132 KV Shaha Substation

Project related pending points

1) On date 13/12/2023 & 14/12/2023 respectively diagnostic testing of 132kV

Transformer No.01 & 02 carried out. During testing, it is found that, tan
delta measurement values of HV bushings & Winding (HV – E) of 132/33kV
25 MVA Transformer 01 & 02 are either higher than or near to the standard
acceptable limits. Reports have already been submitted vide letter under
reference No. 06. Further, vide email under reference No. 07 PAC division,
Nashik has informed that, serial numbers of the bushings of Tesla make
PTF Sr.No.TTL/PP/2/16613 are different from those offered for FAT.
Repeated measurement with different kit (doble make) on 02/01/2024 by
EHV Testing unit Nasik 01 has also shown same results as obtained before.
This has been informed vide letter under reference No. 09

2) SCADA/SAS (substation automation system) is not in use yet; work is still being
carried out .Considerable works related to SCADA/SAS (substation automation
system) are pending. Site Engineer for SCADA & Relay works is not there since
14/02/2024.
3) On 03/03/2023 both transformers tripped simultaneously & on 25/03/2023
Transformer 01 tripped. At both tripping events, no fault was detected & earthing
strips of LV neutral found burnt indicating poor/weak earthing. In the view of this it
is of utmost importance to ascertain healthiness of whole substation earthing
system by measurement of earth resistance values of each individual pit once
again.
4) BCU relay of 33kV Capacitor Bank 02 has been taken out for repairs on
06/10/2023 which is yet not installed.
5) Remote tap changer has not been taken in service yet.
6) Yard lighting: 06 Nos. out of 16 No. lamps from 05 different fixtures (LM) have
stopped working in switch yard. Lamps from one fixture has dislocated from its
position hence there is dark in that particular area of switchyard. 03 Nos. of Street
lights out of 05 has stopped working.
7) While carrying out operations of transformer 01 & 02, it is observed that, HV bus
isolator operates (gets open or close) from panel simulator control switch (89ACS
ISOL CNTRL SW) even though ‘Auto/Manual’ switch is in manual mode which is
quite risky from operations point of view as, this switch is meant for testing/status
purpose only. This issue needs to be attended on utmost priority.
8) Fire buckets provided are empty. Further buckets provide doesn’t have handle at
the bottom as per standards.
9) LM ladder foundation work is still pending.
10)Emergency lighting in control room should get ON automatically however; it turns
ON only after switching ON its MCB.
11)Feeder bay No.06 bus isolator is not operational (motorized operation) in either
remote or local mode & is to be closed or open manually.
12)Inverter unit provided for SCADA computers & allied systems is faulty since
considerable period of time required to be replaced/repaired at an earliest.
13)Substation staff needs to be trained for SCADA related operations before
functioning of system in full phase.
14)Among the each group of 05 cooling fans provided to transformer, 01 fan has not
been fitted properly. Instead of fitting it with nuts & bolts it is just fitted using steel
wires.
15)Exhaust fans not provided for battery room.
16)Work of air conditioning system is not complete yet. Three AC modules (one from
battery room & two from control room) are not working properly. One AC module
is not provided even though AC supply point is provided in control room. Also,
water leakage has started from one of the Air conditioner unit in control room.
PLCC room AC unit has also stopped working recently. Ice is getting
accumulated at its refrigerant pipe valve located at its outdoor compressor unit.
17)Electrification of SAS room is also incomplete.
18)Ceiling fans are provided with regulator only there is no switch provided in fan
wiring circuit at all locations
19)Electrification of store room is incomplete. Lighting fixture of store room and
parking shed is not working.
20)Top & bottom skirts of B phase bus side Insulator of 33kV bus isolator of 33kV
Shaha feeder is broken & required to be replaced.
21)KWH LEDs of MFM meters of 33kV Shaha, Deopur &Wavi feeder (blinks/kwh)
are found not blinking same needs to be addressed earlier.
22) Cable gland holes in some panels are still open & are required to seal properly.
23)TF 01 CCM box three phase mains supply terminals are found burnt during the
period when work of RTCC panel was in progress & same has been informed to
agency by Whatsapp also on date 27/10/2023 for earliest replacement to avoid
further complications like short circuit etc which will eventually affect the supply of
OLTC motors & cooling fans.
24)Oil levels of both transformers on MOLG are different though both are of same
make & capacity.
25)There is a persistent LED indication of 'TC1 faulty' on BCU relay of 132kV
Kopergaon line since 13/12/2023. During detail investigation in this regard,
testing team has found that, 52X relay NO contact has got stuck and because of
which continuous positive command was extended up to TC 1 coil in CB due to
which it got faulty and TCS 1 faulty command appeared on CRP. Therefore, it is
required to replace 52X relay and TC1 coil of CB on very urgent basis. It is also
found that, CB trip command through TC2 trip is not wired up from TNC and BCU
&hence it is required to check this for every feeder and extend CB trip command
from TNC and BCU from TC2 at an earliest.
26)The hex key (Allen Key) to open hex bolts of internal panel door of 145kV ABB
GCB to access its trip coils has not been handed over to substation staff & is very
essential in the events of troubleshooting or testing. Same is required to be
handed over at an earliest for each installed GCB. Testing team couldn’t access
trip coils during troubleshooting of problem mentioned at Sr.No.26.
27)Operation & maintenance manuals of the equipment installed have not been
handed over to substation staff yet.
28)Limit switches of bus isolator of Capacitor Bank 01 have not been set for
motorized operation & when isolator closed manually, AC supply of ACDB of
bays found tripped. Submitted for your kind information please.
29) On date 01/02/2024 differential protection relay of 132/33kV 25MVA TF 01
found stopped working & getting rebooted repeatedly. Transformer has to
be H/T @ 19:26 hrs of 01/02/2024 as per instructions of PAC Division Nashik
as its principal protection system was out of order. Transformer was
charged on 04/02/2024 02:20 hrs. after provision, testing & commissioning
of new SIEMENS make relay by Testing Unit Nashik 01.Now, faulty
differential protection relay has been sent for repairs on date 05/02/2024 &
is still under repairs with ZIV. In the view of this operational reliability of ZIV
relays provided at 132kV Shaha substation need to ascertained as prior to
this, distance protection relay of 132kV Babhaleshwar line also shown
same problems & has been repaired by ZIV.
30)Following SCADA operation problems are found in recent period of time.
A. 33kV Bus section bay encountered problems while executing
operations from SCADA
B. 33kV Deopur feeder CB not getting close from SCADA & BCU as well
C. 33kV PT 02 isolator not getting close from SCADA.
In future also issues like above may be encountered when spare feeder
bays will get operational as per requirement.
31) 33kV Capacitor Bank 01bus isolator manual operation rod is not aligned
properly.
32)U clamps provided at bushing terminal jumps of TF 02 are not of proper size &
required to be replaced with proper size U clamps.
33) It is requested to confirm regarding readiness of spare 33kV bays in all aspects
as work of new 33kV feeders is going on in the vicinity of substation which will be
connected in nearest future of time by MSEDCL. This is being mentioned
because in the month of September 2023, on account of red hot on 33kV Wavi
feeder it was required to be shifted on spare bay No. 04 using bay interconnector
isolator available. However, at that time Contractor (M/s. Ideas) informed that
testing of spare bay No. 04 is pending. From this instance to till date no testing
activity by contractor has been observed by this office at Spare bay No. 04 or
other remaining 04 Nos. of spare bays if any.

Testing related issues (As per MOM):

1) 33kV feeder 01 & 02, TC-1 & TC-2 looping at CB required to be removed for
individual monitoring of its healthiness.
2) CB A.C fail input wiring needs to be done for all 33kV feeders.
3) Ethernet switch ring formation & MFM metering MODBUS ring formation is
pending.
4) SCADA runtime license installation is pending for both SCADA systems.
5) Adjacent panel DC fail wiring is pending for all 33kV bays except Capacitor Bank
01, 02 & Feeder 01, 04.
6) All 33kV feeders TCS-1 & TCS-2 faulty status is not observed at panel even
though CB DC is unhealthy.
7) SCADA configuration & testing is pending. (Only 132kV feeder-2 distance
protection relay, 33kV feeder 3,4,5,6,7 & 8 protection relay signals tested on
SCADA)
8) Gateway hardware available at site however configuration witnessing is pending.
9) Fault records are recorded in relay only after resetting 86 & LEDs which should be
rectified.
10) For all 33kV feeder relays it is observed that, fault records are not getting
generated for faults less than 30 ms.
11) BCU gets hang in case of continuous operation on BCU HMI.
12) 132kV TBC Y phase CT core 4 to earth value is low (1.29 MΩ).
13) CRM test of all isolators is pending.
14) Proper size shorting strips are required to be used for CORE-FRAME-TANK
shorting however same is found shorted with flexible copper wire.
15) Main tank & OLTC SDB wiring is pending for TF-1 & TF-2.
16) RTCC & FCC signal testing & trial is pending.
17) There is persistent indication of ground fault on 48V battery charger & doesn’t
get reset.
18) There is persistent notification of ‘communication failure’ on SCADA system for
all bays except 33kV bus bar & TF 02 HV.
19) 132/33kV Transformer 2 bus isolator is getting operated from control panel even
when simulation switch on control panel is on manual position, requires
rectification on top priority
20) Isolator remote/local switch status input is not available at BCU, for monitoring its
input wiring is to be done.
21) 33kV Capacitor Bank 01 & 02 leading power factor protection configuration is
pending.
22) While testing the differential relay, during LV side pickup test, it is observed that,
relay is not picked up when current is ramping.
23) Fault current in relays are shown in Amp & mAmp instead of kAmp & Amp
respectively.
24) Following material, software is required to be handed over to Testing Unit for
testing related work, to maintain database & troubleshooting purpose.
a) Relay communication software & Station relay project backup.
b) SAS software, SAS/DR PC windows genuine OS setup.
c) Printer Software.
d) Relay communication cables (as applicable for relay type) USB serial
converter (preferably MOXA).
25) Following documents (hard & soft copy) to be handed over to testing unit .
a) Relay setting /logic files
b) As built corrected software CRP drawings. Separate for each feeder with
proper binding.
c) CB schematic drawing including BOM & operation manual.
d) Transformer FCC, RTCC,SDB schematic drawings & SBD manual.
e) Battery charger drawing, BOM & operation manual.
f) Relay type-wise manual, RTCC relay & MFM manuals.
26) KWH LEDs of MFM meters of 33kV Shaha, Deopur &Wavi feeder (blinks/kwh)
are found not blinking same needs to be addressed earlier.
27) Inverter unit provided for SCADA computers & allied systems is faulty since
considerable period of time required to be replaced/repaired at an earliest.
28) Feeder bay No.06 bus isolator is not operational (motorised operation) in either
remote or local mode & is to be closed or open manually.
29) Emergency lighting in control room should get ON automatically however; it turns
ON only after switching ON its MCB.
30) BCU relay of 33kV Capacitor Bank 02 has been taken out for repairs on
06/10/2023.
31) Oil levels of both transformers on MOLG are different though both are of same
make & capacity.
32) On date 13/12/2023 & 14/12/2023 respectively diagnostic testing of 132kV
Transformer No.01 & 02 carried out. During testing, it is found that, tan delta
measurement values of HV bushings & Winding (HV – E) of 132/33kV 25 MVA
Transformer 01 & 02 are either higher than or near to the standard acceptable
limits. Reports have already been submitted vide letter under reference No. 06.
Repeated measurement with different kit (doble make) on 02/01/2024 by EHV
Testing unit Nasik 01 has also shown same results as obtained before. This has
been informed vide letter under reference No. 08.
33) There is a persistent LED indication of 'TC1 faulty' on BCU relay of 132kV
Kopergaon line since 13/12/2023. During detail investigation in this regard,
testing team has found that, 52X relay NO contact has got stuck and because of
which continuous positive command was extended up to TC 1 coil in CB due to
which it got faulty and TCS 1 faulty command appeared on CRP. Therefore, it is
required to replace 52X relay and TC1 coil of CB on very urgent basis. It is also
found that, CB trip command through TC2 trip is not wired up from TNC and
BCU & hence it is required to check this for every feeder and extend CB trip
command from TNC and BCU from TC2 at an earliest.(to be done by agency)
34) On date 01/02/2024 differential protection relay of 132/33kV 25MVA TF 01 found
stopped working & getting rebooted repeatedly. Transformer has to be H/T @
19:26 hrs of 01/02/2024 as per instructions of PAC Division Nashik as its
principal protection system was out of order. Transformer was charged on
04/02/2024 02:20 hrs. after provision, testing & commissioning of new SIEMENS
make relay by Testing Unit Nashik 01.Now, faulty differential protection relay has
been sent for repairs on date 05/02/2024 & is still under repairs with ZIV. In the
view of this operational reliability of ZIV relays provided at 132kV Shaha
substation need to ascertained as prior to this, distance protection relay of
132kV Babhaleshwar line also shown same problems & has been repaired by
ZIV.
34)Following SCADA operation problems are found in recent period of time.
A. 33kV Bus section bay encountered problems while executing operations
from SCADA
B. 33kV Deopur feeder CB not getting close from SCADA & BCU as well
C. 33kV PT 02 isolator not getting close from SCADA.
In future also issues like above may be encountered when spare feeder bays will
get operational as per requirement.
35) It is requested to confirm regarding readiness of spare 33kV bays in all aspects
as work of new 33kV feeders is going on in the vicinity of substation which will
be connected in nearest future of time by MSEDCL. This is being mentioned
because in the month of September 2023, on account of red hot on 33kV Wavi
feeder it was required to be shifted on spare bay No. 04 using bay
interconnector isolator available. However, at that time Contractor (M/s. Ideas)
informed that testing of spare bay No. 04 is pending. From this instance to till
date no testing activity by contractor has been observed by this office at Spare
bay No. 04 or other remaining 04 Nos. of spare bays if any.

Civil pending points.

1) Earthing pipe is not covered properly near transformer which has got uncovered
while carrying out leveling work.
2) Door of SAS room is fitted but work is not satisfactory as door doesn’t open &
close in smooth manner & door closing mechanism also not provided to the
same.
3) Windows of battery room needs protective net covering as small birds can enter
battery room from windows. Water pipe line of battery room is also incomplete.
4) Plumbing work of restroom, battery room & toilets is pending.
5) Water pump is required to be provided for pumping water from water storage
tank at ground & has not been provided yet. This provision is of utmost
importance in the situation when bore gets dry after rainy season & water
storage tank will be filled from external sources like water tanker. Also there is
no lid provided for water storage tank at ground.
6) Proper electrical supply arrangement has not been provided for bore well water
pump motor. Its control panel is kept freely on the open ground & cable has
been laid randomly on the ground & is being exposed to extreme weather
conditions causing rapid deterioration. Now many times motor doesn’t pump
water immediately when switched on. New starter is required to be provided
with proper shelter for it.
7) Tile (Skirting) work of control room above cable trench is incomplete.
8) Shutter of store room is not working. Also glass of one of the window of store
room is broken.
9) Construction material such as broken bricks, sand is there at various locations
inside cable trench.
10) Main gate & gate located near store has alignment issues because of which it
cannot be locked or opened easily.
11) Middle hinge of Auxiliary (small) gate at entrance is found broken.
12) Door closing mechanisms of some doors found got jammed or not working
properly.
13) During heavy rains it is observed that, water is getting percolated or leaked
through frames of glass windows provided at first floor of control room. Proper
sealing at edges of frames is required to be done.
14) In men’s wash room granite partition provided between urinals has got loose.
15) At some points it is found that angle structure carrying fencing above compound
wall has become loose.
16) At location near main gate, fencing has not been provided for small portion of
compound wall.
17) All cupboards provided have same lock & all cupboard doors can be unlocked
with single key which is not desirable. Hence locks are required to be replaced.
18) In ladies washroom, flush of western toilet is not working & water pipe of flush
has also got choke up further jet spray of the same also found damaged. Water
inlet pipe of wash basin tap is broken in ladies wash room.
19) Water tap of kitchen sink has got leaked. It is observed that, most of the water
taps provided in wash rooms or kitchen are either got leaked or not working
within a year of fitting.