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TECHNICAL INSPECTION REPORT OF

500KV GRID STATION NTDC SHIKARPUR


1. AUTO TRANSFORMERS BANKS T-6 & T-7 (600 MVA, 500/220 KV EACH),
200MVA SPARE UNITS

1. Maximum loading of 500/220kV auto transformer T-6 (LV- Side) recorded 975 Amps in 02 -
09-2017 at 09.00 hrs.
2. Maximum loading of 500/220kV auto transformer T-7 (LV- Side) recorded 975 Amps in 02-
09-2017 at 09.00 hrs.
3. Minimum loading of 500/220kV auto transformer T-6 (LV- Side) recorded 190 Amps in 18-12-
2017 at 05.00 hrs.
4. Minimum loading of 500/220kV auto transformer T-7 (LV- Side) recorded 190Amps in 18- 12-
2017 at 05.00 hrs.
5. Online monitors system Hydrocar 1003 make MTE is installed on each unit/phase of T-6 and T-
7.During inspection found that water(H2O) contents of red phase of T-7 reading is 61ppm
which is highly alerts, further added that this alert signal is not communicated to the control
room which is very necessary. Dehydration of the above mentioned red phase unit is
recommended and should be carried out as early as possible.
6. Online monitor for spare unit of 500/220kV Auto Transformer is not commissioned.
7. During clamp on measurement of the core to ground, clamp to ground, body-I to ground, body-
II to ground and neutral to ground of T-6 and T-7 are found on higher side. Example given
neutral current of blue phase for T-7 is recorded 227.5A so matter should be taken with
manufacturer for further advice.
8. Thermostat and heater system for Marshalling Kiosk and Control Cubicle in yard area is not
working.
9. Silica Jel of Main tank and OLTC for the spare unit of 500/220kV is completely exhausted which
should be replaced as early as possible.
10. Cable sheath not individually grounded for Marshalling kiosks and Control cubicle ,tap changer
control cubicle etc. and cable tag not provided in some of the MKs ,Control cubicle etc.
11. Lubrication of the operating mechanism of OLTC especially bevel gears is not being done as
per SOP.
12. AVR TapCon 230 make MR installed on T-6 and T-7 is not commissioned.
13. Master Follower scheme for parallel operation is not implemented.
14. Main Tank of Spare Unit Must be grounded from at-least 2 Points.
15. Calibration of the Winding & Oil Temp Gauges is not done.

2. AUTO TRANSFORMERS T-1, T-2 & T-3 (160 MVA, 220/132 KV) AND
POWER TRANFORMER T4 AND T-5 (10/13MVA, 132/11.5KV)

1. Maximum loading of 220/132kV auto transformer T-1 (LV- Side) recorded Amps in
…………. at …… hrs.
2. Maximum loading of 220/132kV auto transformer T-2 (LV- Side) recorded Amps in
…………. at …… hrs.

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3. Maximum loading of 220/132kV auto transformer T-3 (LV- Side) recorded Amps in
…………. at …… hrs.
4. Maximum loading of 132/11.5kV Power transformer T-4 (LV- Side) recorded Amps in
…………. at …… hrs.
5. Maximum loading of 132/11.5kV Power transformer T-5 (LV- Side) recorded Amps in
…………. at …… hrs.
6. Minimum loading of 220/132kV auto transformer T-1 (LV- Side) recorded 20 Amps in
07.11.2017 at 04.00 hrs.
7. Minimum loading of 220/132kV auto transformer T-2 (LV- Side) recorded 20 Amps in
05.11.2017 at 03.30 hrs.
8. Minimum loading of 220/132kV auto transformer T-3 (LV- Side) recorded 20 Amps in
05.11.2017 at 03.30 hrs.
9. Minimum loading of 132/11.5kV Power transformer T-4 (LV- Side) recorded 20 Amps in
01.11.2017 at 01.00 hrs.
10. Minimum loading of 132/11.5kV Power transformer T-5 (LV- Side) recorded No Load.
11. Dissolve gas analysis test was conducted in July 2016 for Auto Transformer T-3 and during
observation found that carbon mono oxide gas is out of limit which means that cellulose(paper)
is being heated up. So it is strongly recommended that immediately sample should be taken for
another DGA analysis to establish the trend of carbon mono oxide and other combustible gases.
Meanwhile arrangement should be made for de-gasing / regeneration of transformer oil.
12. Oil Tangent Delta test must be performed as per SOP
13. Dissipation factor value of HV bush of yellow phase for Auto transformer T-1 is recorded
0.916% which is very on higher side so test should be repeated and if DF values remain same
then HV bush should be replaced as early as possible.
14. AVR TAPCON230 for Auto transformer T-3 not energized since commissioning of the grid
station.
15. AVR TAPCON230 for Auto transformer T-2 is missing.
16. Winding temperature WTI and OTI remote indication 2 found defective for Auto transformer
T-3.
17. Winding temperature WTI and OTI remote indication 2 found defective for Auto transformer
T-1.
18. MW meter found defective for Auto transformer T-3.
19. Winding resistance test is not being performed on Auto transformers T-1, T-2 and T-3 as per
SOP.
20. Dissipation factor value of LV bush of red phase for Auto transformer T-2 is recorded 0.7091%
which is very on higher side so test should be repeated and if DF values remain same then HV
bush should be replaced as early as possible.
21. Oil leakage observed from radiator fins oil bleeding point and main Buccholz gas sampling point
of Auto transformer T-2.
22. 01 No. fan is not working whereas fan No 14 bearing found noisy for T-2 Auto transformer.
23. Lubrication of the OLTC operating mechanism especially bevel gear is not being done as per
SOP.
24. Fan marking is required for Auto Transformer T-1, T-2 and T-3.
25. Fan group Start / Stop, Winding and Oil temperature alarm and tripping from the oil and
temperature gauges through source (temperature gauges) being done but not properly as per
SOP.(as per setting start / stop of the fan groups as well as alarm and tripping settings)

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26. Insulation resistance test for Clamp to ground and Core to ground is not being done as per SOP.
27. 02 Nos. DC supervision relay make ELab for the panel of T-4 and 11kV Outgoing feeder Alif
Shah Shaheed 1 are defective.
28. Siemens relay is defective installed on 11kV Outgoing panel.
29. Sampling point for the main buchholz relay is dirty and seepage is also there.
30. Oil pot for the silica gel of main tank for T-5 is plastic made (green color) which should be
replaced with transparent glass.
31. Oil Tangent Delta test must be performed as per SOP

3. CIRCUIT BREAKERS

A. 500KV CIRCUIT BREAKERS


1. Found that space heater/thermo state and door light of mostly CBs are not being worked.
2. Timing and contact resistance not being performed as per SOP since commissioning of the
500kV Grid.
3. Dew point (ppm) and Purity of SF6 gas not performed as per SOP since commissioning of the
500kV Grid Station.
4. DC minimum trip test not performed as per SOP since commissioning of the grid station.
5. All functional test of circuit breaker not performed as per SOP.
6. On / Off and charging indication glass cover always getting fallen due to non-fixing of the glass
cover during operation of the circuit breaker.
7. Mechanism steel stand not properly grounded.

B. 220KV CIRCUIT BREAKERS

1. Found that some space heater/thermo state and door light of mostly CBs are not being worked.
2. Dew point test of SF6 gas performed only in 2013 and 2014.Dew point performed for one
breaker along with local staff. Now dew point testing of all circuit breaker is in progress
3. Purity test of SF6 gas not performed since commissioning of the 220kV Grid station.
4. Lubrication of the 220kV Circuit breakers spring charge mechanism is required as early as
possible.
5. Pneumatic circuit breakers controlling air compressor filter is choked therefore replacement of
the air filter is required as early as possible.
6. All functional tests not performed as per SOP.
7. Some steel parts of the circuit breaker not properly earthed.
8. Compressor oil should be replaced as per recommendation of the manufacturer.
9. Over Hauling of circuit breakers should be done as per recommendation of the manufacturer.

C. 132KV CIRCUIT BREAKERS

1. Found that some space heater/thermo state and door light of mostly CBs are not being worked.
2. Dew point test of SF6 gas performed only in 2013 and 2014.Dew point performed for one
breaker along with local staff. Now dew point testing of all circuit breaker is in progress
3. Purity test of SF6 gas not performed since commissioning of the 220kV Grid station.

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4. Lubrication of the 220kV Circuit breakers spring charge mechanism is required as early as
possible.
5. All functional tests not performed as per SOP.
6. Some steel parts of the circuit breaker not properly earthed.
7. Over Hauling of circuit breakers should be done as per recommendation of the manufacturer.
8. Tripping dash pot overhauling should be done as per recommendation of the manufacturer.

4. ISOLATORS

1. Contact resistance test for 500kV, 220kV and 132kV isolators not performed as per SOP.
2. Lubrication of the moving sliding rolling part of the isolator for 500kV, 220kV and 132kV
isolators is required.
3. Female finger should be cleaned and lubricated for 220kV and 132kV isolators.
4. 220kV isolators D4Q20, D4Q10, D4Q31 and D3Q22 alignments is out.
5. 500kV, 220kV and 132kV isolators steel bays is not properly earthed.

5. CURRENT TRANSFORMERS,CAPACITOR VOLTAGE TRANSFORMERS


AND VOLTAGE TRANSFORMERS

1. Insulation resistance test for 500kV, 220kV and 132kV CTs, PTs and CVTs not performed as
per SOP.
2. C&DF test for 500kV, 220kV and 132kV CTs, PTs and CVTs not performed as per SOP.
3. Current and voltage ratio for 500kV, 220kV and 132kV CTs, PTs and CVTs not performed as
per SOP.
4. All 500kV Line side CVTs are not properly earthed.

6. CAPACITOR VOLTAGE TRANSFORMERS INSTALLED ON 500/220KV


SWITCH YARD

1. Found that the marking is missing on CVTs control box.


2. Found that Space Heater/ thermo state system are not being functional.
3. Found that the door lighting system is defective.
4. C&DF, Voltage ratio, Insulation Resistance etc. tests are not being performed as per SOP.

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7. Transmission Line Losses
Monthly statement record for different months regarding T/L Losses checked. Detail is as under
please.
Transmission Line Losses
Feb-2018
Name Of T/Line Jan-2018
132kV Shikarpur new-
5.44% 2.63%
Madeji(E10Q1)
132kV Shikarpur-Larkana 2.68%
Energy meters not
caliberated since
220kV T/Line Shikarpur-UchKDA33
commissioning in 17
220kV T/Line Shikarpur-Guddu-I
march 2017, Line losses
are abnormal.

8. 500/220/132 KV PROTECTION PANELS AND RELAYS TESTING

A. 500kV PROTECTION RELAY PANELS AND CONTROL PANELS

1. Cable Sheath not earthed individually for 500kV C.P B01+WC1, B02+WC1, B04+WC2 and
B00+WC6.
2. Cable Duct overloaded for 500kV C.P B01+WC1, B02+WC1, B04WC2 and B00+WC6.
3. Vermin proofing not done for 500kV C.P B01+WC1, B02+WC1, B04WC2 and B00+WC6.
4. Setting of thermostat not done for 500kV C.P B01+WC1, B02+WC1, B04WC2 and B00+WC6.
5. Web are there in 500kV C.P B01+WC1, B02+WC1, B04WC2 and B00+WC6, so cleaning is
required.
6. Cable duct tagging not present for 500kV C.P B02+WC1 and B00+WC6.
7. Heater is disconnected for C.P B00+WC6.
8. H9 annunciator block windows for C.P B04+WC2 is not light on when pressing the test button.
9. P5 ammeter of 500kV T/Line Dadu-1 installed on C.P B01+WC1 is defective.
10. H4 annunciator block behavior is abnormal when pressing the test button installed on C.P
B02+WC1.
11. Scada/Local selector switch is permanently on local position since commissioning of the grid
station which shows that scada scheme still not implemented.
12. Annunciation block No. 1, 2 and 3 are defective for AVR Panels of T-6 and T-7.
13. Energy meters have not been commissioned till yet for all 500kV Transmission lines and Auto
Transformers banks.
14. Cable sheath not individually earthed for all 500kV Relay panels.
15. Thermostat setting not done for all 500kV Relay panels.
16. Vermin proofing not done for all 500kV Relay panels.
17. Cable duct overloaded for 500kV relay panels B02+R11, B02+R15, B01+R15, B04+R15 and
Bus bar protection panel R17.
18. Wiring from relay panel B01+R13 and B01+R14 to Vaj panel B01+R13 and B01+R14
respectivevly is passed through by making a hole between panels which is not standardized.
19. HV connection relay is dismantled from B01+R14 panel for remedy.
20. Alarm led is glowing for over flux relay installed on B01+R14 transformer panel.

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21. Switch yard lighting is in progress.
22. Thermostat setting and Vermin Proofing not done for all Event Recorder,Fault Recorder
and RPH2 panels installed in new building. Also cable sheath not individually earthed.

B. 220kV PROTECTION RELAY PANELS AND CONTROL PANELS

1. Cable Sheath not earthed individually for 220kV C.P D07+C1, D08+C1 and D00+C6.
2. Cable Duct overloaded for 220kV C.P D07+C1, D08+C1 and D00+C6.
3. Vermin proofing not done for 220kV C.P D07+C1, D08+C1 and D00+C6.
4. Setting of thermostat not done for 220kV C.P D07+C1, D08+C1 and D00+C6.
5. Web are there in 220kV C.P D07+C1, D08+C1 and D00+C6, so cleaning is required.
6. P841 relay installed on D00+C6 panel not commissioned.
7. Cable duct not present in D00+C6 panel.
8. Energy meters for 220kV T/Lines Guddu-I and Uch-I have not been commissioned till yet.
9. Independent SMS CTs and PTs have been installed on 160MVA Auto Transformer T-1 and T-
2 but still not commissioned aslo independent CTs and PTs for SMS project still not installed at
160MVA T-3.Further added SMS energy metering room have been constructed.
10. Cable Sheath not earthed individually for D07+R1, D07+R2, D08+R1, D08+R2, D08+R5,
D07+R5, D08+R6, D07+R6, D07+R11, D08+R15 and Bus bar panel R7.
11. Grounding plate not properly installed in D08+R2.
12. Standardize grounding plate not given in D07+R6, D08+R5.
13. Vermin proofing not done for D08+R5, D07+R11, D08+R5 and Bus bar panel R7.
14. Heater element, Protection relays are not present in Bus Bar panel R7.
15. Door lamp not healthy for C.P D4C2, D2(2C1), D1(1C1).
16. P15 MW meter installed on C.P D3C1 is non operational.
17. Cable duct overloaded for C.P D4C2.
18. Cable tagging not done for C.P D3C1.
19. Vermin proofing not okay for C.P D3C1, D1 (1C1) and synch C7.
20. 220kV current ammeter for y phase is non operational / damaged installed on C.P D2 (2C1).
21. 04 Nos. annunciation test lamp failed installed on C.P D2 (2C1).
22. Annunciation window 01 No. found defective for Dia 1 Shikarpur-Rohri-I.
23. Sema Phore indication found unhealthy on few 220kV and 132kV control panels.
24. Dia 7 and Dia 8 newly commissioned earth switches (D7E10 and D8E10) are not working from
remote.
25. Door lamp for most of the 220kV relay panels in old building is not healthy.
26. Thermostat setting for all 220kV relay panels in old building is not done.
27. Cable duct cover is missing for 220KV Guddu1 (1R2), T1 1R3, 1R5 BF, 220kV Busbar R7, 2R5
BF, D3R4, D4R1 Guddu II.
28. Vermin Proofing is not Ok for Most of the 220kV Relay Panels in Old Building
29. Cable Duct is overloaded for few Relay Panels in Old Building.
30. ABB relay REL 670 is defective which is installed on 220kV relay panel Guddu-II.

C. 132kV PROTECTION RELAY PANELS AND CONTROL PANELS

1. Door Lamp is not Healthy for most of the Relay & Control Panels
2. Thermostat Setting Not Done for All Panels
3. Setting of thermostat not done for 220kV C.P D07+C1, D08+C1 and D00+C6.
4. Web are there in 220kV C.P D07+C1, D08+C1 and D00+C6, so cleaning is required.
5. P841 relay installed on D00+C6 panel not commissioned.
6. DC positive is solidly grounded for 110V DC Set-1 and Set-2.

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D. 500kV PROTECTION RELAY TESTING

1. 500/220 Auto Transformer T-6 and T-7 Protection Relays.

a. 5th harmonic test of Main and Rough balance protection relays not done for T-6 and T-7 Auto
Transformer.

2. 500kV Transmission Lines Protection Relays

a. Stage 3 time setting of over voltage relay (P922make Schneider) installed on B04R11, B01R11
and B02R11 panels is 0.1 sec but in actual it is instantaneous as per commissioning testing
reports.
b. On all 500kV Transmission lines, In case of Zone 2 Phase to ground fault + Signal receive
(Aided Trip) Auto recloser relay Set-1 and Set2 will not be initiated by Distance Set-I and SetII
as marshalling is not done for the above said scenario.
c. Master follower logic is not implemented completely as for example if line is operating only on
Mid C.B (Q3) prior to fault then if C.B is tripped on Zone 1 Phase to ground fault then Mid C.B
will become master and its setting will be of master relay.
d. Auto Recloser is Blocked on 500kV T/Line Dadu-I and Dadu-II as testing/setting is not done at
other end.
e. Auto recloser for 500kV Transmission line Guddu-II will not be successful for most of the case
as one auto recloser relay is not present at other end.
f. Resistive reach not done for all Distance relay Set-I (7SA612 make Siemens) installed on all
500kV Transmission lines.
g. Power swing test not done for all distance relays set-I and set-II installed on all 500kV T/Lines.

E. 220kV PROTECTION RELAY TESTING

1. 220kV Transmission Lines Protection Relays

a. Power swing test of Distance relays Set-I and Set-II not done for newly commissioned 220kV
T/Line Uch-I and Guddu-I.
b. On all 220kV Transmission line Uch-I and Guddu-I, In case of Zone 2 Phase to ground fault +
Signal receive (Aided Trip) Auto recloser relay Set-1 and Set2 will not be initiated by Distance
Set-I and Set-II as marshalling is not done for the above said scenario. Tele-protection is not
commissioned and auto recloser is out of service for both above mentioned T/lines.
c. Master follower logic is not implemented completely as for example if line is operating only on
Mid C.B (Q3) prior to fault then if C.B is tripped on Zone 1 Phase to ground fault then Mid C.B
will become master and its setting will be of master relay.
d. Breaker failure relay installed in old 220kV Relay room has not been tested since commissioning
of the grid station due to non-availability of shut down.
e. Bus Bar protection Scheme tested in 2015 which should be tested annually as protection relays
are static type.
f. Power swing test for distance relays not done as per SOP.
g. Testing of Distance relay (Micro Mho make GEC) tested in end of 2016 which should be done
on next available shut down.

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F. 132kV/11KV PROTECTION RELAY TESTING

a. Testing for 132/11.5kV Power transformer protection relays and mechanical equipment testing
done in 2015 and 2016. Whereas shut downs were applied for annual testing but not approved.

10. EARTHING MESH


1. Earth mesh integrity test is not being done as per S.O.P.

11. LIGHTENING/SURGE ARRESTORS


1. Insulation resistance (Megger) test is not being done as per S.O.P.
2. Operation counter functional test is not being done as per S.O.P.
3. LCM test is not being carried out as per SOP.

12. STATION BATTERY

1. Both Battery impedance test and capacity test for newly commissioned 220Volt DC battery
banks is not done nor battery charger calibration have been performed.
2. Active material shading and terminal growth have been started on 220V DC set I&II and 110V
DC Set-I & II of old 220kV and 132kV DC system.
3. Capacity test is recommended as it has not been performed as per SOP
4. For 500k/220kV yard (newly commissioned), inverter system has been installed for Control
building only whereas 500kV Switch yard is still in progress.
5. DC positive is solidly grounded for 110v DC set-I and Set-II at old system.
6. DC grounding is also observed for 220V DC Set I and Set-II for new system(500kV Yard)
7. Automatic switching of stand by DC charger not done for newly commissioned 500kV system.
Also online monitoring showing grounding issues.
8. At present Float voltage of DC chargers installed on new 500kV system is 245.8V which is on
higher side and which can lead to the damage of batteries so that immediate action is required.

13. FIRE EXTINGUISHER

1. Dry powder type and foam Chemical types fire extinguisher refill due date 09.18. 03 Nos.
chemical foam type checked for functional test but failed.

14. LIGHTING SYSTEM

Total Lights Working Defective Required

132kV Yard 29 25 04 12

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220kV Yard 26 24 02 10

500kV 45 45 0 0

220kV Extended Portion Nil - - 34

Boundary Wall Nil - - 34

Colony Area 09 08 01 9

Total 109 102 07 31

15. SECURITY CAMERAS

Total Working Defective Required


Nil - - 62

16. GENERAL POINTS OF GRID STATION

1. 500kV HV Bush got damaged after energization of the 500kV system which have been replaced
with spare one. No such kind of bush is available with the Gris maintenance staff to cope with
the next emergency situation.
2. 01 No. pole of 500kV Circuit breaker got damaged soon after energization of the 500kV system
which has been replaced with the spare one. Further added that grading capacitors are not
provided with the spare poles without them spare poles are useless.
3. Installation / Commissioning tools specially required for 500kV SF6 Circuit breakers example
given lifting up tool not provided.
4. Only one A.E (P&I) and Lab Assistant is presently working at the Grid station including newly
commissioned 500kV system which is not sufficient for maintaining P&I related activities of
the whole grid station. P&I staff is not posted as per yard stick.
5. Maintenance staff should be posted as soon as possible for 500kV system.
6. 220V DC contactor make finder installed in new 500kV system (indoor and outdoor) are
problematic as they are being damaged due to heating of the diode.
7. PPE must be provided to all technical staff as per SOP.
8. Periodic training should be arrange for technical staff (Officers & Officials) as per SOP.
9. Universal relay testing set provided with only one current which is not capable to perform the
slope test for differential relays.
10. Power cable for auxiliary transformers 1 and 2 in newly commissioned 500kV system should be
connected to two separate Outgoing panels. Auxilary load will be shift on Diesel generator
manually whereas it should be automatically switched on ,on failure of main AC

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supply.Moreover hi-pot results of one power cable is unsatisfactory hence cable may be replaced
for Aux. Transformer T-2.
11. Construction of 02 Nos. Watching towers is in progress which is not adequate, also boundary
wall should be raised as per SOP for the security system of the grid station.
12. Furnitures for Newly Constructed Building is required. Furthermore furnitures are also required
for old control building.
13. Battery banks are installed on wooden racks for 500kV system which slightly cracked, however
original steel supplied racks along with battery banks are available at the sites.

Engr.M. Ijaz Khan Manager (R&D) Engr.Muhammad Irfan


o/o CE(TSG) NTDC, NKLP,Lahore Sr. Engr. 500 kV G/Station, Shikarpur

Engr. Fahimuddin Qureshi Asst. Manager (P&I) Mr.Syed Tahir BukhariAsstt. Manager (Grids)
o/o CE(TSG) NTDC, NKLP,Lahore o/o CE(TSG) NTDC, NKLP Lahore

Engr. Nadeem Akhtar Asstt. Manager Engr. Shuhabuddin Khoso


o/o CE TSG (SOUTH) NTDC, Hyderabad. Asst. Manager(P&I) 500kV G/S, Shikarpur

Engr.Ahmed Ali Mahar Engr. Aqeel Ahmed


Asst.Manager (M) 500kV G/Station, Shikarpur Asst. Manager (O&M) 220kV G/S, Shikarpur

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