for improvement:
➢ Equipment Upgrades: Evaluate the condition and performance of existing equipment,
such as transformers, switchgear, circuit breakers, and protection relays. Consider
upgrading to newer, more efficient models that offer improved performance, reliability,
and safety features.
➢ Automation and Remote Monitoring: Implement automation and remote monitoring
systems to enable centralized control and real-time monitoring of the substation. This
allows for faster response to faults, improved operational efficiency, and better
maintenance planning.
➢ Power Quality Monitoring: Install power quality monitoring equipment to continuously
monitor and analyse the quality of power supply, including voltage levels, harmonics,
transients, and other parameters. This helps identify potential issues and allows for
proactive maintenance and corrective actions.
➢ Fault Detection and Localization: Implement advanced fault detection and localization
systems, such as fault location algorithms or fault passage indicators. These systems
help identify the precise location of faults, reducing outage durations and enabling
faster restoration of power.
➢ Lightning Protection: Review and enhance the lightning protection system of the
substation, including lightning rods, grounding systems, surge arresters, and shielding.
Ensure compliance with relevant standards and regulations to minimize the risk of
lightning-induced damage.
➢ Personnel Safety: Evaluate and improve safety measures for personnel working in the
substation, including proper training, personal protective equipment (PPE), clear safety
procedures, and effective signage. Regular safety audits and awareness programs can
help ensure a safe working environment.
➢ Energy Efficiency Measures: Identify opportunities for energy efficiency
improvements, such as optimizing equipment loading, implementing energy
management systems, or incorporating energy-saving technologies. This can reduce
operational costs and environmental impact.
➢ System Upgrades and Expansion: Consider the future growth and load requirements of
the substation. Evaluate the need for capacity upgrades, additional feeder lines, or
transformer installations to accommodate increased demand.
It's important to conduct a thorough assessment of the specific substation's requirements,
budget, and regulatory guidelines to prioritize and plan for improvements effectively. Engaging
with experts and consulting with relevant stakeholders will help determine the most appropriate
improvements for the 11 kV substation.
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CONCLUSION
During this Industrial Training, we learned that how the incoming power from the nearby grid
is transmitted and to process it from high voltage to lower voltage level as we required to
operate electrical Equipment’s as per our need. In the mean process we understand the working
of double-pole substation, indoor substation and also learned about the various personnel safety
protocols, energy efficiency, system upgrades and expansion and fault detection.
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REFERENCES
1) https://elscotransformers.com/blog/guide-to-transformer-kva-ratings-how-to-
determine-what-size-transformer-you-need/
2) https://electricianworld.net/electrical-cable-types-sizes/
3) https://renownpower.com/types-of-lightning-arrester/
4) https://opencivilengineeringjournal.com/VOLUME/11/PAGE/757/FULLTEXT/#:~:te
xt=Cross%20arms%20are%20horizontal%20elements,end%20cross%20arm%20confi
guration%2C%20respectively
5) https://www.eeeguide.com/transformer-substation/
6) https://www.electricalclassroom.com/parts-of-a-transformer/
7) https://electricguider.com/what-is-indoor-sub-station/
8) https://www.etechnog.com/2021/12/what-is-pole-mounted-substation-use.html
9) https://circuitglobe.com/electrical-substation.html
10) https://circuitglobe.com/electrical-substation.html
11) https://www.pinterest.com/petermotpe/%E9%9B%BB%E5%8A%9B/
12) https://www.indiamart.com/proddetail/11-kv-horn-gap-fuse-17175141388.html
13) Electrical Machines by Ashfaq Hussain
14) https://www.tradeindia.com/products/11-kv-pin-insulator-c2787014.html
15) https://www.electricalpowerenergy.com/2017/01/high-voltage-circuit-breaker/
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