{"id":4284,"date":"2026-03-02T14:43:53","date_gmt":"2026-03-02T09:13:53","guid":{"rendered":"https:\/\/www.balajiengineers.in\/blog\/?p=4284"},"modified":"2026-03-14T15:10:56","modified_gmt":"2026-03-14T09:40:56","slug":"substation-commissioning-errors-that-lead-to-early-failures","status":"publish","type":"post","link":"https:\/\/www.balajiengineers.in\/blog\/substation-commissioning-errors-that-lead-to-early-failures\/","title":{"rendered":"Substation Commissioning Errors That Lead to Early Failures"},"content":{"rendered":"\t\t
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\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"blog-img\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Introduction<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Commissioning a substation is the final, but\u00a0most critical<\/b>, phase before energization. However, minor oversights during this process can snowball into\u00a0costly failures<\/b>, equipment damage, or unsafe operation within weeks or months of operation.<\/p>

In this post, we\u2019ll explore the\u00a0top substation commissioning errors<\/b>, their impact, and\u00a0how to avoid them<\/b>\u00a0through best practices.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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1. Skipping or Rushing the Pre-Commissioning Checklist<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Many teams skip thorough checks due to tight deadlines. This includes –<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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  • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tIncomplete tightening of busbar joints<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
  • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tMissing insulation resistance (IR) tests<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
  • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tNo secondary injection testing of relays<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t
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    Impact –<\/strong> Leads to high contact resistance, false relay tripping, or delayed fault clearing.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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    2. Improper Earthing of Equipment<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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    Visit –<\/strong> Earthing electrode manufacturers suppliers exporters Maharashtra India to more about Perfect earthing solutions.<\/p>

    Earthing continuity is often not tested rigorously.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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    • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tHigh earth resistance not addressed<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
    • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tEarth electrode not bonded properly with structures<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
    • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tShared neutral-earth connections in LT panels<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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      Impact –<\/strong> High risk of electric shock, equipment malfunction during faults, failure in lightning surge protection.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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      3. CT\/PT Polarity or Ratio Errors<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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      Instrument transformers must be correctly tested and labeled during commissioning.<\/p>

      Errors include –<\/strong><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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      • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tWrong ratio settings<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
      • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tImproper burden connection<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t
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        Impact – <\/strong>Relay coordination fails. May lead to untripped faults or nuisance tripping.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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        4. Incorrect SCADA Configuration or I\/O Mapping<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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        SCADA systems often face issues like:<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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        • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tWrong status indication on HMI<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
        • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tDelayed command execution<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
        • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tNon-functional remote breaker operation<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t
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          Impact –<\/strong> Operators receive false readings or are unable to control equipment remotely during emergencies.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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          5. Misalignment of Moving Contacts in Isolators<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
          \n\t\t\t\t\t\t\t\t\tIsolators must be aligned to ensure –\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
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          • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tProper closing of fixed and moving contacts<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
          • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tSmooth manual or motorized operation<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t
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            Impact –<\/strong> Contact burns, phase-to-earth flashovers, or operational jamming during service.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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            \n\t\t\t\n\t\t\t\t\t\t<\/span>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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            6. Relay Settings Not Verified With Actual Protection Philosophy<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
            \n\t\t\t\t\t\t\t\t\tMany engineers copy relay settings from another substation without verifying actual site parameters.\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
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            Impact –<\/strong> Relay may operate outside intended time-current characteristics, defeating the grading plan.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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            \n7. No Load Testing of Auxiliary Systems<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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            Systems like battery banks, chargers, tripping circuits, and annunciation panels are often ignored.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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            Impact –<\/strong> DC supply failure during actual faults or breaker fails to trip due to control supply drop.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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            How to Avoid These Commissioning Errors<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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            • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tUse a detailed commissioning checklist<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
            • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tConduct loop testing from relay to breaker<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
            • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tPerform mock trip tests<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
            • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t Verify CT\/PT polarity and ratio with a test kit<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
            • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t Always cross-check interlocks and safety schemes<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
            • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tAlign moving contacts of isolators mechanically and electrically<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
            • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tInclude third-party witness testing for sensitive projects<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t
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              \n\t\t\t\t\t<\/path><\/svg><\/div>\n\t\t\t\t\t\t<\/span>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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              People Also Search For -<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
              \n\t\t\t\t\t\t\t\t\tIf you’re working on substation projects or commissioning, you might also find these topics helpful –\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
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              • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t What is a substation commissioning checklist ?<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
              • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\tHow do you test CT and PT before energizing a substation ?<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
              • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t Common reasons for SCADA system failures in substations<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
              • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t How to verify relay settings before substation handover ?<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
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              • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t Why is earthing resistance testing critical during commissioning ?<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t\t\t
              • \n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t<\/path><\/svg>\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t\t What causes transformer failure after energization ?<\/span>\n\t\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t
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                Conclusion -<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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                Substation failures shortly after commissioning are often preventable. By investing time in proper testing, alignment, documentation, and verification, you ensure long-term reliability and safety of your electrical infrastructure.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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                Remember –<\/strong> Commissioning is not just a formality \u2014 it’s your first protection against future failure.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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                Tags of blog -<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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                #SubstationCommissioning #ElectricalTesting #RelayCoordination #HVSubstation #ControlWiring #SubstationChecklist #IsolatorAlignment #CTPTTesting #SubstationSafety #BalajiIsolators<\/p>

                Trusted vendor for solar EPC projects in India | 33kV isolator for wind energy substation | substation package for renewable EPC projects | where to buy substation isolators for solar | approved vendor list for renewable energy tenders | SCADA-compatible isolators for solar plants | electrical commissioning support for EPC projects | channel partner for solar transmission components | solar evacuation substation equipment manufacturers | wind turbine grid connection substation vendor | renewable energy transmission | solar PV grid connectivity | wind turbine evacuation system | electrical balance of plant (eBoP) | renewable energy substation design | grid synchronization equipment | smart grid ready isolators | solar park infrastructure suppliers | balance of system (BoS) for solar EPC | electrical contractors for utility-scale solar<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"

                Introduction Commissioning a substation is the final, but\u00a0most critical, phase before energization. However, minor oversights during this process can snowball […]<\/p>\n","protected":false},"author":1,"featured_media":4285,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"default","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"set","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"footnotes":""},"categories":[1],"tags":[],"class_list":["post-4284","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized"],"_links":{"self":[{"href":"https:\/\/www.balajiengineers.in\/blog\/wp-json\/wp\/v2\/posts\/4284","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.balajiengineers.in\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.balajiengineers.in\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.balajiengineers.in\/blog\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.balajiengineers.in\/blog\/wp-json\/wp\/v2\/comments?post=4284"}],"version-history":[{"count":25,"href":"https:\/\/www.balajiengineers.in\/blog\/wp-json\/wp\/v2\/posts\/4284\/revisions"}],"predecessor-version":[{"id":4358,"href":"https:\/\/www.balajiengineers.in\/blog\/wp-json\/wp\/v2\/posts\/4284\/revisions\/4358"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.balajiengineers.in\/blog\/wp-json\/wp\/v2\/media\/4285"}],"wp:attachment":[{"href":"https:\/\/www.balajiengineers.in\/blog\/wp-json\/wp\/v2\/media?parent=4284"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.balajiengineers.in\/blog\/wp-json\/wp\/v2\/categories?post=4284"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.balajiengineers.in\/blog\/wp-json\/wp\/v2\/tags?post=4284"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}