USAID ENERGY POLICY PROGRAM

TECHNICAL AUDIT REPORT

RAWAT 500KV GRID STATION

January 2015

This program is made possible by the support of the American people through the United States Agency for
International Development (USAID)

USAID ENERGY POLICY PROGRAM

TECHNICAL AUDIT REPORT

RAWAT 500KV GRID

STATION

Contract No: AID-EPP-I-00-03-00004

Order No:
AID-391-TO-12-00002

USAID Energy Policy Program

House 4, Street 88, Sector G-6/3
Ataturk Avenue, Islamabad, Pakistan
Tel: +92 (51) 835 7072, Fax: +92 (51) 835 7071
Email: jhicks@aeai.net

DISCLAIMER
The contents of this report are the sole responsibility of Advanced Engineering Associates International Inc. (AEAI) and
do not necessarily reflect the views of USAID or the United States Government.

Technical Audit of Rawat 500kV Grid Station

Introduction:
This report covers the technical audit of Rawat 500kV Grid Station (GS), located at G.T. road,
near Islamabad. It was commissioned at 220kV level on July 13, 1991. Later on, the GS was
upgraded to 500kV level on February 19, 1997. It has 1350MVA total transformation capacity,
feeding Islamabad and its surrounding areas.
There are three (03) 450MVA-500/220kV, two (02) 250MVA-220/132kV, one (01) 160MVA220/132kV autotransformers and two (02) 13MVA-132/11kV power transformers that are
owned and maintained by NTDC. There are five (05) 500kV, six (06) 220kV and thirteen (13)
132kV circuits linking this station to others. It is connected to Nokkar 500kV GS, Tarbela hydro
power station and Ghazi Barotha hydro power station through 500kV circuits and to Mangla
hydro power station, ISPR 220kV GS, Bahria Town 220kV GS and Islamabad University 220kV GS
through 220kV circuits. For 500kV and 220kV switchyard, one and half breaker scheme and for
132kV switchyard double bus single breaker scheme is used. Single line diagram is attached
(Annex-A).
EPP audit team comprising of technical experts visited this GS from April 28, 2014 to May 16,
2014. This report reflects their findings and prioritized fixes.

Findings:
Observations of technical experts are as under:
1) Loading condition of transformers is tabulated below:
Transformer
No.

Rating
Voltage
Ratio
(kV/kV/kV)

Power
(MVA)

HV/LV Current
(A)

T-1

500/220/23
500/220/23
500/220/23
220/132/11
220/132/11
220/132/11
132/11.5
132/11.5

450
450
450
250
160
250
13
13

495/1125
495/1125
495/1125
656/1093
420/700
656/1093
56.8/653
56.8/653

T-2
T-3
T-4
T-5
T-6
T-7
T-8

Max. Load
Max.
Current
Percentage
Recorded (A) Loading of
transformers
(%)
1080
96
1080
96
1080
96
1100
100.6
700
100
1100
100.6
640
98.01
582
89.13

From above, it is evident that all transformers are loaded above the prescribed criteria per
NEPRA grid code clause OC 4.9.5 supported by IEC (International Electro-technical Commission)
which allows up to 80% loading of transformers. According to IEC Standard 60354, continuous
loading of transformer above 80% at ambient temperature equal to or above 40C, prohibits
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Technical Audit of Rawat 500kV Grid Station

the transformers short time overloading beyond its nameplate ratings. Exceeding this limit
reduces the expected useful life of transformers in proportion to the amount and duration of
overload. A 220kV transformer bay is available for extension purpose. The 160MVA-220/132kV
transformer T5 needs to be augmented with a 250MVA transformer in order to give relief to T4
and T6. As per NEPRA grid code the 11kV system has to be eliminated from NTDC grid stations.
Therefore, the load of two (02) 13MVA-132/11.5kV transformers should be shifted to
surrounding grid stations by IESCO.
2) The following tests have not been performed as required per SOPs for grid system
operation and maintenance:
a. Detailed oil testing and Dissolved Gas Analysis (DGA) test of oil of all
transformers - In the absence of these tests, the quality of transformer oil
cannot be ascertained in view of the contents of various undesired gases in the
oil and other important parameters such as moisture content, flash point,
kinematic viscosity, interfacial tension, acidity and tangent delta etc., resulting
in breakdown of transformers
b. Leakage current measurement (LCM) test of lightning arresters
c. Capacitance & dissipation factor (C&DF) test of current transformers (CTs),
potential transformers (PTs) and capacitor voltage transformers (CVTs)
d. SF6 purity and moisture content test for 220kV and 132kV circuit breakers
It is necessary to conduct all tests timely to ensure healthiness of the equipment.
3) Overhauling of nine (09) 500kV circuit breakers (CBs), fourteen (14) 220kV CBs and five
(05) 132kV CBs is pending due to unavailability of spare parts. The insulator jacket of
interrupting chamber of AEG make 500kV CBs gets cracked over the passage of time.
Three or four instances of such failures had taken place in the past and were replaced
with the available spare ones which have now been exhausted. Any such happening in
future will result in the breakdown of these circuit breakers.
4) The 132kV isolators provided with remote control operation are inoperative and they
are operated manually in the switchyard. This result in unwanted delays of operation of
the equipment. Grounding mats of 132kV isolators are either missing or damaged and
those available are not grounded properly which is a safety hazard for the operator.
5) Tele-protection (PLC aided) and direct transfer trip (DTT) is not available on 220kV
transmission circuits. DTT is required for remote end tripping on Breaker Failure
Scheme when there is no guarantee that relaying at remote line terminals will actuate
quickly enough to minimize consequential damage.
6) Sequential event recorders and fault recorders are not operative/defective. Voltage and
power recorders are out of circuit since long due to lack of maintenance. This data helps
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Technical Audit of Rawat 500kV Grid Station

engineers to check proper functioning and settings of the protection system and identify
components that failed to operate in the event of a fault.
7) Tie Line/Stub protection is not available for four (04) 220kV transmission lines. There are
short sections of the current path within a grid station that are not properly protected by
the general protection. These sections are called stubs and they are usually between the
circuit breaker and the current transformer and also section between the circuit
breakers and the open line isolator. The stub protection is used to detect the fault
current in the blind spots" and to generate a quick trip command to the respective CBs.
8) The GS is missing around forty five (45) important relays such as: (For details see AnnexB and D).
a. Ten (10) Thermal overload protection relays on transformers
b. Six (06) Tertiary earth fault relays on transformers
c. Four (04) Trip lock out relays on transformers
d. Three (03) Neutral over current relays on 220/132kV transformers
e. Three (03) Rough balance differential protection low impedance relays on 220/132kV
transformers
f. Six (06) HV and LV connection differential protection relays on 220/132kV transformers
g. Two (02) back up earth fault relays - AC Series Trip on transformer T8
h. Six (06) Distance to fault locators on some transmission circuits
9) Auto-reclosers on almost all 220kV and 132kV transmission lines are blocked. Autoreclosers can significantly reduce the outage time, reduce transmission line damage and
thus provide higher service continuity.
10) Moreover, spare parts for twenty one (21) CBs are not available for future overhauling.
Spare parts should be arranged for major maintenance of three (03) 500kV CBs, five (05)
220kV CBs and thirteen (13) 132kV CBs in near future (For details see Annex-B).
11) Thermovision survey of the GS has not been carried out. It should be carried out on
priority basis for the detection of loose joints, if any, for proper remedial measures to
avoid any breakdown.
12) The Tower Nos. 26 to 45 of 220kV Rawat-Islamabad University circuit lie in Bahria Town
housing society where surrounding levels have been raised above the chimney level and
stagnant water causes erosion of stubs and tower members, which may cause
breakdown of the line thereby affecting power supply to Islamabad University 220kV GS.
Tree cutting is required from tower No. 130 to 164 on priority basis to avoid outage of
the line. It was reported that the said tree cutting is not being allowed by Capital

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Technical Audit of Rawat 500kV Grid Station

Development Authority (CDA). The matter needs to be taken at the appropriate forum to
expedite the required tree cutting.
13) Retaining wall is required for tower no. 39 and 377 of 500kV Rawat-Nokhar circuit-1,
tower no. 216, 222, 223, 235 and 251 of 500kV Rawat-Barotha circuit-1, tower no. 2, 21,
268 and 275 of 500kV Rawat-Barotha circuit-2, tower nos. 63, 66, 79, 81, 82, 88, 95, 100,
110 and 123 of 220kV double circuit Rawat-Islamabad University circuit and tower nos.
70 and 76 of 220kV Rawat-Mangla circuit. Thermovision survey of all the circuits should
be carried out on priority basis for detection of loose joints, if any, for proper remedial
measures to avoid any breakdown.

Recommendations:
Sr. No.

Transmission and Grid

Recommendations
One (01) 450MVA-500/220kV
transformer bank may be
added. Alternately, one existing
450MVA-500/220kV
Loading of transformers is
transformer bank may be
above the prescribed criteria
augmented with 750MVA. One
per NEPRA grid codes i.e. 80%.
160MVA-220/132kV
transformer T5 may be
augmented with a 250MVA to
give relief to T4 and T6.
These tests need to be done on
Detailed oil testing, Dissolved
priority basis to ascertain quality
Gas Analysis and C and DF test
of oil, healthiness of the
for all transformers are due.
transformer and its insulation.
LCM test for all lightning
All other tests should be carried
arresters and C&DF test for all
out per the SOPs to ensure
CTs and CVTs is due.
healthiness of the equipment.
Overhauling of twenty eight
Spare parts for the overhauling
(28) CBs is pending due to
of nine (09) 500kV, fourteen (14)
unavailability of spare parts.
220kV and five (05) 132kV CBs
The insulator jackets of
should be arranged. At least six
interrupting chamber of AEG
(06) interrupting chambers
make 500kV CBs gets cracked
should be provided for use in
over the passage of time.
emergency.
The 132kV isolators are
operated manually in the
Needs to be replaced with
switchyard. The grounding
appropriate ones per the
mats are either missing or
relevant NTDC specifications.
damaged and those available
are not grounded properly.

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Findings

Remarks

NTDC have trained

staff for overhauling
of CBs and workshop
facilities for repairing
of CBs

Technical Audit of Rawat 500kV Grid Station

Sr. No.

Findings

Tele-protection and direct

transfer trip (DTT) facility is
out of circuit on most 220kV
circuits.

Tie line protection is not

available for four (04) 220kV
transmission lines.
The following equipment on
transformers is not installed:
Ten (10) Thermal overload
protection relays, six (06)
tertiary earth fault relays, and
(01) overload (current based)
protection relay on T6 are not
installed and six (6) AVR relays
are out of circuit.
Forty five (45) important
relays are missing at this GS.
(for details see Annex-B and D)

Inoperative sequential event

recorders, fault recorders and
voltage recorders for 220kV
system.

Auto-reclosers are blocked on

all 220kV and 132kV lines

HV connection, LV connection
and rough balance differential
relays are not installed on

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Protection
Recommendations
System Protection and
telecommunication
departments of NTDC should
look into it and make concerted
efforts to enable Carrier aided
facility at either ends of the
transmission lines in order to
clear faults rapidly.
Recommended to be installed.
Thermal overload and overload
(current based) protection has a
vital role against sustained
overloading. Hence
recommended to be installed
and configured precisely. All
other missing and defective
relays need to be installed. (for
details see Annex-B and D)
All missing and defective relays
need to be installed with latest
version.
It is strongly recommended to
make sequential event
recorders, fault recorders and
voltage recorders functional.
Such data helps engineers to
check proper functioning of
protection system and identify
the components which failed to
operate as expected.
"System Protection" and
"System Operations"
departments have to review the
matter and take appropriate
action for restoration of autoreclosers. This can significantly
reduce the outage time,
reduction in transmission line
damage and thus provide higher
service continuity.
Needs to be installed to
sectionalize the differential
zones.

Remarks

Technical Audit of Rawat 500kV Grid Station

220/132kV transformers to
sectionalize the differential
zones.

Sr. No.

Findings

General
Recommendations

Thermovision survey of GS is
not done.

Thermovision survey needs to

be carried out to avoid any
major breakdowns

Twenty (20) 220kV towers lie

in Bahria town housing society
where surrounding levels have
been raised above the chimney
level and stagnant water
causes erosion of stubs and
tower members. Dangerous
tree cutting is also required for
35 towers. Retaining walls are
missing for twenty three (23)
towers of various 220kV and
500kV circuits. Thermovision
survey of circuits is not done.

The level of the chimney of

tower foundation to be raised
by at least 9 inches above the
raised NSL (Natural Surface
Level) after proper jacketing of
the chimneys with appropriate
size and number of steel bars.
Retaining walls for eleven (11)
500kV and twelve (12) 220kV
towers of the concerned circuits
to be constructed to safeguard
the tower foundations against
flowing water. Thermovision
survey needs to be carried out
on priority basis to avoid any
major breakdowns.

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Remarks

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