Motilal Nehru National Institute of Technology, Allahabad
Department of Electrical
Engineering
SUMMER TRAINING
REPORT ON
400 kV / 220 kV
SUBSTATION
AT
POWER GRID CORPORATION OF INDIA
LIMITED (PGCIL)
Saharanpur, Uttar Pradesh
Submitted in Partial Fulfillment of the Requirements for
Summer Internship
(One-Month Duration)
Submitted By: Submitted To:
Name: Nitin Kumar Department of Electrical Engineering
Roll No.: 20225058 Motilal Nehru National Institute of
Branch: [Link] – Electrical Engineer- Technology, Allahabad
ing
Year: Final Year
Power Grid Corporation of India
Limited
Under the Guidance of: Saharanpur Substation, Uttar Pradesh
Mr. Rahul Kumar (Asst. Manager)
PGCIL, Saharanpur Substation July 2025
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Acknowledgement
I am sincerely grateful to Mr. Rahul Kumar , my industry guide at PGCIL
Saharanpur Substation, for his valuable guidance and support throughout my
one-month internship.
I also thank the management and staff of PGCIL Saharanpur for welcoming
me and providing a practical learning environment.
My heartfelt appreciation goes to the Department of Electrical
Engineering, Motilal Nehru National Institute of Technol-
ogy, Allahabad
especially my academic mentors, for their continued encouragement and assis-
tance.
Finally, I would like to thank my family and friends for their unwavering support
and motivation during this period.
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TABLE OF CONTENTS
1. Acknowledgement 2. Certificate 3. Table of Contents
4. Chapter 1: Introduction 5. Chapter 2: Overview of
PGCIL & Saharanpur Substation 6. Chapter 3: Single Line
Diagram (SLD)
3.1 Layout Overview 3.2 Component Roles and Flow Explanation
7. Chapter 4: Substation Equipment Details
4.1 Transmission Feeder 4.2 Circuit Breakers 4.3 Isolators 4.4 Current
Transformer 4.5 Potential Transformer 4.6 Interconnecting Trans-
former 4.7 CVT 4.8 Bus 4.9 Bus Reactor 4.10 Lightning Arrester 4.11
Protection relays 4.12 Earth Switch & Earthing Grid 4.13 Towers
and Insulators
8. Chapter 9: Conclusion & Learning Outcomes
1: Introduction
India’s power landscape relies on a robust transmission network to
connect generation centers with load regions. As the central transmis-
sion utility, the Power Grid Corporation of India Limited (PGCIL)
was established in 1989 and granted Maharatna status, overseeing
over 180,000 km of EHV lines and around 280 substations as of April
[Link] transmits roughly 50% of India’s electricity, maintaining
system reliability with more than 99% network availability, achieved
through advanced operations and maintenance
Within this national framework, each regional substation plays a
vital role in stepping down voltage, regulating system stability, and
enabling bidirectional power flow. The 400 kV substation at Saharan-
pur, Uttar Pradesh, is one such critical node in PGCIL’s Northern
[Link] functions as a hub for high-voltage power switching, net-
work interconnection, and load relief in a region characterized by
increasing electrification and industrial growth.
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2: Overview of PGCIL & Saharanpur Substation
2.1 PGCIL: Strategic National Asset
PGCIL, a Schedule ‘A’ Maharatna public sector enterprise under
the Ministry of Power, operates the National Grid across more than
485 GW of generation capacity as of June 2025. The company
manages both HVAC and HVDC systems, provides consultancy and
telecom services via its optical ground wire network, and maintains
over 99.8% system availability. By the end of 2024, its network
included approximately 280 substations and nearly 180,000 circuit-km
of transmission lines, with transformer capacity exceeding 546,000
MVA.
2.2 Saharanpur 400 kV Substation
The Saharanpur Power Grid Substation is a 400/220 kV high-voltage
transmission substation operated by the Power Grid Corporation of
India Limited (PGCIL) in Uttar Pradesh. Its primary function is to
step down voltage from 400 kV to 220 kV, enabling efficient integration
into the regional transmission network and onward distribution. With
a designed capacity of around 500 MVA, it plays a crucial role in
grid connectivity, load management, and voltage regulation, ensuring
stable and reliable power supply across the region. Connected via
the Roorkee–Saharanpur 400 kV transmission line, the substation
also serves as an interconnection point for multiple high-voltage lines,
equipped with transformers, circuit breakers, busbars, and protection
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systems to handle switching operations and isolate faults. As part
of India’s growing transmission infrastructure, it is a core node for
both operational stability and future grid expansion in western Uttar
Pradesh.
2.3 Operational Role & Network Importance
Voltage Transformation: Converts high-voltage 400 kV supply to 220
kV for further distribution.
Grid Interconnection: Connects the Northern and Eastern regional
grids to balance power flow.. Reactive Power Support: Incorporates
series compensation and FACTS devices to maintain voltage stability
and support long-distance power transmission.
3: Single-Line Diagram & Substation Layout
3.1 Single-Line Diagram (SLD)
A Single-Line Diagram is a simplified representation of a three-phase
electrical system using standardized symbols. It shows connections—
transformers, busbars, breakers, isolators, CTs, VTs, and reactors—
along a single line for clarity. This diagram is essential for modeling
your power flow study and designing protection schemes.
3.2 Layout of the substation:
List of 400kV Incoming and Outgoing Feeders:
400 kV Feeders
→
1.403 – Roorkee Line Outgoing/Ingoing EHV feeder to Roorkee.
→
2.406 – Baghpat Line Outgoing/Ingoing EHV feeder to Baghpat.
→
3.409 – Future Line I Reserved bay for future connection.
→
4.412 – Future Line II Reserved bay for future connection.
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→
5.415 – Future Line IV Reserved bay for future connection.
→
6.418 – Future / Unnamed Feeder Potential bay for expansion.
.
.401, 402, 404, 405 – Step down from 400 kV to 220 kV for feeding the 220 kV
bus
3.3 Component Roles :
1. Transmission Lines (Feeders)
Carry high-voltage power between substations or from generating
stations. Examples in Saharanpur: Roorkee Line (403), Bagpat Line
(406).
2. Circuit Breakers (CB)
Switch ON/OFF circuits under normal or fault conditions. Protect
equipment by isolating faulty sections quickly.
3. Isolators / Disconnect Switches
Provide visible isolation for maintenance.
Operated only after circuit breaker is open (no load breaking).
4. Current Transformers (CTs)
Step down high current to safe levels for metering and protection.
Feed signals to protection relays and SCADA.
5. Potential Transformers (PTs) / CVTs
Step down high voltage to safe measurable values.
Provide voltage inputs to protection relays and metering.
6. Busbars
Conducting paths connecting multiple circuits in the substation.
Allow flexible switching between feeders and transformers.
7. Interconnecting Transformers (ICTs)
Step down voltage from 400 kV to 220 kV (or vice versa). Enable
interconnection between different voltage levels.
8. Bus Reactors
Absorb excess reactive power.
Control bus voltage during low load periods.
9. Protection Relays
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Detect faults like overcurrent, earth fault, or differential issues. Send
trip commands to circuit breakers to protect the system.
10. SCADA System
Supervisory Control and Data Acquisition.
Monitors voltages, currents, power flows, and breaker status.
Allows remote operation of substation equipment.
4: Substation Equipment Details
4.1 Transmission Feeders:
A transmission feeder in a power grid substation is essentially the high-voltage
line that connects the substation to another substation or generating station for
the purpose of transmitting bulk power.
4.2 Circuit Breakers:
A circuit breaker in a power grid substation is a switching device that can open
or close an electrical circuit under normal load or fault conditions, protecting
equipment by quickly interrupting fault currents and enabling safe isolation for
maintenance.
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4.3 Isolators (Disconnectors)
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An isolator in a power grid substation is a mechanical switching
device used to provide a visible and safe isolation point for equipment
during maintenance. It is operated only when the circuit is
de-energized (after the circuit breaker has opened) and ensures that
no current flows, protecting personnel from electrical hazards.
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A Current Transformer (CT) in a power grid substation is a measuring device
that steps down high transmission line current to a safe, proportional value for
metering, monitoring, and protection. It provides input to protection relays and
measuring instruments, enabling accurate current measurement without directly
exposing equipment or operators to high voltage.
4.4 Potential Transformer
A Potential Transformer (PT), also called a Voltage Transformer
(VT), in a power grid substation is used to step down high voltage to
a safe, proportional value for metering, monitoring, and protection.
It allows instruments and protection relays to accurately measure
system voltage without being directly exposed to the high-voltage
line..
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4.5 1nterconnecting Transformer (ICT)
An Interconnecting Transformer (ICT) is installed in the substation
to link two different busbar sections or systems. It does not serve
as the main step-down transformer; instead, it provides operational
flexibility and system support.
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4.6 Capacitive Voltage Transformer (CVT)
A Capacitive Voltage Transformer (CVT) in a power grid substation
is a type of voltage transformer that uses a capacitive voltage divider
along with a transformer to step down very high transmission voltages
(like 220 kV o 400 kV) to a safe, measurable level for metering,
monitoring, and protection. CVTs are also often used for carri
communication in power lines, as they can couple high-frequency
signals onto the transmission line for telemet and control.
Functions
[Link] Measurement – Steps down very high voltages (e.g., 220
kV, 400 kV) to standard secondary values (e.g., 110 V) for meters
and relays.
[Link] Input – Feeds accurate voltage signals to protection
relays for fault detection.
[Link] Communication – Acts as a coupling device for high-
frequency communication signals over power lines (Power Line Carrier
Communication – PLCC).
[Link] – Electrically isolates measuring equipment from the high-
voltage system.
4.7 Buses in Power Grid
A bus in a power grid substation is a common conducting point where
multiple circuits such as feeders, transformers, and other equipment
are interconnected.
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Function – Distributes electrical power to different circuits, main-
tains uniform voltage across all connected lines, and allows opera-
tional flexibility for switching and maintenance.
Material – Constructed from high-conductivity metals like alu-
minium or copper to handle high currents with minimal energy
losses.
Types of Bus Arrangements –
Single Bus – Simple, cost-effective, but less reliable.
Double Bus – Two parallel buses for improved reliability.
Main and Transfer Bus – Main bus for operation, transfer bus
for backup during maintenance.
Ring Bus – Circuits connected in a loop, allowing isolation without
complete outage.
Breaker-and-a-Half Scheme – High-reliability setup with three
breakers for two circuits.
Application in EHV Substations – In high-voltage grids like the
400/220 kV Saharanpur substation, buses are designed for extra-high
voltage operation,
providing reliable, flexible, and efficient power distribution
400 kV Main Bus in Saharanpur Substation
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4.8 Bus Reactors
A bus reactor is a shunt-connected inductor installed between the
busbar and ground, or between two sections of a bus, in a substation.
Function –
Absorbs excess reactive power generated in the system during low-
load conditions.
Helps control and stabilize bus voltage within permissible limits.
Improves system stability by reducing voltage fluctuations.
Use in 400 kV Systems –
Especially important in EHV and UHV substations where long trans-
mission lines can cause high no-load voltages.
In the 400/220 kV Saharanpur substation, bus reactors are connected
to the 400 kV main bus for voltage regulation.
Construction – Made as air-core or oil-immersed reactors, rated
for high voltage and continuous operation.
Operation – Can be switched in or out using circuit breakers de-
pending on system voltage conditions.
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50 MVAr Bus Reactor
4.9 Lightning Arrester
A lightning arrester (LA) is a protective device installed in a sub-
station to protect equipment from overvoltages caused by lightning
strikes or switching surges
Function –
Diverts high-voltage surge currents safely to the ground.
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Limits the peak voltage that appears across equipment insulation.
Prevents damage to transformers, circuit breakers, busbars, and other
substation components.
Working Principle –
Under normal voltage, the arrester remains non-conductive.
When a surge occurs, it becomes conductive, providing a low-
resistance path to ground. After the surge passes, it returns to its
non-conductive state.
Types –
Metal Oxide Surge Arresters (MOSA) – Common in modern
EHV substations.
Gap-type Arresters – Older technology, less common now.
Placement in Substations – Installed close to major equipment
like power transformers, ICTs, and near line entries to protect from
incoming surges.
4.10 Protection Relays
Protection relays are automatic devices that detect abnormal con-
ditions (faults) in the power system and initiate tripping of circuit
breakers to isolate the faulty section.
Function –
Monitor current, voltage, frequency, and other parameters.
Detect faults such as short circuits, overcurrent, earth faults,
over/under-voltage, and frequency deviations.
Send trip commands to circuit breakers for system protection. Types
–
Electromechanical Relays – Older, mechanical type.
Static Relays – Use electronic components.
Numerical Relays – Digital, programmable, widely used in modern
EHV substations like Saharanpur.
Placement in Substations – Installed in the control and relay
panels of the control room, connected to CTs, PTs, and breakers for
real-time monitoring and action.
Importance –
Prevents damage to expensive equipment.
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Improves system reliability and stability.
Minimizes outage duration by quickly isolating faults.
Relay Panel
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4.11 Earth Switch & Earthing Grid
Earthing is critical for safety and proper operation in a high-voltage
substation.
Earth Switch:
A switch used to ground (earth) a line or busbar before maintenance.
Ensures the equipment is not accidentally energized while work is
carried out. Provides visible isolation and safe working conditions.
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Earthing Grid:
A network of interconnected conductors buried in the ground through-
out the substation area.
Purpose:
Maintains all exposed metal parts at ground potential.
Ensures fault currents are safely discharged into the earth.
Protects personnel and equipment during lightning or fault condi-
tions.
Design Features of Earthing at Saharanpur Substation:
GI (Galvanized Iron) strips and copper conductors used.
Resistance maintained below prescribed limits (usually 1 ).
Mesh layout ensures step and touch potentials are within safe limits.
Earth Switch:
Local Earting
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Earthing Grid:
4.12 Towers and Insulators
Towers:
Transmission lines entering or leaving the substation are supported
by steel lattice towers.
Types near the substation:
Suspension towers (hold conductors in tension with insulators).
Tension towers (used where direction changes or at dead ends).
Purpose: Safely carry high-voltage conductors while maintaining
clearances from the ground and other structures.
Insulators:
Devices that support and electrically isolate the live conductors from
grounded structures (like towers or busbars).
Types commonly used:
Disc insulators: for suspension in strings on transmission towers.
Post insulators: for busbars and equipment in the yard.
Composite/Polymer insulators: used in polluted areas for better
performance.
Function: Prevent leakage currents and withstand mechanical and
electrical stress.
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TOWER
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INSULATOR
Control Room
The control room is the central operating hub of a substation, where
all monitoring, control, and protection activities are managed. It
houses relay panels, SCADA systems, communication panels, meter-
ing units, and control switches for all equipment in the yard.
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Circuit Breaker (CB) tests
1. Contact Resistance Test
Measures the resistance across closed CB contacts to detect wear,
pitting, or poor connections.
2. Timing Test
Checks the opening and closing time of the breaker to ensure it
operates within specified limits.
3. Trip Coil Current Test
Measures the current drawn by the trip coil to confirm proper coil
health and operation.
4. Pole Synchronism Test
Verifies that all poles of the breaker operate simultaneously to avoid
system imbalance.
5. Insulation Resistance Test
Measures insulation quality between phases and earth to ensure
dielectric strength.
6. Dynamic Contact Resistance Measurement (DCRM)
Monitors contact resistance during movement to detect internal
contact issues.
7. Mechanical Operation Test
Assesses the mechanical integrity of the breaker’s operating mecha-
nism.
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9.1 Key Takeaways & Learnings
Gained practical understanding of 400/220 kV substation layout and
its major equipment.
Learned the functions and operation of transformers, circuit break-
ers, isolators, busbars, reactors, CTs, PTs, CVTs, and lightning
arresters. Acquired hands-on experience in CB Palm Portal testing
and protection relay panel operations.
Understood SCADA monitoring and control for real-time substation
operation.
Developed knowledge of electrical safety procedures and importance
of preventive maintenance.
Strengthened problem-solving and technical analysis skills through
equipment performance assessment.
Enhanced teamwork and communication skills by working alongside
experienced engineers and technicians.
9.2 Conclusion
The internship at Power Grid Corporation of India Limited, Saha-
ranpur Substation, provided an in-depth exposure to the functioning
of a 400/220 kV EHV substation. It offered practical insights into
the operation, testing, and maintenance of critical equipment, along
with the application of safety standards and monitoring systems like
SCADA and CB Palm Portal. This experience not only reinforced
my academic knowledge but also enhanced my technical competency,
analytical skills, and understanding of the importance of reliable
power transmission in the national grid. The learnings gained will
serve as a strong foundation for my future career in the power sector.
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