PROJECT REPORT

ON

“CONDITION MONITORING OF ELECTRICAL EQUIPMENTS

at Sai Wardha Power Limited, Group of KSK Energy
Ventures, Warora

Submitted in Partial Fulfillment of Requirement

For the Award of Degree
Master of Business Administration (M.B.A)
To R.T.M Nagpur University, Nagpur
For Academic Year 2014-2015
Submitted By

JAYKUMAR SINGH

PRN NO: 2013016600677985

Under the Guidance of

Ms. MAMTA NAKHATE (PROF)

Mr. DINESH MEWADE (MANAGER ELECTRICAL, KSK)

Submitted Through
Wainganga College of Engineering & Management near Gumgaon Railway
Station, Dongargaon, Wardha Road, Nagpur
 CERTIFICATE

I hereby certify that this project Report entitled “CONDITION

MONITORING OF ELECTRICAL EQUIPMENTS at SAI WARDHA

POWER LIMITED (A Subsidiary of KSK ENERGY VENTURES), WARORA

submitted by Mr. JAYKUMAR SINGH to Rashtrasant Tukadoji Maharaj
Nagpur University, Nagpur in the faculty of MASTER OF BUSINESS
ADMINISTRATION is bonafide and original research work carried out under
my guidance and supervision. It is a piece of research of sufficiently high
standard to warrant its submission to the University for the Award of the
said degree.
No part of the thesis has been submitted for any Degree or Diploma or
published in any other form.

The assistance and help rendered to the researcher during the course
of his investigation in the form of basic source material and information have
been duly acknowledged.

Project Guide HOD

Ms. MAMTA NAKHATE Mr.SANDIP PALI

2
 DECLARATION

I, hereby declare that project entitled “CONDITION MONITORING OF

ELECTRICAL EQUIPMENTS at SAI WARDHA POWER LIMITED (A

Subsidiary of KSK ENERGY VENTURES), WARORA submitted in the partial
fulfillment of the Post Graduate Program in Operation management, is my
own accurate work.

I further declare that all the facts and figures furnished in this project report
are the outcome of my own intensive research and findings.

This report is based on my personal opinion hence cannot be referred to

legal purpose.

Place: DONGARGAON
SUBMITTED BY

Date: 30/03/15 Mr. JAYKUMARSINGH

3
 ACKNOWLEDGEMENT
It was delightful learning experience to be associated with KSK ENERGY
VENTURES. The six weeks spent at SWPL WARORA, taught me many things
which will be with me throughout my life. It is with greatest pleasure and
pride that I present this report before you. At this moment of triumph it
would be unfair to neglect all those who helped me in the successful
completion of this project. First of all, I would like to thank the HOD MBA of
our college PROF.SANDIP PALI for the help and guidance rendered for the
completion of the project. It is beyond words to express our immense
gratitude to our project guide Ms. MAMTA NAKHATE for the guidance and
inspiration throughout this work. I am also very much thankful to managers
of all the ELECTRICAL department for their co-operation while I visited their
respective divisions. Last but not the least I thank my family members for
their encouragement and support.

Mr.JAYKUMARSINGH

4
 INDEX

PAGE
CONTENTS
NO.
Introduction 6
1.1 Executive Summary
1.2 Condition monitoring
1.3 Overviews & Objectives
1.4 Principles & Methods
1.5 Course Content
1.6 Condition monitoring of motor
1.7 Condition monitoring of Transformer
1.8 Limitations
Company Profile 31
2.1 Overview of KSK ENERGY VENTURES
2.2 KSK projects
2.3 Historical Profile of KSK ENERGY VENTURES
Research Methodology 38
3.1 Objective
3.2 Hypothesis
3.3 Research design
3.4 Limitation & Scope
Data Collection & Analysis of Data 41
Reliability & Availability 52
Conclusion 53
Bibliography 54

5
INTRODUCTION

6
1.1 EXECUTIVE SUMMARY
This course will give an overview of the monitoring of the condition of
high voltage plant (mainly switchgear and power transformers) with an
emphasis in the ageing and degradation of the electrical insulation
materials.
The fundamentals of the electrical insulation affecting the Power
Systems Equipment will be explained. This will cover the insulation
structures based on solid, liquid and gas insulating materials commonly
used in the manufacturing of high voltage plant.

High Voltage testing and the main partial discharge diagnostic

techniques will be presented to provide an overview on the existing tools
to assess the state of the electrical insulation before and after the
installation of the High Voltage equipment. Special consideration will be
given to modern partial discharge measurements in the most important
substation plant assets as switchgear and transformers. The lecture will
be supported with practical demonstrations of various partial discharge
detection techniques.

This report also considers how the many benefits of condition

monitoring and maintenance should be balanced against the increased
failures that may occur due to the infant mortality of replacement
components, or from the mistakes that might occur during any intrusive
intervention. The second part of this Application Note acts as a guide to
the selection of equipment and monitoring methods, and the frequency at
which they should be employed. The tests reviewed include temperature
monitoring, vibration monitoring, oil analysis and various electrical
tests. This allows the selection of test equipment and methods in line
with budget and in house skills. No matter how well established a site
condition monitoring regime is, changes in motor duties, site operations
or just learning from past motor failures, means that periodic reviewing
of condition monitoring activity is always worthwhile.

7
 1.1 CONDITION MONITORING
Modern power plants depend heavily on rotating machines such as
steam turbines, gas turbines, and generators and so on. To maximize
power plant profit, rotating machines of power generation trains should
be operated with maximum reliability, maximum capacity, maximum
efficiency and minimum operating and maintenance costs.

Effective monitoring and high reliability starts with basic-design

phase, particularly with rotating machine specification and power
generation train basic design. Inadequate specification impacts
extensively power generation train reliability. Proper bidding
phase clarification (particularly extensive bid evaluation prior to
vendor selection and purchase order placement) establishes an
effective machine reliability basis. A proper development strategy
is necessary for successful condition monitoring and predictive
maintenance.

Power generation companies maximize profits by operating the

un-spared (critical) power generation trains without shutdown.
They are investing heavily on identifying and eliminating potential
reliability issues through effective condition monitoring and
predictive maintenance to meet continuous and efficient
operation. Power generation train manufacturers maximize profit
by manufacturing the machinery to meet project specifications
and applicable codes at the lowest cost to assure the equipment
will be reliable for the warranty period. Rotating machine
manufacturers usually do not initiate improvements to extend
reliability and trouble-free operation beyond the manufacturer
warranty period. Many manufacturers believe they cannot stay
competitive and in business if they design and produce
equipment beyond code and client specification requirements for
a long-term (let's say 20 years) of trouble-free operation. This is
key to understanding power generation train reliability and
required actions to increase reliability.
For effective reliability analysis as well as failure analysis and
trouble-shooting, all facts-- particularly operating condition
changes, piping and foundation changes and ambient condition
changes--must be considered. Power generation trains should be
considered as a complete system including transmission system
and coupling and involving auxiliaries such as gear unit (if
applicable), lube oil system, cooling system (if any), seal system
and so on. The power generation packages regardless of type
always become customized because of the environment (such as
network, site conditions, unique battery limits, unique piping
arrangement, specific foundation and so on). Each machine has
its own unique signature.

1.3 OVERVIEW AND OBJECTIVES

Today's industrial policy and globalization has made industrial
environment very competitive including electricity generation.
Proactive maintenance strategy to reduce down-time of critical
machines plays significant role in present competitive scenario.
Substantial savings in maintenance cost can be achieved by
applying prudent CONDITION MONITORING in process industry.
Plant
Machineries are invaluable assets and are designed to operate
under extremely harsh condition, where a failure may be
catastrophic, both in safety and economic aspects. Condition
Monitoring plays a vital role in providing higher availability of
plant machinery by detecting problems before they result in a
major machine malfunction or breakdown.
The course is designed to impart class room & practical training
to participant on basic aspects of condition monitoring,
methodology, techniques along with case studies.

9
1.4 PRINCIPLES AND METHODS:

As a starting point for any discussion on condition monitoring it is

useful to define what is meant by the term, and to describe how
it relates to other techniques used in the operation and
maintenance of machines, such as alarm and shut down systems
or methods for failure and problem investigation.
The crudest method for operating machines is to run them until
they fail, and then to try and repair them in order to make them
fit for further service. This method of operation can be very
expensive in terms of lost output and machine destruction, and in
addition can in-volve hazards to personnel. It is now well
recognized that, particularly in the case of large and expensive
plant, it is more economical and operationally satisfactory to
carry out regular maintenance. This involves the maintenance of
the machine or its various components at re-gular intervals, to
reduce the likelihood of failure during a time when the machine is
re-quired to be available for use. The problem in planning this
type of maintenance lies in the choice of an appropriate
maintenance interval for the machine, because the actual running
time before maintenance is really needed is not constant, but
varies from one occasion to another, due to differences in the
operation of the machine in the behavior of its compo-nents. Fig.
1 shows how the running time to failure of a typical machine
would be likely to vary if no preventive maintenance were carried
out. The vertical line in this diagram repres-ents the safe time
interval between preventive maintenance works which could
catch all the failures before they occurred. If this safe overhaul
interval is chosen, however, there will be many occasions when
the machinery will be overhauled long before it is really
necessary, such as in those cases at the right hand side of the
curve where it could have run on for much longer without failing.
This situation wastes production time, and by increasing the
frequency of maintenance operations increases the incidence of
human errors on reassem-bly of the machine.

10
A more satisfactory compromise in terms of maintenance strategy
is to carry out preventive maintenance at what may be irregular
intervals, but to determine these intervals by the ac-tual
condition of the machine at the time. For such condition-based
maintenance to be possi-ble, it is essential to have knowledge of
the machine condition and its rate of change with time. The main
function of condition monitoring is to provide this knowledge.

There are two main methods used for condition monitoring, and
these are trend monitoring and condition checking. Trend
monitoring is the continuous or regular measurement and
in-terpretation of data, collected during machine operation, to
indicate variations in the condi-tion of the machine or its
components, in the interests of safe and economical operation.
This involves the selection of some suitable and measurable
indication of machine or compo-nent deterioration, such as one of
those listed in Fig.2, and the study of the trend in this
measurement with running time to indicate when deterioration is
exceeding a critical rate. The principle involved is illustrated in
Fig.3, which shows the way in which such trend moni-toring can
give a lead time before the deterioration reaches a level at which
the machine would have to be shut down. This lead time is one of
the main advantages of using trend monitoring rather than simple
alarms or automatic shutdown devices.

Condition checking is where a check measurement is taken with

the machine running, us-ing some suitable indicator such as,
again, one of those listed in, and this is then used as a measure o
the machine condition at that time. To be effective the
measurement must be accurate and quantifiable, and there must
be known limiting values which must not be exceeded for more
than a certain number of permitted further running hours. To fix
these values requires a large amount of recorded past experience
for the particular type of machine, and this makes the method
less flexible than the trend monitoring, particularly if it is required
to give lead time as well as machine knowledge. It can be
particularly useful, however, in a situation where there are
several similar machines operating together as in this case
comparative checking can be done between the machine which is
monitored, and other machines which are known to be in new or
good condition. These two methods of condition monitoring are
compared in greater detail in Table 1, and the resulting
advantages in terms of the provision of lead time and better
machine know-ledge

1.5 COURSE CONTENT:

1. Importance of conditioning Monitoring & type of maintenance

practices.
2. Type of Condition monitoring
3. Vibration analysis
4. Fundamental of Vibrations in machines
5. Overview of vibration standards.
6. Types of Vibration Sensor.
7. Measurement and capturing data.
8. Spectrum & Phase analysis
9. Analysis of Lube oil.
10. Thermography in plant & its benefits.
11. Condition monitoring of Electrical Equipment / Switchyard
12. Condition monitoring in Thermal Power Plants

12
EQUIPMENTS THAT CAN BE INSPECTED:

1. Stator and rotor windings and air gaps

2. Transformer windings
3. Lubrication conduits
4. Electrical machinery
5. Pumps, valves, and gears
6. Switchgears
7. Transformers
8. Cables and connectors
9. Insulating liquids
10. Motors and generators
11. Bus bar
12. Isolators
13. Current transformer
14. Power transformer

And there are many other electrical equipment’s that can be

inspected and monitor for smooth operation of plant

13
APPLICATIONS: -
Equipment to be monitored
Specific equipment that can be monitored by electrical condition
monitoring techniques are:-
1. Electrical Distribution Cabling
Mega ohm meter, Time Domain Reflectometry, Hi-Pot, IRT (if
visible), and Airborne Ultrasonic

2. Electrical Distribution Switchgear and Controllers

Timing, Visual Inspection, IRT, and Airborne Ultrasonic.

3. Electrical Distribution Transformer

Oil analysis, Turns Ratio, Power Factor, and Harmonic Distortion.

4. Electrical Motors
Current Draw, Motor Current Spectrum Analysis, Motor Circuit
Analysis, Mega ohm meter. Hi-Pot, Surge Test, Conductor
Complex Impedance, Starting Current, and Coast-Down Time.

5. Generators
Mega ohm meter, RF, and Coast-Down Time.

6. Distribution System
Hi-Pot, Ultrasonic, Power Factor, and Harmonic Distortion

14
ADVANTAGES OF CONDITION MONITORING
1. Extend bearing service life

Vibration Condition Monitoring is an essential element in detecting and

identifying defects. When found early enough, cost savings can be realized
by repairing rather than replacing due to a bearing failure

2. Maximize machine productivity

Through effective Vibration Condition Monitoring it is possible to virtually

eliminate plant downtime due to unexpected machine failure.

3. Minimize unscheduled downtime

Vibration Condition Monitoring facilitates the planning of repairs during non-

peak production hours.

4. Safely extend overhaul intervals

Vibration Condition Monitoring enables the scheduling of maintenance on a

needs-only basis.

5. Minimize the number of, open, inspect and repair if necessary,

overhaul routines

Vibration Condition Monitoring identifies the necessary repair and overhaul

activities.

15
6. Improve repair time

As a result of machine maintenance planning becoming possible, the actual

repair/maintenance work is more cost effective.

7. Increased machine life

A well-maintained machine lasts longer than a poorly maintained one.

8. Improve product quality

Often, the overall effect of improved maintenance is improved product

quality. For example, in paper machines, vibration has a direct effect on the
quality of the paper product.

9. Reduce product cost

The elimination of unexpected downtime, reduction of repair costs and

increased service intervals all lead to reduced product cost. Also with
vibration condition monitoring, some machines can be run at increased
loads, or speeds to further reduce operating cost.

10. Enhance product safety

Monitoring machinery on a regular basis reduces the chance of dangerous

malfunctions that could endanger employees and the environment. Alarm
levels can be set to suit individual pieces of machinery.

16
1.6 TECHNIQUES FOR CONDITION MONITORING OF
MOTORS

MOTOR MONITORING METHODS:

TEMPERATURE MONITORING
Understanding what exactly a safe or normal operating
temperature is essential but not always that easy. It will be
influenced by several factors:
 Design of motor

 Ambient (local) temperature

 Load factor

 Ventilation method

 Voltage supply (voltage level, balance and distortion)

Even so, understanding when there is a temperature related

problem is difficult, and so looking at the motor temperature
history, or comparing with similar motors can be very helpful.
Several potential problems should be looked for:

 Bearing over-heating, especially of the hotter Drive End, (the

Non Drive End or NDE has the advantage of forced cooling).
 Local hot spots on the casing, identifying a stator winding fault
(less frequent).

 For motors with VSD control there may be additional

temperature stress due to both the higher harmonic content of
the supply and the reduction in forced cooling if operating at low
speeds with high torque load

17
For larger machines, consideration should be given to installing
permanent monitoring devices to continuously monitor critical
areas such as the bearings and the stator windings. Options for
sensors are resistance temperature detectors or thermocouples.
In a low voltage motor, an option is to fit thermistors that can be
built in to trip the motor when the temperature increases above a
certain point. It is essential to regularly clean the motor to keep
the ventilation paths clear, especially on open ventilated motors
Blocked ventilation is one of the most common causes of
overheating of the machine due to restricted cooling.
Infra-red thermography is ideal for quick monitoring, showing
temperature across a whole motor very quickly. Spot
measurement using infra red thermometers is much less costly
than proper thermal imaging cameras, but is considerably more
time consuming and it is much harder to spot anomalies that may
occur in unexpected places.

VIBRATION MONITORING

Full bandwidth vibration monitoring is a powerful way of

understanding the condition of a motor, and can often be used to
pinpoint the precise cause of the vibration by linking the
frequency to the different moving components. It is even more
valuable when considering vibration in complex systems where
there may be a transmission and pump, fan or other driven
component in the assembly. Both mechanical and electrical faults
can be detected using this method of monitoring. Issues such as:
bearing fluting, air gap variation, broken rotor bars and
misaligned couplings can all be identified and remedied.
Permanent fixtures such as displacement probes and
accelerometers may be attached to the motor in order for the
vibration levels to be monitored at all times. Low cost amplitude
only vibration monitoring can quickly assess for overall condition,
and is particularly successful at identifying bearing wear.
The standard, ISO 10816 Mechanical vibration -- Evaluation of
machine vibration by measurements on nonrotating parts, gives
definitive values of vibration criticality, making it easy to get a
snapshot of performance without a pre-history of the machines
vibration profile. Examples of these are shown below, where the
Zone boundary corresponds to the vibration limit applicable to
different frequency bands

OIL SAMPLING AND ANALYSIS OF BEARING LUBRICATION

Bearing selection varies with motor size:
 Small motors commonly use sealed ball and roller bearings,
where no monitoring is possible.
 Medium motors commonly contain greased ball and roller
bearings, supplemented with additional grease where required.
 Large motors may also have ball and roller bearings, either
lubricated with grease or oil, but high speed and large mechanical
forces may require the use of white metal oil lubricated bearings.

On oil lubricated motors, the presence of metal or other particles

in the oil indicates excessive wear. By analyzing the particles
found in the sample, the exact component that is deteriorating
and leaving particles in the oil can be easily identified, making it
easy to schedule a repair. The sample can also show whether the
oil is still effective as a lubricant, whether too little oil is flowing,
or if the oil is still to the correct specification.

ELECTRICAL TESTS
There are many electrical tests and investigations that can be
used to determine the condition of key constructional factors.
Some tests can be done while the motor is still in operation,
‘online’, while some require the motor to not be in use, ‘offline’.
Offline testing allows for more comprehensive testing to be done.
Tests include surge test, winding resistance/coil resistance
testing, meg-ohm test, polarization index testing, high potential
test and step voltage test. Testing the state of the windings by
the winding resistance and insulation resistance test is a good
way to begin, as any other test will be affected by the winding
condition. Online testing is done whilst the motor is operating,
and while tests are more limited, they do have the advantage of
reflecting real life operating conditions.

MOTOR CIRCUIT ANALYSIS

Motor Circuit Analysis is the practice of performing a series of low

voltage tests to gather some electrical measurements from
various points around the motor and then analyzing the results to
develop an idea of the condition of the motor. A particular benefit
of Motor Circuit Analysis is that it only uses a low voltage signal,
so greatly reducing the risk of damaging the motor compared
with the application of high voltages.

PARTIAL DISCHARGE (ELECTRIC INSULATION TESTING)

A high voltage motor (> 5 kV) can be monitored for the presence
of partial discharge, which occurs in the areas of the insulation
where there is a void or poor clearances. This test can be done
online or offline. If performed online, there are special capacitors
that are connected permanently to the motor so that the
capacitive coupling of the winding can be monitored, either
continuously or periodically. If the test is being done while the
motor is offline, a separate power supply is used to energise the
windings at a high voltage so that partial discharge can be
investigated. A technique called Electrical Scanning can also be
carried out using an Ultrasonic Acoustic Monitor to look for and
observe arcing and corona discharge throughout the motor.

WINDING RESISTANCE TEST

A winding resistance test is a quick and accurate way to check

the condition of the conductors in the coil; the results can
indicate the existence of short circuits, as well as show any
imbalances between phases due to turn count differences. The
voltage across the coil is measured once a current has been
introduced. The value of the resistance is then calculated and
assessed using former measurements of the same kind for
comparison. Any change to the resistance is an indication of
damage within the winding.

INSULATION RESISTANCE AND POLARISATION INDEX

TESTS

The Insulation Resistance test (Winding to Earth test) involves

measuring the leakage current when a chosen DC voltage is
applied to the motor. The resistance is derived from the leakage
current measured 60 seconds after the voltage has been applied.
This test can identify ground wall insulation damage, and shorted
or contaminated windings. For high voltage motors, if the winding
to earth test provides enough evidence to consider the windings
to be in reasonable working condition, then a Polarization Index
test may be carried out. This is carried out in the same way as
the Insulation Resistance test, but compares a ten minute figure
to that given after one minute. It analyses the insulation walls’
capability to polarize. A high capability usually indicates good
quality insulation, whereas a low capability usually indicates poor
insulation quality or contamination such as moisture. Under some
conditions the difficulty of measuring the very low leakage
currents means that the results of this test may be inconclusive.
The Polarization Index test would not be used on a low voltage
machine.

SURGE AND HIPOT TESTS

A surge test and a high potential (HI Pot) test are similar in that a
voltage larger than the operating voltage is applied to the motor
to analyze its behavior. A surge test is used to determine whether
there is damage or faults in the insulation between the turns in
the winding. High voltage transients that a motor experiences
under normal operating conditions can ruin the motor’s
insulation. The test works by replicating the effect of these
transients. Each phase of the motor is tested using a value of
voltage chosen in reference to the standard functional voltage of
the system and the results are examined for signs of a defect.
Defects can be discovered at very early stages of a fault. Another
benefit of this test is that it limits the amount of energy applied
with these transients, meaning that the test can be performed
without causing additional damage. After the manufacturing
process a motor will be subjected to a High Potential test. By
applying a voltage much higher than the standard operating
voltage, twice the working voltage plus 1 kV, from the windings
to the frame of the motor, faults within the insulation windings
can be identified. This test is usually only performed once at full
voltage, as it can cause damage if done multiple times.
Sometimes, a user will ask for this to be performed following a
repair on the motor. After a minute of applying this high voltage
to the motor, the leakage current is measured and analyzed. An
unusually elevated leakage current is a warning of poor insulation
– either phase to phase, or phase to earth.
STEP VOLTAGE TEST

The Step Voltage test consists of applying a range of increasing

DC voltages to the motor. The test will reveal any imperfections
in the condition of the insulation by showing a reduction in
resistance with increasing voltage. The time this test takes is
dependent on how many steps are applied. Usually, a minute per
voltage step is counted.

ELECTRICAL SIGNATURE ANALYSIS

Electrical signature analysis uses the measurement of either

voltage or current waveform from a motor to determine whether
there is a fault. If this is done frequently, trends can be
distinguished and faults can be found before serious damage is
caused. However, previous values are not necessarily needed to
indicate an existing fault; from examining the signatures received
it is possible to see where faults may be developing. Electrical
signature analysis while the motor is running allows a number of
different parameters to be tracked. Depending on whether you
are focusing on current or voltage, a number of parameters will
be monitored at various frequency levels including the level of
voltage, the level of current, torque, and any unbalances in the
voltage and current. By recording data for a wide range of values,
it increases the chance of discovering a fault early on, which may
mean that severe damage can be avoided. It is only effective,
however, if the results are actually compared with those
previously recorded and trends are looked for, and the results are
interpreted properly.

Using this method, many faults can be found including:

 Broken rotor bars

 Abnormal levels of air gap eccentricity

 Mechanical problems

 Rotor winding asymmetry

 Mechanically induced current components due to mechanical

influences in the drive train

23
1.7 TRANSFORMER CONDITION MONITORING
TECHNIQUES:

Transformers are generally reliable pieces of plant and cover a

vast range of sizes on power stations. However, the outage of
any transformer may be catastrophic especially for important and
high rating power transformers that supply large number of
loads. Faults are often difficult to diagnose locate in transformers
due to complicated winding structures, but a multi- parameter CM
approach gives valuable data to diagnose the fault and suggest
its location. Where insecure pairs can then be made, both
downtime and costs can be significantly reduced. CM can prevent
transformer unplanned outages and catastrophic failures cause by
faults. It allows ageing of the plant to be monitored and therefore
controlled and possibly predicted and extended. According to old
and recent research in the field transformer condition monitoring,
it can be divided into five main categories. shows the main
categories transformer CM techniques. In the remaining of this
paper, each techniques of the transformer condition monitoring
techniques will be explained and discussed.
Transformer Condition Monitoring Techniques:-

1. Thermal analysis

2. Vibration analysis

3. Dissolved gas analysis (DGA)

4. PD analysis

5. Frequency response analysis (FRA)

THERMAL ANALYSIS
Thermal analysis of the transformers can provide useful
information about its condition and can indicate any incipient
inside it. Many of the incipient faults cause change in thermal
behavior of the transformer. It is usually accepted that
transformer life can be affected very much for a continuous
maximum hotspot temperature of 98°C on the paper
insulation. Beyond this, it is assumed that the rate of ageing
doubles for every increase of 6°C.Also, the transformer
subjected to degradation due to direct thermal effects, and
enhanced oil temperatures are likely to accelerate other ageing
processes. The condition of the oil can affect the ability of
transformer to withstand emergency overloading.

VIBRATION ANALYSIS

The usage of the vibration signals in assessing the transformer

health is relatively a new technique and its research is under
development compared with the other methods of the
transformer CM The health condition of the core and windings can
be assessed using vibration signature of transformer tank.Also,
vibration analysis used for assessing the health of the On Load

Tap Changer

According to the tank vibration consists of two types; core and

winding vibrations. These generated vibrations propagate through
the transformer oil until reaching the transformer walls, at which
the vibration signature of the transformer can be collected via
vibration sensors. Accelerometers are used to collect the vibration
signals by attaching it to the transformer walls. The collected
signal can be found as a series of decaying bursts, each of the
bursts the result of a combination of a finite number of decaying
sinusoidal waveforms. The vibration signals collected and
measured using accelerometers. The collected vibration signal
was analyzed using Fourier transform to show that the transient
vibration signals are concentrated in the range from 10 to 2000
Hz. The condition assessment of the transformer OLTC was
successfully done using vibration signatures. Any OLTC has its
own vibration signature regarding the number of the rising edges
of the vibration busts and the duration between each successive
two rising edges. The features can be extracted from the
collected data using many signal processing techniques. The
continuous wavelet transform was used to analyze the vibration
bursts generated from the operation of the OLTC due its reliable
ability to extract the useful features from the non-stationary and
fast transient signals. As a conclusion, the usage of the vibration
analysis was used to assess the health of the transformer or
some important parts of it such as OLTC. However, there is a
good chance for development in this area because the research
focused on using the vibration analysis for assessing the health of
the OLTC only; therefore, more work is needed to assess the
condition of all transformer parts.

PARTIAL DISCHARGE ANALYSIS

Partial discharges (PDs) occur in a transformer when the electric
field strength exceeds the dielectric breakdown strength of a
certain localized area in which, an electrical discharge or
discharges partially bridge the insulation between conductors.
The dielectric properties of the insulation may be severely
affected if
subjected to consistent PD activity overlong periods of time. This
may lead to catastrophic failure if the PD activity remains
untreated. As the insulation system of the transformer is
regarded as a critical aspect of a transformer condition, suitable
safeguards are required to monitor and assess the condition of
the insulation. Investigations into partial discharge phenomena in
liquid dielectrics (such as oil) have been less common and
subsequently less well understood than solid dielectrics. PD can
be detected and measured using piezo-electric sensors. Also,
optical fiber sensors were used to capture signal successfully.
Ultra High Frequency (UHF) sensors are relatively newer than
traditional PD measurement methods. UHF sensors were used to
measure the PD occurred in power transformers.
DISSOLVED GAS ANALYSIS
The insulation of power transformers is generally very reliable.
Insulation ageing in transformers is most commonly associated
with long-term effects of the operating temperature, moisture
and air. Since a significant proportion of transformers on the
network are over 30 years old, it is necessary to assess the
chemical age of their insulations and, possible, to predict their
rates of ageing
relative to their present and future loading conditions. Dissolved
Gas Analysis DGA) researchers sees that electrical measurements
(partial discharge, dielectric loss, dc resistance, dielectric
strength,
Etc.) Have no clear and strong correlation between electrical
properties and the physical and chemical states of the oil-paper
insulation. The thermal degradation of oil results in the
production of hydrogen, methane, ethane, ethylene, acetylene,
CO, CO2 and other products of oil breakdown include alcohols,
organic acids, aldehydes, peroxides, etc. For any given oil
sample, the absolute and relative concentrations of fault gas can
be used to indicate the type, intensity and location of the fault. A
variety of methods are available to achieve this, laboratories may
rely upon defined critical levels of gases, rates increase in gas
level (on a year by year basis), or one of the various
methodologies associated with Rogers, Duve or Dome berg. The
recommended practice for oil sampling, extraction of the gases
and methods of analysis are detailed in IEC 567. After analyzing
the gas concentrations and using the gas ratio codes, the fault
can be diagnosed using these key tables that relate the ratio of
gases with the defect. Some artificial intelligent agents can be
trained on the DGA ratio codes to classify some incipient faults,
which have some irregular gas ratios that can be interpreted by
the sample usage of the ratio
codes. The problem of the usage of DGA analysis in assessing
the
condition of the transformer is that it needs special Arrangements
to measure the dissolved gases.

Wireless Remote Monitoring & Control

(GPRS/GSM enabled Wireless SCADA)
Wireless SCADA i.e. Wireless Supervisory Control & Data
Acquisition is a remote wireless data logger for industrial &
process automation. This is a GPRS/GSM based SCADA system
with 'Plug & Play' feature.
Soft bit has launched a range of remote data loggers for wireless
industrial & process automation. These wireless remote data
loggers can be used for real time data acquisition, monitoring &
control of remotely installed electrical systems, HT/LT electric
motors, HV/LV transformers, generators, HT/LT distribution
panels, boilers or any electrical machine & system. The micro-
processor based wireless remote data logger works on "Plug &
Play" methodology i.e. this comes fully pre-programmed and you
only need to connect it with a machine to be monitored &
controlled from a remote location.

Following are the main advantages of Remote Data

Logger.
a)- Energy Auditing/Management i.e., Energy Conservation
b)- Remote Condition Monitoring of Machines
c)- Remote Monitoring & Control of any machine &system
d)- Remote Power Monitoring & Management
e)- SCADA - Industrial Automation
f)-Enterprise Integration
g)- Security Applications

28
Data Monitoring - Wireless Remote Data Logger
(Wireless SCADA): -
Once the remote data logger is connected & energized, the user
can monitor the parameters in the following ways:
1) - LCD Screen: The various electrical parameters of machine
can be monitored locally on the LCD screen of the data logger
itself.
2) - SMS Alert: User can activate SMS alerts to receive messages
on his/her mobile phone. This requires a GPRS/GSM enabled SIM
card.
3) - Email Alert: User can activate Email alerts to receive
messages on his/her mobile phone. This requires a GPRS/GSM
enabled SIM card
4) - Remote Web Account (Optional): User can monitor all the
parameters live in real time if he/she has activated the remote
web account. This service requires activation and is on annual
chargeable basis. If the user has activated his/her "Remote Web
Account" then all the parameters can be monitored from a remote
PC/Laptop. User can also do the switching operations from the
remote PC/Laptop. An exceptionally low cost wireless GPRS/GMS
based SCADA solution for remote industrial automation
Conclusions: -
Management of maintenance activities at facilities on military
installations is a complex and expensive task. This report
presents a variety of techniques that can monitor equipment
condition and anticipates failure. For some noncritical,
inexpensive, and easily replaced components, run-to-failure
method may be an acceptable practice. For large, complicated,
expensive, mission-critical items, run-to-failure may be
unacceptable. Maintenance to maximize service life of equipment
or components and surveillance of performance degradation can
allow repairs/replacement without interruption of mission-critical
activities. For certain installations, it may be more economical to
use contract services to maintain Infrequent, complex, and
expensive equipment and processes.
1.8 LIMITATIONS
The technologies presented can be divided into two categories:
Energized: -
Those technologies that can safely provide information on
energized systems and require the system be energized and
operational. These technologies include IRT, Ultrasonic, Motor
Current Readings, Starting Current, Motor Current Spectrum
Analysis RF, Power Factor, and Harmonic Distortion.

De-Energized: -
Technologies that require the circuit to be de-energized for safe
usage include Surge Testing, Hi-Pot Testing, Time Domain
Reflectometry (TDR), Mega ohm meter, Motor Circuit Analysis,
Transformer Oil Analysis, Turns Ratio, and Conductor Complex
Impedance.

30
 COMPANY PROFILE

Sai Wardha Power - KSK Energy Ventures Limited

We are a power project development company in India, with experience in

developing and operating multiple power plants across India. We operate in
the power generation business and have long-term fuel access to our various
power plants. Our power projects are in various phases of operation and
development, including operational power projects, a power project under
construction and power projects in the planning phases. We were established
in 2001 to capitalize on the emerging opportunities in the Indian power
sector and focus on developing, operating and maintaining power projects.
We supply power through a combination of long-term, medium-term and
short-term PPAs to a combination of industrial consumers and state-owned
entities in India. In the fiscal year 2014, we had total consolidated revenues
from operations of `21,118.01 million and incurred losses of `1,628.89
million.

Our promoter company, KSK Energy, is incorporated and registered in

Mauritius, and is a wholly-owned subsidiary of KSK Power Venture plc, an
Isle of Man incorporated entity that is currently listed on the London Stock
Exchange. We are a listed subsidiary of KSK Power Venture plc. Our
individual Promoters, Mr. S. Kishore and Mr. K.A. Sastry, prior to setting up
the Company, have been involved in the development of power projects in
various advisory and consultant roles.

We currently have (i) Six power plants (aggregating 2062 MW) including two
units of 600 MW (that is part of our 3,600 MW Mahanadi power plant with an
aggregate of six units), that are fully operational and (ii) four remaining
units of the 3,600 MW Mahanadi power plant (aggregating 2,400 MW) that
are currently under various stages of construction. In addition, certain other
thermal, solar and hydro power projects, including outside India, are in
various stages of planning.

2.1 KSK Energy Ventures Limited

We are a power projects development company in India, with track record of

developing and operating power plants. We were established in 2001 to
capitalize on the emerging opportunities in the Indian power sector and
focus on developing, operating and maintaining power projects. We supply
power to a combination of industrial and state-owned consumers in India.
KSK Energy Ventures has current interests in various operational power
plants capable of generating 2062 MW of power and is currently involved in
constructing 3600 MW KSK Mahanadi Power plant that has two units of 600
MW unit operational and remaining units under various stages of
construction. Additionally, the group has an exciting portfolio of planned
projects across the fuel spectrum.

‘KSK Energy Ventures Limited’ is a Power Project Development company

with over a Decade of experience in power projects and Power plant
operations. Besides power utilities, KSK has a wide range of consumer base
amongst cross section of industries in India such as cement, textiles, steel,
chemicals, automobiles and heavy engineering.
KSK Energy Ventures Limited was promoted by Mr. K.A. Sastry and Mr. S.
Kishore, both first generation entrepreneurs with extensive financial and
energy sector consulting experience prior to the business.

KSKEVL Boasts of total Thermal operational capacity of 852 MW within a

very narrow span of 8 years. Apart from total operational capacity, KSKEVL
is waiting for one of its mega power project of 6 X 600 M.W. in Chhattisgarh,
India.

Wardha Power Company limited((Warora) was a dream come true project of

KSKEVL with total installed capacity of 540 M.W. It was completed in a
record time of one and a half year. The project is located on outskirts of
Warora, District Chandrapur in Maharashtra.

540 MW Sai Wardha Power Limited, Maharashtra

This is a coal-based with the capability of generating 540 MW (4X135 MW) of

power and unit wise commissioning during 2010 and 2011
Location: The power plant is situated in Warora Growth Centre, District
Chandrapur, and Maharashtra, India.

Off Taker: Sai Wardha Warora undertakes power supplies to local utilities
and bulk captive consumers in the state of Maharashtra.

Fuel Supply: Sai Wardha Warora Coal supplies are tied up through cost plus
Fuel Supply Agreement with western Coal Fields
2.2 KSK PROJECTS

34
2.3 HISTORICAL PROFILE:

2013  Commissioning of 10 MW Solar Power Project at Bikaner,

Rajasthan
2012  Execution activities at KSK Mahanadi (6 x 600 MW) in
progress. First unit expected to be operational in the 1st
quarter of the calendar year 2013.
2011  VS Lignite (135 MW) and Wardha Power company Limited,
Warora (540 MW) Power Plants fully operational
2010  KSK moves to the Main Market of LSE
 VS Lignite and Wardha Power (unit wise) commences
generation
2009  Coal supply agreement entered with GIDC for 1800 MW
Power project in Chhattisgarh, Wardha Chhattisgarh capacity
enhanced to 3600 MW in same location
 Group achieves production of the Gurha East lignite block of
VS Lignite power plant
2008  Company transfers 26 MW Coromandel asset in favor of India
cements, to the other shareholder in the power plant
 Effort on KSK Mahanadi Power Company Limited 1800 MW
power plant commences with significant debt tie-up
2007  Sai regency power plant synchronized with the grid
 Sitapuram power plant synchronized with the grid
 Coal supply agreement entered with PIPDIC for proposed
1800 MW JR Power project in Orissa
2006  Arasmeta plant synchronized with the grid
 Collaborative MOU’s with SMDC’s (GMDC, MPSMC and PIPDIC)
for long term coal supply arrangements signed
 KSK Promoter Group Company “KSK Power Venture” lists on
 AIM Market of London Stock Exchange
 Execution of a coal supply and investment agreement with
GMDC for supplies to proposed 1800 MW Chhattisgarh project
 Lafarge confirms request for setup of additional 43 MW power
plant expansion unit
 Effort on Wardha Warora (Maharashtra) 540 MW power plant
commences

2005  Secures allocation of the Gurha East Lignite block, Rajasthan

to VS Lignite from Government of India
 Shareholders Agreement with Zuari cements for setup of 43
MW captive power plant at Sitapuram, AP

2004  Coromandel Electric phase I of 17.4 MW power plant
commences commercial operation
 Memorandum of Understanding with Lafarge India to set up a
43 MW Arasmeta power plant, Chhattisgarh

2003  Commenced work on 10.9 MW, gas based MMS Power plant
in Tamilnadu

2001  Incorporated KSK Energy Ventures Private Limited

 Commences commercial operation of 20 MW Kasargod Power
Plant, Kerala
VISION STATEMENT:
The Partner of Choice for the Independent Generation Sector
“To be amongst the biggest and most admired and trusted Private Power
Developing Companies in the world, delivering reliable and quality power
solutions to our customers at competitive costs, thereby creating superior
value for all stakeholders.”
MISSION:

• To be the single largest provider for the “bulk consumer” segment.

• To maximize creation of wealth, value and satisfaction for the
stakeholders.
• To create the most motivated employee force.
• To be a technology driven, efficient and financially sound organization.
• To contribute towards community development and nation building

LIST OF DEPARTMENTS IN SWPL:

Sr.
Department
No.

1 Personal Department

2 Material management Department

3 Finance Department

4 General Stores

5 Safety/ Laboratory
6 Coal Yard
7 CSR Department

8 Operation Department

9 Maintenance E&I/MECH/Operation/Civil

Table 2.1 Departments of SWPL

37
RESEARCH METHODOLOGY

38
3.1 OBJECTIVES

1. Continuous monitoring of electrical equipment’s

2. To avoid failure of electrical equipment’s
3. To save money by continuous monitoring of electrical equipment’s

3.2 HYPOTHESIS

CONDITION MONITORING improves the overall process of the OPERATION

SYSTEM

3.3 RESEARCH DESIGN

The type of research proposed to be used here is an Exploratory

Research and Descriptive Research.

PRIMARY DATA:-
This data had been collected through meetings and interviews with various
managers and employees of the ELECTRICAL department located in Sai
Wardha power limited . At the same time I had visited various departments
for collection of data. The various areas I visited where electrical
equipment’s is installed & observed various temperature of electrical
equipment’s.

39
SECONDARY DATA:-
Apart from the Department primary data certain secondary data were
required for this project. Followings are the main sources secondary data:
1. Manuals and reports from the company library.
2. Photocopy of electrical equipment’s showing various temperature

3.4 LIMITATION & SCOPE

1. Officials were likely to be reluctant to supply any information
regarding failure of equipment’s.
2. Limited manuals, journals were available.
3. Study is restricted only for project work.

40
 DATA COLLECTION
&
ANALYSIS OF DATA
IN Sai wardha power company ltd, there is 220 KV SWITCHYARD,
various electrical equipment’s are installed like
Transformers,Busbar,Isolators,CT& PT etc.

1. Current transformer
Max temp:43.6 deg cel
2.CT with jumpers
Max temp: 41.6 deg cel

42
3. Line-1 CT with jumpers
Max temp:41 deg cel

43
4. Isolators with jumper
Max temp:43.2 deg cel

44
5. Single line thread
Max temp: 39 deg cel

45
6. Bus bar
Max temp: 40.5 deg cel

46
7. 220 KV insulator
Max temp:44.2 deg cel

47
8. Jumpers connecting to bus bar
Max temp: 42.1 deg cel

48
9.PT
Max temp: 40.2 deg cel

49
10. Isolator
Max temp: 39.3 deg cel

50
11. MOTOR
Max temp:77.3 deg cel

51
RELIABILITY AND AVAILABILITY

Since CBM is better in terms of effectiveness of maintenance, the

reliability becomes higher. If done right, it will reduce the amount
of functional failures. Functional failures can have costly
consequences such as increased maintenance cost, secondary
failure, and operational downtime or even reduced safety.

At the same time, the average interval between maintenance

operations will increase. Prescheduled maintenance strategies will
most of the time be performed a lot more often than is necessary
over the lifetime of the system. This means the maintenance
costs is decreased.

52
CONCLUSIONS:

1. By monitoring the performance of the critical machines and

secondary critical machines we can predictive shutdown of the
plant instead of frequent planned shutdowns

2. The root causes of machinery failure can be known by using

the Vibration monitoring System.

3. Lead to increase in the reliability of the system machinery.

4. Reduction of manual intervention that is erroneous.

5. Will eventually increase the plant uptime to 95% overall.

53
BIBLIOGRAPHY

1.Bibliography

 AEMC Instruments, “Understanding Insulation Resistance Testing”,

http://www.powercet.com/uploads/files/AE_Understnd_Insulation_Res
_Testing.pdf

 Condition Assessment of HV Insulation (IET Press, UK 2008)

http://digital
library.theiet.org/ebooks/iet/power_and_energy/po053e?isAuthorized=
no

 Data from Sai Wardha Power Limited, Group of KSK Energy Ventures.

 Tran T. V., and Gol Ö.: Stator End Winding Problems in Large Synchronous
Generators and Some Remedies, International Conference on Electrical
Machines, Bruges, Belgium, Paper 406, 2002.
 www.en.wikipedia.org

 www.youtube.com

 www.google.co.in

 www.ksk.co.in

54