Services

Transformer Explosion & Fire Prevention Solution

Transformer explosions are caused by low impedance faults that result in arcing once the oil loses its dielectricproperties. Oil is then vaporised, and the generated gas is pressurised because the liquid inertia prevents its expansion. The pressure gap between the generated gas bubbles and the surrounding liquid oil generates pressure waves, which propagate and interact with the tank structure. They cause the pressure rise that leads to the tank explosion. These explosions result most of the time in very expensive damages for electricity facilities [20]. Realising that the transformer explosion prevention is the sole effective solution to avoid such financial losses, SERGI designed and patented worldwide the TRANSFORMER PROTECTOR (TP) in 1999.

The TRANSFORMER PROTECTOR (TP) is a transformer explosion and fire prevention technology based on the direct mechanical response of a Depressurisation Set to the tank inner dynamic pressure increase due to a fault. Since transformers always rupture at their weakest point, the Depressurisation Set is designed to be this weakest point in term of inertia to break before the tank explodes. For that purpose, the Decompression Chamber is equipped with a Rupture Disk (RD). Indeed, after an electrical fault has occurred, the pressure rises, and the Depressurisation Set (DS) opens as soon as the pressure close to the TP has reached the calibrated pressure. Oil is then quickly expelled from the transformer tank, through the Decompression Chamber (DC), and into an Oil Gas Separation Tank (OGST), so that the TP depressurises the transformer tank within milliseconds, and prevents the transformer from exploding. Indeed, once the TP has activated, the mechanical energy is evacuated and the transformer is protected even if the electrical arc is still fed for one second.

The TRANSFORMER PROTECTOR (TP) is the only proven solution against transformer explosion and fire. The TP complies with NFPA codes 850 and 851, which recommend Fast Depressurization Systems for all Power Plants and Substations.

The TP is activated within 0.5 to 20 milliseconds, depending on arc locations and transformer size, by the first dynamic pressure peak of the shock wave, avoiding transformer explosions before static pressure increases.

Transformer explosions and fires are very damaging and frequent. A recent one-year research project led to the discovery of 730 transformer explosions in the USA only. Many experts anticipate that the number of failures per year will increase significantly in the near future because of the shorter duration life*. Transformer explosions and fires create environmental pollution, costly plant outages, and are a risk to human lives.

After TP activation, the transformer is saved from explosion and fire. However, most of the companies avoid disclosing any information regarding transformer failure and all other technical details. Nevertheless, to date there are 19 TP known Successful Activations.

Transformer Oil Filtration Services

All high capacity transformers in use today have to cope with voltages in excess of 400KV. Therefore it becomes imperative to maintain optimal insulation properties of the transformer oils by rigid control over moisture, dissolved gases, particulate contamination and acidity.

Transformer oils deteriorate with time and the decay begins the moment the transformer oil is shipped from Manufacturer’s factory. High temperatures, the presence of oxygen and water, the catalytic action of the materials within the transformer, all combine to result in oxidation and cracking of the transformer oil. The by-products of this oxidative process are acidic in nature, which results in an ever-increasing rate of deterioration of the transformer and its oil. This type of contaminated oil completely loses its insulating properties which will affect the life of the transformer in the long run. Hence the insulation properties of transformer oils should be maintained periodically by filtering this oil through our advanced filtration machine.

The periodic and proper treatment of these insulating fluids will result in the improvement of the properties of the entire insulating system of power transformers and will extend the effective lifetime of the asset.

Many thousands of oil filled transformers containing huge quantities of insulating oil are in service today. As you are aware, the mineral oil in these transformers is intended to,

  1.  Provide dielectric strength of the transformer insulation system.
  2.  Provide efficient cooling.
  3.  Protect the transformer core and coil assembly from chemical attack.
  4.  Prevent the build-up of sludge in the transformer.

When the properties of the oil have changed enough that oil can no longer satisfactorily perform any one of the above mentioned functions, the oil is said to be bad. Continuing to operate a transformer with bad oil significantly reduces the transformer life expectancy.

The principal functions of the insulating fluid are to serve as a dielectric material and an effective coolant. To perform these functions, the insulating fluid must possess specific qualities at the time of initial impregnation of the transformer core and filling of the tank at the manufacturer’s factory and which must be maintained at the same level in field operation if optimum performance is to be guaranteed. Typically these qualities are well defined by international and national standards.

Based on these functions of good oil, the goals to be reached include,

  • Operating the transformer in the “ sludge free range”
  • Preventing the premature transformer failure due to transformer oil oxidation products
  • Conserving two very valuable resources – Oils & Transformers

 

Filtering System

Filtration is carried out through high efficiency non hygroscopic filter cartridges. The filter medium is progressively denser in the direction of flow this unique feature ensure large dust holding capacity.

Degassing System

The optimally designed degassing chamber consists of columns of rasching rings to ensure maximum exposure of oil to high vacuum, which causes moisture and gases to evaporate, the flow of oil is indicated through the slight glass provided on the chamber.

Control Cabinet

The machine is equipped with a sturdy and easily accessible electrical control cabinet.
 

Vacuum pump

Vacuum pumping system of high throughput capacity & high quality is provided for evacuating the degassing chamber & is capable of achieving & sustaining a high degree of vacuum.

Outlet glandless centrifugal pump

The filtered oil from the degassing chamber is drawn out by a centrifugal glandless pump, this gland lass feature ensures total isolation of the filtered oil from the atmosphere & is essential for maintaining the quality of the oil.

Oil filtration Capacity

Our transformer oil filtration machine filters 6000 Liters of oil per hour and it is the best one in its class.

EPC of GIS (Hybrid) Substation

Design, Engineering, Supply, Installation, Testing and Commissioning of 132 KV/33 KV Substation at Jat Tarodi (Nagpur) with Hybrid type outdoor GIS bay units and associated 132 KV Underground Power cable feeders.

The scope of work is as follows:

Establishment of 132 KV S/S at Jat Tarodi using 132 KV Hybrid type outdoor GIS bay units having 2 main bus arrangement (Main I & Main II) and 33 KV Indoor GIS ( Single bus ) on turnkey basis including Design , Engineering, Supply of all equipments / materials / mandatory spares and tools , erection, testing and commissioning of all required materials with associated civil works including clearing of the site , removal of obstacles , liasoning for approvals / clearances from concerned authorities for 132 KV GIS S/S. ( Supply of Transformers will be in MSETCL’s scope )

  •  2 x 132 KV outdoor GIS (Hybrid) Bays for Feeders.
  •  2 Nos. 132KV outdoor GIS bays for 132/33 KV, 50 MVA Power Transformer.
  •  132 KV outdoor GIS Bay for Bus coupler.
  •  2 x 132 KV Bus PTs bays.
  •  Erection of 2 x 25 MVA, 132/ 33 KV Power Transformers to be supplied by owner.
  •  33 KV metal clad Indoor SF6 GI switchgear board with configuration 2I/C + 1B/S + 12O/G + 2 Bus PTs.

Retrofit/overhauling of ABB/CGL circult breakers

Effective time based, condition based or reliability centered maintenance maximizes the reliability of the equipment. ABB service technicians utilise the most advanced diagnostic and repair practices.

Customer expectation

  1. Assure operational reliability of the complete substation including primary and secondary equipment
    • Switchgears, transformers, substation equipment and auxiliaries, field devices, control system, etc.
  2. Reduction of maintenance cost through effective maintenance plans and concepts

GK Power response

  1. Time based maintenance: Periodic maintenance shall guarantee the availability and the reliability of the equipment. This maintenance may include waste parts. Parts with a restricted life cycle can be exchanged.
  2. Condition based maintenance: Control of technical components according to maintenance schedule focused on conditional requirements. Prerequisite is a detailed assessment of the installed equipment.
  3. Reliability centred maintenance: The consequences of a failure are additionally evaluated. RCM is the right amount of maintenance for the right equipment at the right time.

Costumer benefits

  1. Calculable costs and cost reduction
  2. Increased reliability and availability of equipment and system
  3. Lower risk of unscheduled down times
  4. Avoid costs because of downtime and production losses
  5. Keep performance on defined level
  6. One point of contact for all maintenance activities

Substation Maintenance Process

  1. Circuit Breaker Maintenance
  1. Maintenance frequencies
  2. Inspection
  3. Testing
  4. Interpreting test results
  5. Devices covered
  • Air circuit breakers .
  • iVacuum circuit breakers
  • Oil circuit breakers
  1. Insulating Liquids
  1. Sampling
  • Routine tests
  • Dissolved-Gas Analysis (DGA
  1. Testing
    • Color
    • Dielectric breakdown voltage
    • iInterfacial tension
    • Neutralization number
    • Moisture
  2. Dissolved-Gas Analysis (DGA)
  3. Interpreting test results
  1. Transformers
  1. Inspection
  2. Testing
  • Insulation resistance
  • Winding resistance
  • Power factor tests
  • Coree excitation curren
  • Turns ratio (TTR)
  • Gas blanket tests
  1. Lightning Arrestors
  1. Inspection
  2. Maintenance
  3. Testing
  1. Protective Relays
  1. Application
  2. Instrument transformers
  3. Inspection
  4. Testing
  5. Calibration
  • Devices covered
  • Voltage
  • Transformer differential
  1. Ground Grid Systems
  1. Types of test equipment
  2. Inspection
  3. Testing
  1. Batteries and Chargers
  1. Maintenance
  2. Inspection
  3. Testing

EPC of EHV Substations

We offer our clients with efficient erection and commissioning services at reasonable charges. These services are being rendered by using advanced technology and sophisticated machines. The various kinds of erection and commissioning services we offer are as follow:

HT Cable Termination

We have carried out the terminations for prestigious clients such as General Motors and others. Our professionals are well versed with latest technology of Double Cable Termination Kits which enable them to carry out the work with more efficiency.

Switchyard Erection

We undertake switch yard erection for our esteemed clients at convenient charges. The erection is done for Switchyard of 22 KV, 33KV, 132 KV, 220KV substations. These services also include CT, PT & LA, Isolators, gantries and towers if required. The switchyards are of radial or Lilo type with around 8 to 10 Bays. We also take Switch yards for generation also (wind or thermal).

Overhead Line Erection

We undertake the task of installing any HT or LT electrical equipments such as Power / Distribution transformers, Vacuum or SF6 Circuit Breakers, Air Breakers and Panels. These services are rendered for Indoor & GOD, DO, LA, DP Structures for registration formalities. Along with supplying install test & charge Unitized Substation, we make conventional plate type, pipe type or maintenance free earthing with correct values.

Along with these, we also undertake tasks for Overhead Lines Erection. We have erected several Kilo Meters of Overhead Lines of 11 KV, 22 KV & 33 KV. These lines are of Pin type or Suspension type Single Circuit / Double Circuit or Multiple Circuit. Single Pole, DP type or Tower type up to conductor size 200 sqmm. Moreover, we carry out the OH Line work especially for Dedicated or Express Feeders

Panel Erection

Our experience and technical expertise allow us to efficiently execute panel erection. These erections are being done by our professionals who are well versed with the latest technology and various sophisticated machines.

 

We install following type of panels:

  •  Side / Bottom / Top entry
  •  Indoor / Outdoor type
  •  LT or HT type
  •  Capacitor or APFC Panels
  •  Wall / Floor mounting or OH mounting
  •  Synchronizing AMF Panels
  •  PLC Panels

Sub-Station Automation

We offer some of the best products, practices and resources in the power industry for executing successful substation automation programs. We offer an assortment of products and solutions such as controllers and intelligent electronic devices (IEDs), portable test equipment and transformer management systems that enable utility personnel to further improve asset performance and network reliability.

The Utility Challenge

  •  Improve equipment and network reliability
  •  Reduce operations & maintenance budgets
  •  Improve enterprise wide access to operational and non-operational data
  •  Enhance network security
  •  Maximize useful life of existing substation assets
  •  Enhance ability to provide on-demand energy
  •  Respond to regulatory and competitive pressures
  •  Address loss of experienced personnel familiar with old equipment

 

Why Automate?

  •  Acquire and distribute large amounts of real-time data
  •  Manage, correlate and share non-operational data
  •  Enhance network security of real-time and non-operational data
  •  Perform the functions of several individual devices within one device (reduce capital expenditures)
  •  Use fewer devices to wire and configure (reduces installation costs)
  •  Utilize modern substation communication solutions (reduce engineering and commissioning costs)

 

Support reuse of legacy equipment by communicating with existing devices and adding new functions on integrated devices (reduce capital and installation expenditures)

Integrate the monitoring of primary equipment at substations and the health of substation and feeder IEDs (enhance reliability)

Implement an expandable scalable architecture to meet future physical and functional station requirements (reduce life cycle costs – protect future value of investment)

Substation automation is a rapidly increasing area of interest and benefit to utilities. Substation automation goes beyond traditional SCADA to provide added capability and information that can further improve operations and maintenance, increase system and staff efficiencies, and leverage and defer major capital investments.

Applications and data of interest may include remote access to intelligent electronic devices (IED)/relay configuration ports, waveforms, event data, diagnostic information, video for security or equipment status assessment, metering, switching, volt/VAR management, and others.

Newer microprocessor-based relays and other intelligent devices provide unprecedented flexibility and rich functionality which, in turn, provide low cost monitoring analysis and diagnosis of electrical faults in the power network. Many newer IEDs provide optional network interfaces such as distributed network protocol (DNP) 3.0 over transmission control protocol (TCP)/internet protocol (IP)/Ethernet. Additionally, more utilities are gaining access to fiber optic based communications at some substation locations. Even more utilities are implementing IP wireless communication solutions to substations. IP networks to substations can greatly enhance substation automation possibilities and benefits such as primary equipment condition data, fault statistics, and data useful for preventive equipment maintenance.

GK Power is actively planning, designing, and implementing substation automation solutions. We have an experienced team that knows the vendors, products, design options, communication solutions, and implementation hurdles. We help our clients find the best approach, while managing costs and risks.

Services Include:

  •  Develop a business case for substation automation.
  •  Evaluate existing systems and develop strategies to migrate to new applications and technologies.
  •  Design an overall solution to integrate substation equipment with communication systems and head-end applications.
  •  Specify detailed designs and help select all equipment from intelligent devices, substation servers, remote terminal units (RTUs), network switches, firewalls, wide area networks, head-end applications, and others.
  •  Estimate impacts on utility staff resources during implementation and post-implementation.
  •  Assist with configuration, integration, and testing of the solution.
  •  Present and lead a workshop to educate your team on a technology or address a more strategic objective involving substation automation.

 

Enterprise Integration

Installing standalone substation automation, SCADA, Advanced Metering Infrastructure (AMI), Outage Management System (OMS) and other control center applications often by itself delivers huge benefits to utilities in efficiently managing and operating their electrical infrastructure. However, this is just the tip of the iceberg when compared to the benefits these systems can deliver when operated in an integrated fashion. While the integration costs add up to only a fraction of the original cost of the standalone automation systems, the benefits usually far outweigh these costs, thereby accelerating the Return on Investments (ROI) of both the integration as well as the original system investments.

The next frontier at most utilities is quality integration and information presentation that give personnel the information they need and customers the service they expect. GK Power is working with clients to take them to the next level. As an independent consultant, GK Power is knowledgeable about the leading suppliers of solutions for information systems and applications across the enterprise. We make the most out of what suppliers are delivering to our clients.

Do your systems lack the ability to deliver the reports you expect?

Do your customer service representatives have the information they need to answer customer questions and respond to requests?

Are you leveraging the capability of your SCADA system, AMR system, OMS system, and others?

Which of your suppliers are realistically in the business of delivering solutions that cut across multi-vendor systems?

Have you considered that the key to getting the best value from your technology investments may require a new approach?

Can your utility maintain for the long-term all the technical people needed to implement and support ever-changing technology, so you can conquer the next frontier?

Maintenance of Sub Station Equipments

Effective time based, condition based or reliability centered maintenance maximizes the reliability of the equipment. ABB service technicians utilise the most advanced diagnostic and repair practices.

Customer expectation

  1. Assure operational reliability of the complete substation including primary and secondary equipment
    • Switchgears, transformers, substation equipment and auxiliaries, field devices, control system, etc.
  2. Reduction of maintenance cost through effective maintenance plans and concepts

GK Power response

  1. Time based maintenance: Periodic maintenance shall guarantee the availability and the reliability of the equipment. This maintenance may include waste parts. Parts with a restricted life cycle can be exchanged.
  2. Condition based maintenance: Control of technical components according to maintenance schedule focused on conditional requirements. Prerequisite is a detailed assessment of the installed equipment.
  3. Reliability centred maintenance: The consequences of a failure are additionally evaluated. RCM is the right amount of maintenance for the right equipment at the right time.

Costumer benefits

  1. Calculable costs and cost reduction
  2. Increased reliability and availability of equipment and system
  3. Lower risk of unscheduled down times
  4. Avoid costs because of downtime and production losses
  5. Keep performance on defined level
  6. One point of contact for all maintenance activities

EPC of Transmission Line (132KV to 400KV)

We carry out the installation of various EHV transmissions tower lines for our clients. These are being done by our qualified professionals who work as per the client’s requirements and industrial standards. Moreover, the use of sophisticated machines for these compliments the skills of our professionals.

Transmission Tower

We undertake installations for single circuit transmission lines. The tower Line work involves Survey, check survey, and span calculations which are very much essential for tower extensions. The advantages of our services are as follow:

  1. Tower designs and prototype approval is done
  2. Towers are for 110 KV, 132 KV, 220 KV and 400 KV
  3. Tower line design with towers of 20, 150, 300, and 600
  4. Complete bill of material is done
  5. The foundation details such as marshy land, water, hard rock and DFR are given
  6. Foundation Tame plates are also supplied for erection

EHV Transmission Tower

We install the double circuit and multi circuit transmission lines for our esteemed clients. The Tower Line work involves Survey, check survey, and span calculations essential for tower extensions. Moreover, Tower designs and prototype approval is done. The towers are for 110 KV, 132 KV, 220 KV and 400 KV and Tower line design with towers of 20, 150, 300, and 600. We ensure complete billing of the material. The foundation details such as marshy land, water, hard rock and DFR are given and the foundation tame plates are also supplied for erection.

Hot Line Maintenance

Live Line Maintenance is occupying important role in Recent Trends in maintenance Technologies of E.H.T Transmission lines and Switchyards. GK Power is playing a key role in introducing this useful technology to utilities. We undertake all types of Live Line Works Under Hot Stick and Bare Hand methods in power generating station switchyards, major sub-stations, and Transmission Lines.

GK Power carry out preventive maintenance and fault rectification works on all Live voltages without interrupting power transmission / generation. We are a group of dedicated committed, trained and experienced Engineers and Technicians who set for ourselves a high standard of performance in Live Line Maintenance . Our Technicians are trained in Hotline techniques at leading training institute in India. With our vast experience, we started to take up all types of Live Line works in switchyards, substations and Transmission Lines.

World Class Technology Solution