Megger
Megger
Megger
Introduction:
The measurement of insulation resistance is a common routine test performed on all types of electrical wires and cables. As a production test, this test is often used as a customer acceptance
test, with minimum insulation resistance per unit length often specified by the customer. The results obtained from IR Test are not intended to be useful in finding localized defects in the
insulation as in a true HIPOT test, but rather give information on the quality of the bulk material used as the insulation.
Even when not required by the end customer, many wire and cable manufacturers use the insulation resistance test to track their insulation manufacturing processes, and spot developing
problems before process variables drift outside of allowed limits.
Selection of IR Testers (Megger):
Insulation testers with test voltage of 500, 1000, 2500 and 5000 V are available.
Voltage Level
IR Tester
650V
500V DC
1.1KV
1KV DC
3.3KV
2.5KV DC
5KV DC
When DC Voltage is used (Most used in All Megger), Test Voltage (D.C) = (2X Name Plate Voltage).
DC Test Voltage
24V To 50V
50V To 100V
50V To 100V
100V To 250V
100V To 240V
250V To 500V
440V To 550V
500V To 1000V
2400V
1000V To 2500V
4100V
1000V To 5000V
Measurement Range
250V DC
0M to 250G
500V DC
0M to 500G
1KV DC
0M to 1T
2.5KV DC
0M to 2.5T
5KV DC
0M to 5T
Make sure that all connections in the test circuit are tight.
Test the megger before use, whether it gives INFINITY value when not connected, and ZERO when the two terminals are connected together and the handle is rotated.
During Meggering:
Make sure when testing for earth, that the far end of the conductor is not touching, otherwise the test will show faulty insulation when such is not actually the case.
Make sure that the earth used when testing for earth and open circuits is a good one otherwise the test will give wrong information
Spare conductors should not be meggered when other working conductors of the same cable are connected to the respective circuits.
After completion of cable Meggering:
Test the functions of Points, Tracks & Signals connected through the cable for their correct response.
In case of points, verify positions at site. Check whether any polarity of any feed taken through the cable has got earthed inadvertently.
Safety Requirements for Meggering:
Equipment should be discharged (shunted or shorted out) for at least as long as the test voltage was applied in order to be absolutely safe for the person conducting the test.
Make sure all switches are blocked out and cable ends marked properly for safety.
Cable ends to be isolated shall be disconnected from the supply and protected from contact to supply, or ground, or accidental contact.
Erection of safety barriers with warning signs, and an open communication channel between testing personnel.
If above temperature reduces by 10 degree centigrade, IR values will increased by two times.
Meggers is equipped with three connection Line Terminal (L), Earth Terminal (E) and Guard Terminal (G).
Resistance is measured between the Line and Earth terminals, where current will travel through coil 1. The Guard terminal is provided for special testing situations where
one resistance must be isolated from another. Lets us check one situation where the insulation resistance is to be tested in a two-wire cable.
To measure insulation resistance from a conductor to the outside of the cable, we need to connect the Line lead of the megger to one of the conductors and connect the Earth
lead of the megger to a wire wrapped around the sheath of the cable.
In this configuration the Megger should read the resistance between one conductor and the outside sheath.
We want to measure Resistance between Conductor- 2To Sheaths but Actually Megger measure resistance in parallel with the series combination of conductor-to-conductor
resistance (Rc1-c2) and the first conductor to the sheath (Rc1-s).
If we dont care about this fact, we can proceed with the test as configured. If we desire to measure only the resistance between the second conductor and the sheath (Rc2-s), then
we need to use the meggers Guard terminal.
Connecting the Guard terminal to the first conductor places the two conductors at almost equal potential. With little or no voltage between them, the insulation
resistance is nearly infinite, and thus there will be no current between the two conductors. Consequently, the Meggers resistance indication will be based exclusively on the current through
the second conductors insulation, through the cable sheath, and to the wire wrapped around, not the current leaking through the first conductors insulation.
The guard terminal (if fitted) acts as a shunt to remove the connected element from the measurement. In other words, it allows you to be selective in evaluating certain specific
components in a large piece of electrical equipment. For example consider a two core cable with a sheath. As the diagram below shows there are three resistances to be considered.
If we measure between core B and sheath without a connection to the guard terminal some current will pass from B to A and from A to the sheath. Our measurement would be
low. By connecting the guard terminal to A the two cable cores will be at very nearly the same potential and thus the shunting effect is eliminated.
Megger Size
Min.IR Value
250 Volts
500 Volts
25 M
600 Volts
1,000 Volts
100 M
5 KV
2,500 Volts
1,000 M
8 KV
2,500 Volts
2,000 M
15 KV
2,500 Volts
5,000 M
25 KV
5,000 Volts
20,000 M
35 KV
15,000 Volts
100,000 M
46 KV
15,000 Volts
100,000 M
69 KV
15,000 Volts
100,000 M
< 1K V = 1 M minimum
>1KV = 1 M /1KV
As per IE Rules-1956:
At a pressure of 1000 V applied between each live conductor and earth for a period of one minute the insulation resistance of HV installations shall be at least 1 Mega ohm or as
specified by the Bureau of Indian Standards.
Medium and Low Voltage Installations- At a pressure of 500 V applied between each live conductor and earth for a period of one minute, the insulation resistance of medium and
low voltage installations shall be at least 1 Mega ohm or as specified by the Bureau of Indian Standards] from time to time.
As per CBIP specifications the acceptable values are 2 Mega ohms per KV
Insulation resistance tests are made to determine insulation resistance from individual windings to ground or between individual windings. Insulation resistance tests are
commonly measured directly in megohms or may be calculated from measurements of applied voltage and leakage current.
The recommended practice in measuring insulation resistance is to always ground the tank (and the core). Short circuit each winding of the transformer at the bushing terminals.
Resistance measurements are then made between each winding and all other windings grounded.
Windings are never left floating for insulation resistance measurements. Solidly grounded winding must have the ground removed in order to measure the insulation resistance of
the winding grounded. If the ground cannot be removed, as in the case of some windings with solidly grounded neutrals, the insulation resistance of the winding cannot be measured. Treat
it as part of the grounded section of the circuit.
We need to test winding to winding and winding to ground ( E ).For three phase transformers, We need to test winding ( L1,L2,L3 ) with substitute Earthing for Delta transformer
Formula
1 Phase Transformer
Where C= 1.5 for Oil filled T/C with Oil Tank, 30 for Oil filled T/C without Oil Tank or Dry Type T/C.
Temperature correction Factor (Base 20C):
Correction Factor
32
0.25
41
0.36
10
50
0.50
15
59
0.720
20
68
1.00
30
86
1.98
40
104
3.95
122
7.85
50
Megger Size
Coil Voltage
Min.IR Value
Filled T/C
0 600 V
1KV
100 M
500 M
600 V To 5KV
2.5KV
1,000 M
5,000 M
5KV To 15KV
5KV
5,000 M
25,000 M
15KV To 69KV
5KV
10,000 M
50,000 M
IR Value of Transformers:
Voltage
Min IR
LV side
HV side
Value
415V
500V
2.5KV
100M
Up to 6.6KV
500V
2.5KV
200M
6.6KV to 11KV
500V
2.5KV
400M
11KV to 33KV
1000V
5KV
500M
33KV to 66KV
1000V
5KV
600M
66KV to 132KV
1000V
5KV
600M
132KV to 220KV
1000V
5KV
650M
Shut down the transformer and disconnect the jumpers and lightning arrestors.
Apply the test voltage and note the reading. The IR. Value at 60 seconds after application of the test voltage is referred to as the Insulation Resistance of the transformer at the
test temperature.
The transformer Neutral bushing is to be disconnected from earth during the test.
All LV surge diverter earth connections are to be disconnected during the test.
Due to the inductive characteristics of transformers, the insulation resistance reading shall not be taken until the test current stabilizes.
1.
2.
HV (LV + GND)
3.
LV (HV + GND)
1.
HV (LV + TV + GND)
2.
LV (HV + TV + GND)
3.
4.
TV (HV + LV + GND)
1.
1.
2.
3.
TV (HV + LV + GND)
For any installation, the insulation resistance measured shall not be less than:
HV Earth 200 M
LV Earth 100 M
HV LV 200 M
Factors affecting on IR value of Transformer
The IR value of transformers are influenced by
quality of oil
temperature of oil
In accordance with IEEE 43, clause 9.3, the following formula should be applied.
For most windings made before about 1970, all field windings, and
others not described below
IR (Min) = 100 M
For most dc armature and ac windings built after about 1970 (form
wound coils)
IR (Min) = 5 M
For most machines with random -wound stator coils and formwound coils rated below 1kV
Test Voltage
Min IR Value
250V
500V DC
25 M
600V
1000V DC
100M
1000V
1000V DC
100M
2500V
1000V DC
500M
5000V
2500V DC
1000M
8000V
2500V DC
2000M
15000V
2500V DC
5000M
25000V
5000V DC
20000M
34500V
15000V DC
100000M
IR Value
New Motor
20 M
10 M
2 M
0.5 M
For insulation testing, we need to disconnect from panel or equipment and keep them isolated from power supply. The wiring and cables need to test for each other ( phase to
phase ) with a ground ( E ) cable. The Insulated Power Cable Engineers Association (IPCEA) provides the formula to determine minimum insulation resistance values.
R = K x Log 10 (D/d)
Test Voltage
Min IR Value
1KV DC
100 M
10KV DC
1000 M
1KV DC
10 M
5KV DC
1000M
11kV and 33kV Cables between Cores and Earth (As per ETSA Standard)
Application
Test Voltage
Min IR Value
5KV DC
1000 M
5KV DC
100 M
5KV DC
1000 M
5KV DC
15M
The first conductor for which cross insulation is being measured shall be connected to Line terminal of the megger. The remaining conductors looped together (with the help of
crocodile clips) i. e. Conductor 2 and onwards, are connected to Earth terminal of megger. Conductors at the other end are left free.
Now rotate the handle of megger or press push button of megger. The reading of meter will show the cross Insulation between conductor 1 and rest of the conductors. Insulation
reading shall be recorded.
Now connect next conductor to Line terminal of the megger & connect the remaining conductors to earth terminal of the megger and take measurements.
IR Value Measurement (Conductor to Earth Insulation)
Rotate the handle of megger or press push button of megger. The reading of meter will show the insulation resistance of the conductors. Insulation reading shall be recorded after
applying the test voltage for about a minute till a steady reading is obtained.
IR Value Measurements:
If during periodical testing, insulation resistance of cable is found between 5 and 1 M /km at buried temperature, the subject cable should be programmed for replacement.
If insulation resistance of the cable is found between 1000 and 100 K /km, at buried temperature, the subject cable should be replaced urgently within a year.
If the insulation resistance of the cable is found less than 100 kilo ohm/km., the subject cable must be replaced immediately on emergency basis.
Megger Size
Min IR Value
S/S .Equipments
5 KV
5000M
EHVLines.
5 KV
10M
H.T. Lines.
1 KV
5M
LT / Service Lines.
0.5 KV
5M
Megger Size
IR Value(Min)
(Phase-Earth)
5KV,10 KV
1000 M
(Phase-Phase)
5KV,10 KV
1000 M
Control Circuit
0.5KV
50 M
(Pri-Earth)
5KV,10 KV
1000 M
(Sec-Phase)
5KV,10 KV
50 M
Control Circuit
0.5KV
50 M
(Phase-Earth)
5KV,10 KV
1000 M
(Phase-Phase)
5KV,10 KV
1000 M
Control Circuit
0.5KV
50 M
L.A
(Phase-Earth)
5KV,10 KV
1000 M
Electrical Motor
(Phase-Earth)
0.5KV
50 M
LT Switchgear
(Phase-Earth)
0.5KV
100 M
LT Transformer
(Phase-Earth)
0.5KV
100 M
Circuit Breaker
CT/PT
Isolator
IR Value at
Commissioning
Maintenance
Time (M)
Time(M)
HV Bus
200 M
100 M
LV Bus
20 M
10 M
LV wiring
5 M
0.5 M
HV & LV
(10XKV) / KM
(KV) / KM
Phase-Earth
10(KV+1)
2(KV+1)
Transformer Oil
HV & LV
75 M
30 M
HV
100 M
25 M
LV
10 M
2 M
Fixed Equipments/Tools
Phase-Earth
5K / Volt
1K / Volt
Movable Equipments
Phase-Earth
5 M
1M
Equipment
Switchgear
Meggering
immersed
Distribution Equipments
Phase-Earth
5 M
Main Circuit
2 M / KV
Control Circuit
5M
D.C Circuit-Earth
40M
LT Circuit-Earth
50M
LT-D.C Circuit
40M
LT-LT
70M
1M
Circuit Breaker
Relay
involving a waste of energy which would increase the running costs of the installation.
The resistance between Phase-Phase-Neutral-Earth must never be less than 0.5 M Ohms for the usual supply voltages.
In addition to the leakage current due to insulation resistance, there is a further current leakage in the reactance of the insulation, because it acts as the dielectric of a capacitor.
This current dissipates no energy and is not harmful, but we wish to measure the resistance of the insulation, so DC Voltage is used to prevent reactance from being included in the
measurement.
1 Phase Wiring:
The IR test between Phase-Natural to earth must be carried out on the complete installation with the main switch off, with phase and neutral connected together, with lamps and
other equipment disconnected, but with fuses in, circuit breakers closed and all circuit switches closed.
Where two-way switching is wired, only one of the two stripper wires will be tested. To test the other, both two-way switches should be operated and the system retested. If
desired, the installation can be tested as a whole, when a value of at least 0.5 M Ohms should be achieved.
3 Phase Wiring:
In the case of a very large installation where there are many earth paths in parallel, the reading would be expected to be lower. If this happens, the installation should be
subdivided and retested, when each part must meet the minimum requirement.
Test voltage
IR Value(Min)
250V DC
0.25M
500 V DC
0.5M
500 V To 1KV
1000 V DC
1.0M
Required Precautions: