Done by :

Arunkumar M.P
Bijesh K.B
Jijo Francis
Lipin A.K
 ABOUT

FACT is a doyen among the manufactures in India. It started

production in 1944 on the bank of river Periyar. It was then the first
large scale fertilizer factory in the entire country. FACT has three
manufacturing divisions, two divisions at Udyogamandal and one at
Ambalamedu. The overall production capacity of the company is in
the range of 2.58 lakhs of phosphates ad 50,000 tones of
caprolactum.

FACT has also successfully branched out to the field of chemical

and fertilizer technology and design capabilities research ,
development and fabrication engineering services. FACT
engineering and design organization (FEDO) and FACT engineering
works (FEW) are well known names today not only in India but also
outside countries.
FACT has also successfully branched out to the field of chemical and
fertilizer technology and design capabilities research , development and
fabrication engineering services. FACT engineering and design organization
(FEDO) and FACT engineering works (FEW) are well known names today
not only in India but also outside countries.

FACT Udyogamandal division is the oldest in FACT with an installed

capacity of 450TPD of ammonium phosphate and 680TPD of ammonium
sulphate fertilizers.

Besides power received from KSEB, it is also generated in both

Udyogamandal and Ambalamedu complexes ; In Udyogamandal two turbo
generators of 6MW and 16MW capacities are available for power
generation. KSEB power is received at Udyogamandal from Kalamassery
220KV substation.
 LIST OF CONTENTS

INTRODUCTION
SINGLE LINE DIAGRAM
SYSTEM COMPONENTS
FAULT LEVEL CALCULATION
EARTHING SYSTEM
EARTH GRID CALCULATION
DESIGN
REFERENCES
 INTRODUCTION

SUBSTATION :
Defined as : An Assembly of apparatus which transforms the characteristics of
Electrical Energy from one form to another.

For economical transmission and distribution, higher voltage should be used.

Consumers do not use very high voltages.

So they must be transformed into low voltages by means of transformers in sub-

stations.

Thus, a substation may be called as link between the generating stations and
consumers.

The distribution voltages generally used in practice are 66KV, 11KV and 33KV. But
in this project work, we are considering 110KV sub station.
 FAULT LEVEL CALCULATION

Kalamassery fault level = 3600 MVA

2.5% future expansion = 4500 MVA
10% voltage Regulation = 5445 MVA
Base MVA = 100 MVA
Source Impedance = Base MVA x100
Fault level MVA

= 100x100 = 1.8365
5445
Length of ACSR = 5.1 Km
Ohmic impedance of the calculator = 0.292+0.5772
= 0.0841+0.332929
 = 0.6458/Km
= 0.6458x5.1 = 3.29Ω
% Z = KVA x Z = 3.29x100x1000 = 2.72%
10 x KV2 10x1102
% impedance of 110 KV bus at UDL = 1.8365+2.72
= 4.5565
Fault level = 100x100 = 2194.67MVA
4.5565
Fault current= 2194.6 = 11.53 KA
3x110
% Impedence of 20 MVA Transformer = 15.6%
% Impedence of 100 MVA base = 100x15.6 = 78
20
% Impedence of 11KV side of Transformer
= 78 + 4.5565
= 82.5565
Fault level of 11Kv side of Transformer
= 100 x100 = 121.13 MVA
82.5565

Fault current = 121.13 / 3x11 = 6.365 KA

 DESIGN OF SUBSTATION

Earth Resistively  4 spike method

Earth Resistance 10m distance - 0.03 Ω

5m distance - 0.45 Ω
Earth pit - 0.31Ω

P,C, R shorted and is connected to the earth

pit. P2 & C2 are connected to the two
terminals which are connected to the 2
electrodes which are at 20m distances.
Main points to be considered while selecting the site
for EHV Sub-Station are as follows:
i) The site chosen should be as near to the load
center as possible.
ii) It should be easily approachable by road or rail for
transportation of equipments.
iii) Land should be fairly leveled to minimize
development cost.
iv) Source of water should be as near to the site as
possible. This is because water is required
for various construction activities; (especially civil
works, earthing and for drinking purposes etc.)
v) The sub-station site should be as near to the town
but should be clear of public places, aerodromes and
Military / police installations.
vi) The land should be have sufficient ground area
to accommodate substation equipments,
buildings, staff quarters, space for storage of
material, such as store yards and store sheds. with
roads and space for future expansion.
vii) Set back distances from various roads such as
National Highways, State Highways should be
observed as per the regulations in force.
viii) While selecting the land for the substation
preference to be given to the Govt. land over
private land.
ix) The land should not have water logging
problem.
x) The site should permit easy and safe approach
to outlets for EHV lines.
 RESISTIVITY

r= 40x3.14x0.03 = 40x3.14x0.03 = 20.93

1.89 - 0.71 0.18

EARTH GRID AREA CALCULATIONS

Ac2 = If (tc.Tr.Sr.x104/TCAP)/ln(1+(TmTo)(Ko+To))
Where, If = Fault current = 25980A
Tc = Fault current duration = 1Sec
Ar = Efficient if thermal expansion = 0.00423
Sr = Soil resistively = 20.93 Ω m
TCAP = Thermal capacity /unit volume in J/cm3 0C
= SHxSWx4.184 = 4.184x0.114x07.8
= 3.749
Where, SH = Specific heat
SW = Specific weight
At 4500C, Tm = Maximum allowable temp in 0c
= 6200C
To = Ambient Temp in 0C
= 500C
KO = (1-Tr) = 216.64
Tr
Tr = reference temperature for material constant
= 20 0C
Earth grid area , Ac2
= 25.980 (1x0.00423x104x20.93/3.749)/
ln(1+(620-50)/(216+50))
= 533501.28m2
AC = 730:41m2
By including earth satellite earth mat the area of
the earth grid can be increased to 075 m2 (35x25)
DESIGN
Conductor size :
Ondor clonk’s formula provides a reasonable
method to compute the area of iron section for
earthing.
A =I t :  (74/10g10 (1+(Tm-To)/(234+To)x10-3)
Where , A = Area of iron section in m2
 I = rms current in amps
Tm = Max allowable temp in 0C
To = Ambient Temperature in 0C
Max allowable temp for steel in 620oc for
welded joint and 3100C for bolted joints.

The formula is simplified as : A=KI t

Initial design
Assume a preliminary layout of 21mx18m
grid with equally spied conductors and
shown in figure with spacing D=15m grid
burial depth h=0.75m
Grounding mat design :
Considering further expansion fault current
for the design procedure as 259804.
For grounding mat and welded joint are to be
provided.
Area of cross section = A=K I t
= 0.0122-259801 = 317m2
Area of 40mm dia. rod = 40x317 = 1257m2
Hence area of cross section is sufficient earth mat
is designed at a normal spacing of 15m b/w
conductors. As per initial design length of earth
grid including down rods = 36220m
No: of lowers is assumed as 3 and lower foot
resistance as : 10 Ω
Resistance of 3 lowers = 10/3 = 3.33 Ω
Total resistance of line = Resistance of lower +
Resistance of ground wire
 Resistance of ground wire :

Resistance of ground wire is assumed as : 3 Ω

Total resistance of one line = 3.33 +3 = 6.33 Ω
Total resistance of two lines together = 6.33/2
= 3.165 Ω
The resistance of the earth grid may be calculated
as R=(s/4r) +(s/l)
S = 20.93 Ωm
R = Radius of the equivalent surface of the grid
= (area of yard /3.14) = 875/3.14
= 16.68m
R = (20.93/4x16.68+20.93/36220) = 0.31 Ω
Value of electrode resistance = 1/((1/0.31)+1/3.165)
= 0.28
For fault current of 25980 A in 110Kv bas grid
ground return current = 0.357x0.28x11530 =
1152.54A
Minimum length of ground conductor required :
L=Km x Ki x gt/(116+0.174xCsxSs)
Where,

K = 1/2 [ ln ([D2 / 16 h.d] + [(D+2.h)/ 8Dd]2 –[h /

4d] +[Kit/Kh] x ln(8/ (2n-1))]

D = spacing of conductor = 15m

d = diameter of conductor = 0.04m
H= depth of buried conductor = 0.75m
N= 14x1q=16
Used to interconnect the loads and sources of
electrical power
It connects incoming and outgoing transmission
lines
Also connect generator and main transformer in
power plant
Material used: Copper or Aluminium
Size of bus bar to determine max. amount of
current passed
A transformer is a static device that
transfers electrical energy from one circuit to
another through inductively coupled conductors—
the transformer's coils.
A varying current in the primary winding creates
a varying magnetic flux in the transformer's core
and thus a varying magnetic field through
the secondary winding. This varying magnetic
field induces a varying voltage in the secondary
winding. This effect is called mutual induction.
Power transformers are usually the largest
single item in a substation.
Due to large quantity of oil, it is essential
to take precaution against the spread of
fire.
 TRANSFORMER No.4

Make TELK-TRANDORMER WITH ON LOAD TAP CHANGER

Transformer Specification Ref.No.IS 2026-1977

Maker’s Sl No. 120270-2

Type SALOCR

Form 3NYCP

Year of Manufacture 1988

Rated KVA HV 12500/20000

LV 12500/20000

Volts – no load HV 110000V

HV 65.7/105.1

Amperes LV 657/1051

ONAN/ONAF

Type of cooling 15.60%

Impedance voltage (20MVA base) HV/LV HV 3

Phase LV 3

50Hz

Frequency C/S YNyno

Vector Symbol 24000Kg

Transportation Mass 20000Kg

Un-tanking Mass 9495 Kg

Total of oil 41000Kg

Oil Liters 10550 Litres

Air Circulation 8x90 m3/min

POSITION HV CONNECTION HV VOLTS HV CURRENT

1 1N-15 116600 99.2

2 1N-14 114950 110.6

3 1N-13 113300 102

4 1N-12 11650 103.5

5 1N-11 110000 105.1

6 1N-10 108350 106.1

7 1N-9 106700 108.4

8 1N-8 105050 110.1

9 1N-7 103400 111.8

10 1N-6 101750 113.6

11 1N-5 100100 115.5

12 1N-4 98450 117.4

13 1N-3 96800 119.4

A circuit breaker is an
automatically-operated
electrical switch designed to
protect an electrical circuit
from damage caused by
overload or short circuit.

Its function is to interrupt

continuity, to immediately
discontinue electrical flow.
The SF6 is an electro-negative gas and has a
strong tendency to absorb free electrons.
The contacts of the breaker are opened in a
high pressure flow of SF6 gas and an arc is
struck between them.
The conducting free electrons in the arc are
rapidly captured by the gas to form relatively
immobile negative ions.
This loss of conducting electrons in the arc
quickly builds up enough insulation strength
to extinguish the arc.
 FEEDER CIRCUIT BREAKER

Make Crompton greaves everyday solutions

Type GAS CIRCUIT BREAKER 120-SFM-32B

Year of Manufacture 2006

Rated voltage 145Kv

Rated Frequency 50Hz

Rated Normal Current 3150 A

Rated making capacity 100 KAP

Rated short circuit breaking capacity 40 Ka

Rated short time current 40Ka for 3 seconds

Rated lightening impulse withstand voltage 650 KVP

First pole to clear factor 1.5

Rated opr.Seq. 0-0.3sec-CO-3 Min-CO

Rated Gas pressure 7Kg/Cm2-g(at200c)

Gas Wt 8 Kg

Total Weight 1550 Kg

Closing 110V DC, Tripping 110V DC

230V AC

If, 230V AC
 TRANSFORMER CIRCUIT BREAKERS

Make Crompton greaves Nasik, INDIA

Type GAS CIRCUIT BREAKER 120-SFM-32B

Year of Manufacture 1990

Rated voltage 145Kv

Rated Frequency 50Hz

Rated Normal Current 31.50 A

Rated making capacity

Rated short circuit breaking capacity 31.50 KA

Rated short time current 31.5 Ka for 3 seconds

Rated lightening impulse withstand voltage 650 KVP

First pole to clear factor 1.5

Rated opr.Seq. 0-0.3sec-CO-3 Min-CO

Rated Gas pressure 7Kg/Cm2-g(at200c)

Gas Wt 9 Kg
11.) ISOLATORS

These are essentially off load devices although they are

capable of dealing with small charging currents of
Bus bars and connections.
The design of isolators is closely related to the design of
substations. Isolator design is considered in the following
aspects:

• Space Factor
• Insulation Security
• Standardization
• Ease of Maintenance
• Cost

Some types of isolators include:

• Horizontal Isolation types
• Vertical Isolation types
• Moving Bushing types
 FEEDER ISOLATORS WITH EARTH SWITCH

Make G power switch gear ltd, jeedimetla, hydrabad, 500055

Type DB

KV Rating 123

Current Rating 1600A

Year of Manufacture 2005

Impulse Voltage 550Kv peak

Short time current for 1 sec 26.24 Ka rms

Operating Mechanism Motor

Control voltage 110V DC

It Does not Absorb the Lightning

It Does not Stop the Lightning

It Does Divert the Lightning to Ground

It Does Clamp (limit) the Voltage produced by the

Lightning

It Only protects equipment electrically in parallel with it.

 LIGHTENING ARRESTOR

Name of the manufacturer OBLUM ELECTRICAL INDUSTRIES PVT LTD

Trade mark Oblum

Type of identification Metovar

Rated voltage 96Kv

Continuous operating voltage 81Kv (RMS)max

Rated frequency 50Hz

Nominal discharge current 10Ka

Long duration discharge class 3

Pressure relief class ‘A’

The current transformer is used to
measure the very high current passing
through the bus.

It step downs the current and

measurements are taken in the control
room the ratings of CT is based on the
ampere.

These CTs are connected to the control

room through cables.
 FEEDER CURRENT TRANSFORMER -1 (FCT-1)

Ring winding current transformers

Make Brown Boveri-Stromeandler

Type TMRg 110

Year of Manufacture 1957

Voltage 110/220Kv

Ratio 300-150-75-/1/1/1

Power 60VA

Class 0.5 & S20

I Therm 24/12/6

1 Dyn 60/30/15
 TRANSFORMER CTs (TCT-4)

Make Transformer &Electricals Kerala Ltd-TELK

Manufacturing No. 220104

Sl No. 1R,2R,3R

PO No. 19109211 Dt:21/195

Type NPOULVZ-R

Basic Ins level 230/550Kv

Rated Voltage 126Kv

1995

Frequency 50 Hz

Standard Is 2705(Parts 1,2,3) 1992

This is a step down transformer, which step
down the high voltage to a value that can be
measured using the measuring instruments in
the control room.
This has an additional core for the carrier
communication.
The CVT are connected between phase and
ground in parallel to the circuit.
 VOLTAGE TRANSFORMER  CAPACITOR VOLTAGE TRANSFORMER
 IEEE RED DATA BOOK, 1993

 NEWNESS ELECTRICAL ENGINEER’S HAND BOOK,

D.F.WAENE, SECOND EDITION.

 ISO MANUAL ELECTRICAL SYSTEM STUDY AND FAULT LEVEL

CALCULATION BY FEDO.

 POWER GENERATION OPERATION ANDCONTROL BY ALLEN JWOOD

AND BRUDE T W WOLLENBERG.

 ISO MANUAL FOR EARTHING AND SYSTEM STABILITY CALCULATION

BY FEDO.

 STD 80-2000 IEEE GUIDE FOR SAFETY