Pioneering Success: Central Railway’s First GIS Substation at Kharbao

The Kharbao AC Traction Substation project, officially named “Design, manufacture, supply, erection, testing and commissioning of new 220kV/27kV, single phase, 50 Hz, Gas Insulated Switchgears (GIS) base AC Traction Substation complete with two Nos. of 220kV/27kV, 30MVA transformers including 25kV switchgears (GIS), outgoing feeder arrangement, Foundations, Structures & all Ancillary Equipment at Kharbao in Diva – Vasai section of Mumbai Division of Central Railway and dismantling of all equipment of existing 110/25kV AC TSS & disposal of the same to Railway’s nominated scrap depots located at various places in Mumbai area,” is an ambitious and complex undertaking. This project, spearheaded by Leena Electro Mechanical Pvt. Ltd. under the expert guidance of Mr. Laxman Naikwadi and his team, presents numerous technical, logistical, and environmental challenges.

Technical Challenges

The installation of GIS base switchgear in this project requires exceptional precision and specialized skills due to the sophisticated and compact nature of the equipment. The use of SF6 gas for insulation is a critical aspect, necessitating careful handling to prevent leaks, as well as rigorous sealing and testing procedures to ensure safety and functionality. Moreover, integrating the new systems with existing electrical and control systems adds a layer of complexity that requires detailed planning to ensure seamless compatibility.

Logistical Challenges

Site preparation for the Kharbao substation must address significant space constraints and the need for robust foundation structures. Transporting large and heavy GIS components to the installation site presents additional challenges. These components require careful handling to avoid damage during transit, and site access can be particularly difficult in remote or densely populated areas, complicating the logistics further.

Environmental Challenges

Environmental considerations are paramount in this project. Installation must account for varying climate conditions, such as extreme temperatures, humidity, and pollution, all of which can impact the performance of the equipment. Compliance with environmental regulations, especially those concerning the handling and disposal of SF6 gas, is crucial to minimize the environmental impact. This involves adhering to stringent guidelines to ensure safe and responsible management of this potent greenhouse gas.

Additional Considerations

In addition to the aforementioned challenges, the project must ensure high-voltage safety through stringent protocols and emergency preparedness plans. Managing the significant upfront investment and planning for long-term maintenance costs are also critical factors. Effective solutions and best practices include meticulous planning and design, investing in skilled workforce training, utilising advanced tools and technology, and engaging with stakeholders to address site-specific and regulatory requirements.

By adopting these strategies, the Kharbao AC Traction Substation project aims to enhance the efficiency and reliability of the Central Railway’s infrastructure, contributing to a more robust and sustainable railway network.