Case Study: Repair and Recommissioning of 100 MVA ICT at Bidri Substation
Client: Maharashtra State Electricity Transmission Co. Ltd. (MSETCL)
Location: Bidri Substation, Kolhapur District
Project Year: 2019
Sector: Transmission Infrastructure / Substation Services
MSETCL’s 220 kV Bidri Substation in Maharashtra required the urgent repair of a 100 MVA, 220/132/110 kV Interconnecting Transformer (ICT) of IMP make. The transformer, a key component in the power evacuation infrastructure under EHV O&M Division Kolhapur, had developed a fault and required complete overhauling to restore its operational status.
Mahati Industries was awarded the contract to execute the repair, installation, and recommissioning of this large-capacity ICT as per MSETCL’s performance and safety standards.
Challenges and Requirements
The scope of work included:
Complete disassembly and refurbishment of the 100 MVA ICT (Sr. No. PT-5725).
Rectification of faults affecting power transfer between voltage levels.
Compliance with MSETCL’s technical and safety standards for substation assets.
Timely restoration to prevent prolonged downtime at the 220 kV Bidri substation.
Given the importance of the ICT in load balancing and transmission network stability, the project demanded high precision, testing rigour, and timely execution.
Mahati’s Approach & Solution
The Mahati service team carried out detailed diagnostics and then undertook the repair process in line with EHV O&M norms. The transformer’s internal components, insulation system, and tap changer were serviced and validated. Oil treatment, core-coil assembly adjustments, and thermal performance restoration were performed in-house.
Solution Highlights:
100 MVA, 220/110 kV, 3-phase, Yd0 ICT fully overhauled.
Equipment testing conducted per MSETCL and IS standards.
Oil processing, insulation upgrades, and full winding validation completed.
Delivery, installation, and recommissioning done within timeline.
The transformer was transported back to site, installed, and commissioned at the 220 kV Bidri Substation on 18 October 2019.Solution Highlights:
Detailed erection planning, minimising downtime and rework.
Safe handling of preassembled GIS modules to prevent damage.
Testing of HV and LV connections in line with IS and IEC standards.
On-site integration with power transformers and grid tie-ins.
By breaking the scope into modular sequences, the team ensured quality control at every step without delaying downstream activities.
Implementation & Execution
Mahati executed the repair under MSETCL supervision:
Disassembly and technical assessment of transformer condition.
Procurement and replacement of worn or degraded parts.
High-voltage insulation and ratio testing post-assembly.
Transport and site handling using Mahati’s logistics partners.
Final recommissioning at Bidri Substation under MSETCL oversight.
The ICT was successfully recharged on the same day of installation and has remained in trouble-free operation since October 2019, as confirmed by the performance certificate issued in January 2025.
Results & Impact
Transformer performance restored to full operational capacity.
Zero issues observed by MSETCL since commissioning.
Avoided capital expense of ICT replacement.
Minimal downtime ensured for the 220 kV grid section.
All work rated satisfactory per MSETCL documentation and NOC.
This project highlighted Mahati’s ability to handle large-capacity ICTs with full accountability and precision, even under tight operational timelines.
Future Outlook & Scalability
The project reinforces Mahati’s transformer servicing credentials and strengthens its position as a trusted repair partner for state utilities. With a strong record in ICT repair, Mahati continues to support utilities with timely, cost-effective refurbishment services across Maharashtra and beyond.
Why Mahati?
Proven capability in servicing high-capacity transformers.
Experienced field and workshop team trained in ICT diagnostics.
End-to-end service model from pickup to reinstallation.
Adherence to utility standards and transparent documentation.