Commissioning Services Departament Sec

COMMISSIONING SERVICES DEPARTAMENT
Electrical System
Commissioning
Manual
Prepared by: CSD Staff.
TRANSMISSION
ENGINEERING & PROJECT
Electrical System
Commissioning
Manual
SECTION - A
TEST AND TEST OBJECTIVES
TRANSMISSION
INDEX
Paragraph
page
SECTION A
TEST AND TEST OBJECTIVE
GENERAL SYSTEM TESTING REQUIREMENTS
01
1 - 116
INTRODUCTION
1-1
1 - 116
General Commissioning Plan
1-2
1 - 116
Types of testing methods
1-3
6 - 116
Insulation testing
1-4
6 - 116
Switch / Circuit Breaker Testing
1-5
11 - 116
Transformer Testing
1-6
12 - 116
Protective Relays
1-7
13 - 116
Ground System Testing
1-8
14 - 116
COMPONENT TESTING
02
Introduction To Component Testing
2-1
15 - 116
Circuit Switchers
2-2
15 - 116
Transformers
2-3
16 - 116
Switchgear – Medium Voltage
2-4
17 - 116
Switchgear – Low Voltage
2-5
17 - 116
Transfer Switch
2-6
18 - 116
AC / DC Drivers
2-7
18 - 116
Batteries
2-8
18 - 116
Battery Chargers
2-9
20 - 116
Cables
2 - 10
20 - 116
UPS Systems
2 - 11
21 - 116
Description of Uninterruptible Power Supply (UPS) System
2 - 12
22 - 116
Operation of Uninterruptible Power Supply System
2 - 13
23 - 116
Commissioning Test Plan For The UPS System
2 - 14
24 - 116
Installation Inspections and Component Testing Of The UPS System
2 - 15
24 - 116
Energizing and Test Of The UPS System
2 - 16
25 - 116
COMMON TESTS
03
Core Insulation Resistance Test
3-1
34 - 116
Winding Insulation Resistance Test
3-2
36 - 116
Polarization Index Test
3-3
37 - 116
Paragraph
page
Winding Resistance Test
3-4
38 - 116
Excitation Current
3-5
41 - 116
Insulation Power Factor
3-6
42 - 116
Vector Relation-ship Test
3-7
44 - 116
Winding Temperature Indicator (WTI) Test Hotspot Temperature Indicator
3-8
45 - 116
Oil Temperature Indicator Test
3-9
45 - 116
Percent Impedance Test
3 - 10
45 - 116
Turn Ration Test
3 - 11
46 - 116
Insulating Oil Test
3 - 12
49 - 116
Dielectric Strength (Electrical Test)
3 - 12A
49 - 116
Neutralization Number (Acidity) {Chemical Test}
3 - 12B
50 - 116
Interfacial Tension (Physical Test)
3 - 12C
51 - 116
Color (Physical Test)
3 - 12D
51 - 116
Moisture (Water) Content (Chemical Test)
3 - 12E
52 - 116
Power Factor Test (Electrical Test)
3 - 12F
52 - 116
Dissolved Gas In Oil Analysis
3 - 12G
53 - 116
Resistivity, Sediment and / or Precipitable Sludge
3 - 12H
54 - 116
CT & PT Insulation Resistance Test
3 - 13
55 - 116
CT & PT Winding Resistance Measurement
3 - 14
56 - 116
CT & PT Polarity Test or Flick Test with Battery and Phase Identification Test
3 - 15
58 - 116
CT & PT Ratio Test by Current Primary Injection
3 - 16
59 - 116
CT Magnetizing (Saturation) Current Test
3 - 17
60 - 116
CT & PT Loop Resistance Test (Burden Test)
3 - 18
61 - 116
CT & PT Insulation Powder Factor Test
3 - 19
61 - 116
CT & PT Intercore Coupling Check
3 - 20
62 - 116
CT & PT Demagnetization of CT
3 - 21
63 - 116
Contact Resistance Test (Resistance Measurement of Main Circuit)
3 - 22
64 - 116
Gas Leakage Test (Gas SF 6 Gas Tightness Test)
3 - 23
64 - 116
Moisture Content Measurement In Sf6 Gas (Dew Point Test)
3 - 24
64 - 116
Gas Density Switch Test
3 - 25
64 - 116
Air Pressure Switch Test (APS Calibration)
3 - 26
65 - 116
Operating Characteristics Test (Timing Test)
3 - 27
66 - 116
MCS Test
3 - 28
66 - 116
Paragraph
page
Auxiliary Relay Test
3 - 29
67 - 116
VT Secondary Injection (Injection Of Voltage And Measurement Of Voltage In LCC)
3 - 30
67 - 116
Function Test
3 - 31
67 - 116
CT Primary Injection (Turn Ratio) Injection Of Current
3 - 32.A
67 - 116
Measurement of Current in LCC only
3 - 32.B
67 - 116
Bus Bar Stability (Injection Of Current And Measurement Of Current In LCC Only)
3 - 33
68 - 116
Inter Lock Test
3 - 34
68 - 116
10kv Insulation Test On External Earthing Switch’s Pole (10kv Es Insulation)
3 - 35
68 - 116
Power Frequency Withstand Voltage Test (Hi Voltage Test)
3 - 36
68 - 116
GIS High Voltage Test
3 - 36.1
69 - 116
VT High Voltage Test
3 - 36.2
69 - 116
Partial Discharge Measurement
3 - 37
70 - 116
Phase Identification
3 - 38
70 - 116
DC Sheath Test
3 - 39
71 - 116
DC Conductor Resistance Test
3 - 40
71 - 116
Measurement of Capacitance
3 - 41
72 - 116
Earth Resistance Measurement
3 - 42
72 - 116
Verification of Cross Bonding Test
3 - 43
73 - 116
Zero Sequence Impedance
3 - 44
73 - 116
Positive Sequence Impedance
3 - 45
74 - 116
Oil Flow Test
3 - 46
74 - 116
Oil Impregnation Test
3 - 47
75 - 116
High Voltage Test
3 - 48
75 - 116
LIST OF TABELS
Table
Title
Page
1-1
Recommended minimum insulation resistance values at 40°C (all values in MP)
8 - 116
2-1
Medium-voltage cables maximum field acceptance test voltages (kV, dc)
21 - 116
2-16
Possible failures and corrective actions of the UPS system
28/30 - 116
3.2.1
Megohmmeter Connections for Testing Two Winding and Three Winding Transformers
75 - 116
3.2.2
Temperature Correction Factors for Winding Insulation Resistance
77 - 116
3.2.3
Rule of Thumb Test Values
77 - 116
3.2.4
Insulation Condition according to the value of the index
79 - 116
3.4.1
Formulas to Convert Winding Resistance to Reference Temperature
80 - 116
3.5.2
Measurement of Ie in a Delta-Connected Transformer Winding (Routine Method)
85 - 116
3.6.1
Standard series of power factor tests applied to windings in-service.
87 - 116
3.6.2
Measurements for Insulation Power-Factor Tests
89 - 116
3.6.3
Temperature Correction Factors for Insulation Power Factor
91 - 116
3.6.4
Acceptable Power Factor Values
92 - 116
3.10.1
Three-Phase Power Transformer Percent Impedance (Typical Values)
93 - 116
3.12.e.1
Recommended maximum limit of water content in mineral insulating oil of operating gas
blanketed, sealed, or diaphragm conservator transformers
96 - 116
3.12.g.1
Evaluation of the total combustible gas
96 - 116
3.12.g .2
A list of the types and amounts of gases in oil at normal temperature
97 - 116
3.12.g.3
Solubility of Gases in Transformer Oil
97 - 116
3.12.1
Acceptance Values of Insulating oil Tests
98 - 116
3.19.1
Measurements to be made in insulation power-factor tests
103 - 116
3.19.2
Temperature correction factors for insulation power factors
104 - 116
LIST OF FIGURES
Figure
Title
page
1-2
Step-voltage versus time
10 - 116
1-3
Step-voltage high-potential test current
10 - 116
2-1
Static UPS system 150 to 750 WA (courtesy of Liebert).
22 - 116
2-2
Uninterruptible power supply system single line diagram
30 - 116
2-3
Uninterruptible power supply system block diagram
31 - 116
2-4
Uninterruptible power supply system wiring diagram
32 - 116
3.2.1
Schematic Diagram for Measuring the Insulation-Resistance of a Typical Single-Phase (Two-
Winding) Transformer
78 - 116
3.2.2
Schematic Diagram for Measuring the Insulation-Resistance of a Typical Three-Phase Delta-
Wye Transformer
79 - 116
3.4.1
Wheatstone Bridge
80 - 116
3.4.2
Kelvin Bridge
81 - 116
3.4.4
Bridge Network Connections
82 - 116
3.4.5
Front Face of a Kelvin Bridge
83 - 116
3.4.6
Top View of a Digital Low-Resistance Ohmmeter
84 - 116
3.4.7
Top View of a Ducter
84 - 116
3.5.1
Measurement of Ie in a Wye-Connected Transformer Winding
(Routine Method)
85 - 116
3.5.2
Measurement of Ie in a Delta-Connected Transformer Winding
(Routine Method)
85 - 116
3.6.1
Typical Two-Winding Transformer Simplified Diagram
86 - 116
3.6.2
Dielectric Loss of Each Capacitor Divided by Capacitive Volt-Amperes is Equal to Power Factor
86 - 116
3.6.3
Schematic Diagram for Measuring the Capacitance and Insulation Power factor from the High-
Voltage Winding to the Low-Voltage Winding and Ground for a Two-Winding, Single-Phase
Transformer (Method 1, Table 6.1)
87 - 116
3.6.4
Schematic Diagram for Measuring the Capacitance and Insulation Power factor from the High-
Voltage Winding to the Low-Voltage Winding and Ground for a Three-Phase Delta-Wye
Transformer (Method 1, Table 6.1)
88 - 116
3.6.5
Ungrounded Specimen Test on Transformer Bushings
90 - 116
Figure
Title
page
3.6.6
Hot-Collar Test Method for Testing of Bushing Insulators
91 - 116
3.8.1
Hot-Spot” Indicating Circuit
92 - 116
3.10.1
Impedance Measurement for Transformer
93 - 116
3.11.1
Front Panel and Leads of a TTR Test Set
94 - 116
3.11.2
Schematic Diagram for Transformer Turns-Ratio (TTR) Test Set
94 - 116
3.11.3
Transformers turns ratio test connection chart
95 - 116
3.12.f.1
Liquid Insulation Cell Connected for Ungrounded Specimen Testing
96 - 116
3.14.1
Connections for voltmeter-ammeter method of resistance measurement
99 - 116
3.15.1
Windings: subtractive polarity
99 - 116
3.15.2
Windings: additive polarity
99 - 116
3.15.3
Polarity Test with Dc Voltage
99 - 116
3.15.4
Polarity by Inductive Kick
100 – 116
3.16.1
Ratio Test by Current Method
100 - 116
3.16.2
Voltage Readings inside the Transformer Delta Windings
100 - 116
3.17.1
Excitation Test
101 - 116
3.17.2
Excitation Curve for Current Transformer
101 - 116
3.18.1
CT Burden Test
102 - 116
3.21.1
Circuit for demagnetizing current transformers
104 - 116
3.21.2
Method 2: Circuit for demagnetizing current transformers
105 - 116
3.21.3
Method 3: Circuit for demagnetizing current transformers
105 - 116
3.38.1
Phasing check
106 - 116
3.39.1
10KV D.C. Sheath Test
107 - 116
3.40.1
Measurement of Dc Resistance Of Conductor
108 - 116
3.41.1
Capacitance Measurement
109 - 116
3.42.1
Earth Resistance Measurement
110 - 116
3.43.1
Verification of cross bonding test at link boxes
111 - 116
Figure
Title
page
3.44.1
Zero Sequence Impedance Measurement
112 - 116
3.45.1
Positive Sequence Impedance Measurement
113 - 116
3.48.1
Schematic Diagram of a resonant circuit with variable frequency
113 - 116
3.48.2
Circuit diagram of AC H.V.T
114 - 116
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COMMISSIONING SERVICES DEPARTMENT

COMMISSIONING MANUAL
Section A - Page 1 of 116
1 GENERAL SYSTEM TESTING REQUIREMENTS
1-1 Introduction
The purpose of electrical testing on systems and their components is two-fold. The
first is to check the installation of the equipment and perform component and
systems tests to ensure that, when energized, the system will function properly. The
second is to develop a set of baseline test results for comparison in future testing to
identify equipment deterioration. The system should be initially checked for
damage, deterioration, and component failures using specific component checks,
inspections, and tests defined by the equipment manufacturer. Then the
interconnection of the system components should be checked, using de-energized
and energized methods, to verify the proper interconnection and operation of the
components, including on/off control, system process interlocks, and protective
relaying functions. Once the above tests are complete, the system can be energized
and operational tests and measurements should be performed. All steps and results
of the testing should be carefully documented for review and for use in the future
for comparison with the results of future tests. Many of the same component tests
initially run will be performed at regular intervals as part of a maintenance program.
The new results will be compared to the initial results, where variations may be
indicative of problems like deterioration of insulation or dirty equipment. The steps
involved are to review the system and equipment, develop a general system and
specific equipment test plan, provide inspection and checks, perform component
testing, verify and check the continuity of wiring, check control functions, calibrate
instruments and relays, energize portions of the circuits and check for proper
operation in a specific order, and, once complete, perform specific checks and
control tests on the complete system during initial period of operation.
1-2 General Commissioning Plan
There are management, economic, and technical requirements associated with
every Commissioning plan. The development and use of a comprehensive
Commissioning plan is like an insurance policy. While it has specific costs, it does
not usually show any direct paybacks as the systems will usually startup without
significant problems such as equipment failure or lost time. The cost of the tests will
rise with the complexity of the test program. Many inspections and tests are
redundant, but are used as checks and balances before system energization to
ensure successful startup and operation. Many times, if the equipment is in the
same operating condition as when it left the factory and the system design and
installation are adequate.
Once the equipment is identified, the manufacturer's manuals should be used to
identify the required receipt inspections, handling and installation procedures,
energized and de-energized component tests, drawing and wiring verification,
minimum report requirements for on-going maintenance and testing baseline, and
requirements for repair and retesting if certain checks and tests produce
unsatisfactory results. The technical requirements for a commissioning plan can be
stated as follows.
A. Survey of system equipment.
An accurate and complete description of a power system and its equipment is
required for sufficient commissioning plan. This will include written system
description, one-line diagrams, short circuit and coordination studies, three line
diagrams, control logic diagrams, schematic logic diagrams, cable block and
interconnecting diagrams, equipment physical and wiring drawings, equipment
manuals, and auxiliary system manuals and drawings for support systems. These
documents serve to depict the design and operation of the system for use during
installation, testing, startup, operation, and maintenance. Various standards groups
such as the Institute of Electrical and Electronics Engineers
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(IEEE) and National Electrical Manufacturers Association (NEMA) have developed
standards for these materials. Typical drawings and their definitions are as follows:
(1) One-line (single-line) diagram shows, single line and graphic symbols, flow of
electrical power or the course of electrical circuit symbols, and their connection. In
this diagram, physical relationship usually disregarded.
(2) Block diagram. Shows a group of interconnected blocks, each of which
represents a device or subsystem.
(3) Schematic (elementary) diagram. Shows all circuits and device elements of the
equipment. This diagram emphasizes the device elements and their functions and it
is always drawn with all devices shown in deenergized mode.
(4) Control sequence (truth table) diagram shows a description of the contact
positions, connections, made for each position of control action or device.
(5) Interconnection diagram shows only the external connection between controllers
and associated equipment or between various housing units of an assembly of
switchgear apparatus.
(6) Wiring diagram (connection diagram) locates and identifies electrical devices,
terminals, and interconnecting wires in an assembly. This diagram may show
interconnecting wiring by lines or terminal designations.
(7) Circuit layout and routing diagram shows the physical layout of the facility and
equipment and how the circuit to the various equipment runs.
(8) Short-circuit coordination study. Electrical power system data, diagrams, and
drawings are needed during maintenance and testing of electrical equipment. This
may involve information and data relating to protective devices and relays. Such
data are usually found in a short-circuit coordination study and usually encompass
all the short-circuit values available in the power system, relays, and trip device
settings. Normally, this study performs during the construction phase of the facility.
It would be much more desirable to perform this engineering study as part of the
initial facility design, and then validate it during the construction phase to assure
that equipment and values specified have met. When accepting the facility, the
study data should use as a benchmark, and any changes that might had made
during construction in the system should incorporate to update the study for future
references.
B. Listing of critical system equipment.
The major equipment of a system is vital to its operation and failure of this
equipment could be a threat to personnel and system operation, i.e., potential
single point failures. From a review of the system documentation, especially the
single line diagram, a list of critical equipment and the order in which the items
should be inspected, tested, and energized should be developed. From this list, the
plan and schedule for the test program can be developed. Normally the listing in
order of criticality of the equipment is from the normal power source into the
system with onsite sources failing after the main power source and distribution
equipment. The listing maybe difficult to prepare as it will vary for each system, and
therefore a team from system engineering, operations, and maintenance may be
required.
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This will also serve to provide the operations and maintenance personnel an
opportunity to review the system during the early stages of a project, which helps
them in the performance of their work.
C. Steps for the test program.
A test program will commence after completion of installation and will usually
include field inspection and installation checks, de-energized component testing,
verify instrument and relay operation and calibration, visual check of all wiring,
continuity checking of control circuits, energized functional testing of control
circuits, megger testing of power circuits, test of power circuits phasing, energizing
of equipment, and service testing. If problems are found during the testing; an
analysis should be performed, and a repair and retest should be performed that is
approved by the commissioning authority, manufacturer, engineer, and system
operator. Many of these initial tests will be repeated periodically as part of the
system maintenance program depending on the load conditions, duty cycle,
environmental conditions, and the critical nature of the equipment. Because of this,
the completeness and clarity of the test reports is important as they supply baseline
data for comparison with the results of the maintenance tests.
D. General definition of test steps.
Prior to testing, overall completion of installation should be verified including
setting, wiring, grounding of the equipment, and conditioning of the overall area, i.e
., clean complete site to work in. This is considered a pretest. Note: all of the items
below should be performed in strict accordance with the drawings, systems
operations documents, systems operation and maintenance manuals (provided by
contractor), and the engineer's and manufacturer's instructions for each piece of
equipment. The manufacturer typically provides the instructions in the form of
diagrams indicating how to connect the test instruments as well as charts indicating
acceptable and unacceptable values. The engineer's instructions will be found in the
system specifications and drawings, and the manufacturer's instructions are found
in the equipment manuals and drawings. IEEE, NEMA, National Fire Protection
Association (NFPA), and other standards also include acceptable procedures for the
performance of the tests. As the acceptance tests and energization is performed;
failures and repairs, availability of equipment and personnel, schedules, weather,
and other items may cause the delay or nonperformance of a test. In any of these
cases, the missing, failed, newly required, or postponed test should be noted in the
test documentation along with the reason for missing the test and the technical
consequences. An evaluation should be made as to whether the system can be
energized without this test noting the possible effect on safety, personnel, and
equipment operation; and noting when or even if the test should be performed in
the future. If the test yet to be performed or needs to be performed to prove the
adequacy of a repair, the test should be scheduled with the system operations
personnel as part of an ongoing maintenance program.
(1) Field inspection and installation checks include inspection of impact recorders,
verification of removal of shipping braces. Inspection of installation against
drawings and nameplates, inspecting of components for damage and cleanliness,
inspection of insulators for cracking, inspection of anchorage and grounding, sizing
check of fuses and breakers, alignment and adjustment checks, mechanical
operation and interlock checks, lubrication application, verification of insulating
liquid or gas level or pressure, and verification that local safety equipment is in
place.
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(2) De-energized component testing includes pressure and level checks, megger
and insulation resistance testing of equipment and connections including grounds,
turns ratio measurements, polarity tests, insulating liquid dielectric and moisture
testing, power factor or dissipation factor tests, over potential tests, contact
resistance measurements, operation time travel analysis, battery and cell voltage
measurements, charger/UPS (uninterruptible power supply)/generator current and
voltage measurements, and equipment / systems impedance or resistance tests.
(3) Verification of instrument and relay operation and calibration. Include
verification of auxiliary device operation, calibration of instruments and relays,
functional testing of individual instruments/gauges/alarms/relays/limit switches etc.
(4) Visual check of all wiring. Include visual inspection of all wiring against the
schematic and wiring, both internal and external, diagrams.
(5) Continuity checking of control circuits. Include continuity and voltage testing of
all control circuits against schematic diagrams.
(6) Energized functional testing of control circuits. Include energizing of control
circuits and checking all remote and local close/trip operations, protective relay
operations, safety and interlock operations, and all process and communication
operations.
(7) Megger testing of power circuits. Include megger testing of power, current
transformer, and potential transformer buses and cables after connection.
(8) Phase out testing of power circuits. Include primary and/or secondary injection
testing for circuit impedance and polarity checks.
(9) Energizing of equipment. Include energizing of equipment in specific order after
all above testing is complete and evaluated.
(10) Service testing. Include measurement of value and relationship of power,
potential, and current on sources, buses, feeders, and neutrals in the power system.
(11) Post acceptance tests. Include on-going maintenance and operation tests,
corrective action tests, and deferred testing.
E. Reports, form, and records.
Accurate and complete reports, forms, and records should be developed and kept
updated after the testing for the equipment and the system for initial evaluation of
the results before energization and on-going evaluation by operations and
maintenance. Analysis of the data and results should provide a decision to startup
and a guide for future maintenance requirements and its cost. Figures should be
kept for the time, cost, and equipment used for each test for input to the
development of the maintenance program. Care should be taken to ensure that
extraneous information does not become part of the record, because record
keeping might hamper future use. Test reports giving test description and basic
procedure, components, drawing and other document references, test circuit
diagrams, test equipment model and age and calibration date, special tools
required, test forms with results filled in, time to run the test, acceptance criteria,
failure or unusual event information, recommended repair, and when the test
should be performed again for equipment maintenance should be developed for the
tests. Summary logs developed from the information can be used for developing
and scheduling an on-going maintenance program. Forms should be used to
document the results of testing procedures. They should be detailed
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and direct, but simple and durable enough to be used in the field. The forms should
be used as input to the development of the test reports. A well designed form will
contain checklist information for inspections, test procedures, safety and special
precautions, required equipment and tools, reference drawings and manuals,
acceptance criteria, estimated time to perform the test, and remarks/event
recording area. Sample forms for basic equipment and tests are attached.
F. Special precautions and safety.
Many tests on electrical equipment involve the use of high voltages and currents
that are dangerous, both from the standpoint of being life hazards to personnel and
because they are capable of damaging or destroying the equipment under test.
Adequate safety rules should be instituted and practiced to prevent injury to
personnel, both personnel who are performing the tests and others who might be
exposed to the hazard. Also, the test procedures used should be designed to ensure
that no intentional damage to equipment will result from the testing process. It
should be recognized, as the name implies, that over-potential or high-potential
testing is intended to stress the insulation structure above that of normal system
voltage. The purpose of the test is to establish the integrity of the insulation to
withstand voltage transients associated with switching and lightning surges and
hence reduce the probability of in-service equipment failures. Direct voltage over-
potential testing is generally considered a controlled, nondestructive test in that an
experienced operator, utilizing a suitable test set, can often detect marginal
insulation from the behavior of measured current. It is therefore possible; in many
cases to detect questionable insulation and plan for replacement without actually
breaking it down under test. Unfortunately, some insulation might break down with
no warning. Plans for coping with this possibility should be included in the test
schedule. Low-voltage insulation testing can generally be done at the beginning of
the planned maintenance shutdown. In the event of an insulation failure under test,
maximum time would be available for repair prior to the scheduled system startup.
Equipment found in wet or dirty condition should be cleaned and dried before high-
potential testing is done or a breakdown can damage the equipment. Low-voltage
circuit breakers, which require very high interrupting ratings, are available with
integral current-limiting fuses. Although the fuse size is selected to override without
damage to the time-current operating characteristics of the series trip device, it is
desirable to bypass or remove the fuse prior to applying simulated overload and
fault current. If a testing program is to provide meaningful information relative to
the condition of the equipment under test, then the person evaluating the test data
must be ensured that the test was conducted in a proper manner and that all of the
conditions that could affect the evaluation of the tests were considered and any
pertinent factors reported. The test operator, therefore, must be thoroughly familiar
with the test equipment used in the type of test to be performed and also
sufficiently experienced to be able to detect any equipment abnormalities or
questionable data during the performance of the tests.
G. Test equipment.
It is important that in any test program the proper equipment is used. The
Equipment should be calibrated, in good condition, and used by qualified operators.
Any test equipment used for calibration shall have twice the accuracy of the
equipment to be tested. Care should be taken to use a quality or regulated power
source for the equipment as voltage, frequency, and waveform variation can
produce invalid results. All equipment should be operated in accordance with its
instruction manual.
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1-3 Types of testing methods
Types of testing methods include the four categories of tests as well as the tests
themselves.
A. Categories of tests.
There are four categories of tests for electrical equipment; factory, acceptance,
routine maintenance, and special maintenance. Factory tests are performed at the
factory to prove the equipment was manufactured properly and meets specific
design parameters. Commissioning tests, the main subject of this document, are
also proof tests performed on new equipment and systems usually after installation
and before energization. They are run to determine whether the equipment is in
compliance with specifications, to establish benchmarks for future tests, to
determine the equipment was installed correctly and without damage, and to verify
whether the equipment meets its intended design operation and limits . Routine and
special maintenance tests are run after the equipment has been in service for a
certain amount of time to determine the degree of deterioration of certain
equipment physical parameters as operating time increases. Routine tests are
performed on a periodic basis and special tests are performed on defective
equipment to help determine the cause of a failure and/or the extent of the
damage. The same type of tests and measurements are performed for all of the
categories using different voltage values. The acceptance tests are usually run at
80% and the maintenance tests are usually run at 60% of the factory test voltage
values to help indicate deterioration without being destructive.
B. Types of testing methods.
The testing of electrical power system equipment involves checking the insulation
adequacy, electrical properties, protection and control, operation, and other items
as they relate to the overall system. Some of these checks are accomplished using
de-energized component tests, instrumentation and relay operation and calibration
tests, energized functional testing of control circuits, megger testing of power
circuits, phase out testing of power circuits, and service testing.
1-4 Insulation testing
Insulation can either be solid, liquid, or gaseous dielectric materials that prevent the
flow of electricity between points of different potential. Insulation testing is
performed to determine the integrity of the insulation. This usually consists of
applying a high potential voltage to the item and measuring the leakage current
that may flow to ground. Excessive leakage current is an indication of dielectric
breakdown and/or impending failure. Insulation may weaken over time at a rate
tightly related to the operating time and temperature of operation. Therefore, these
tests are run periodically to track the insulation deterioration. Insulation testing, the
most common electrical testing performed, can be reformed by applying a direct
current (dc) or alternating current (ac) voltage. The type and value of the voltage
determines whether the test is considered non-destructive or destructive. The
higher the voltage the more destructive the test. Usually destructive tests are only
run one time in the factory to verify the initial strength of the insulation, and non-
destructive tests are run as acceptance and maintenance tests to erasure
deterioration from the original value. Both the do and ac tests are "go no-go" tests.
In addition, he do test can indicate the amount of deterioration and forecast the
remaining time for safe operation by comparing the leakage current and test
voltage to values from previous tests.
A. Advantage of direct-current testing.
Direct-current test is preferred on equipment whose charging capacitance is very
high, such as cables. Direct-current voltage stress is considered much less
damaging o insulation than ac voltages. The time of voltage application is not as
critical with do voltage as with ac voltage. The test can be stopped before
equipment failure. Measurements can be taken concurrently.
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B. Disadvantage of direct - current testing.
The stress distribution for transformers, motors, and Generator winding is different
for dc voltage than for ac voltage. The residual charge after a dc voltage must be
carefully discharged. The time required to conduct a do high-potential test is longer
than for an ac high-potential test.
C. Direct-current (dc) testing.
When a dc potential is applied across an insulation, the resultant current flow is
composed of several components as follows:
(1) Capacitance-charging current. Capacitance-charging current is the current
resulting from charge absorbed by the capacitor formed by the capacitance of the
bushing. This current is a function of time which also depends on applied do
voltage, insulation resistance and the time constant of the circuit.
(2) Dielectric-absorption current. Dielectric-absorption current is the current that is
absorbed and trapped in the dielectric during the charging of the piece of
equipment and released after the equipment is discharged. This current can be
calculated from test voltage, capacitance, and time. In air-cooled and hydrogen-
cooled ac rotating machines, dielectric absorption varies with temperature.
(3) Surface leakage current. The passage of current over the surface of insulation
rather than through its volume is surface leakage current. In measuring insulation
resistance of armature and field windings in rotating machines (rated 1 hp, 750 W
or greater), a high surface leakage current is usually caused by moisture or another
type of partly conductive contamination present in the rotating machine.
(4) Partial discharge (corona current). This is a type of localized discharge resulting
from transient gaseous ionization in an insulation system when the voltage stress
exceeds a critical value. Partial discharge is not desirable and should be eliminated.
It is caused by overstressing of air at sharp corners of the conductor due to high
test voltage. In shielded power cable systems (rated > 5 kV), humidity or wind can
increase the corona current.
(5) Volumetric leakage current. The current that flows through the volume
insulation itself is volumetric leakage current. It is the current that is of primary
interest in the evaluation of the condition of the insulation. In shielded power cable
systems (rated > 5 kV), humidity, condensation, and precipitation on the surface of
a termination can increase surface leakage current and volumetric leakage current.
Surface leakage current and volumetric current added together is the quotient of
the applied do voltage and insulation resistance. In large ac rotating machines rated
10,000 kVA or greater and rated 6000Vor higher, moisture, on the end windings,
increases surface leakage current and volumetric leakage current especially when
dirt is also on the winding. Since the insulation may weaken over time, age may
cause an increase in the various currents during testing.
D. Insulation-resistance (megger) testing.
For equipment containing electronic components, megger testing must not be
performed. However, this equipment should be tested according to manufacturer
specifications. In an insulation-resistance test, an applied voltage, from 600 to 5000
volts, supplied from a source of constant potential, is applied across the insulation.
The usual potential source is a megohmeter, also known as a megger, either hand
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or power operated that indicates the insulation resistance directly on a scale
calibrated in megohms. A megohmeter that is a hand cranked, a rectifier type, or
battery-operated instrument is suitable for testing equipment rated up to 600 volts.
For equipment rated over 600 volts, use of a 1000-volt or 2500-volt motor-driven or
rectifier-type megohmeter is recommended for optimum test results. The quality of
the insulation is evaluated based on the level of the insulation resistance. The
insulation resistance of many types of insulation is variable with temperature, so
the data obtained should be corrected to the standard temperature for the class of
equipment under test. Published charts similar to table 1-1 are available for this
purpose. The megohm value of insulation resistance obtained will be inversely
proportional to the volume of insulation being tested. For example, a cable 1000-ft
(304.8 m) long would be expected to have one-tenth the insulation resistance of a
cable 100-ft (30.48 m) long if all other conditions were identical. The insulation-
resistance test is relatively easy to perform and is a useful test used on all types
and classes of electrical equipment. Its main value lies in the charting of data from
periodic tests, corrected for temperature, over the life of the equipment so that
deteriorative trends might be detected
Table 1-1 Recommended minimum insulation resistance values at 40°C (all values
in Ma.)
Minimum Insulation Resistance after 1 minute
(MCI)
Test specimen
kV + 1
(Example: 15 kV machine is 1S + 1= 16 MS2)
For most windings made before about 1970, all field windings, and others not
described below
100
For most do armature and ac about 1970 (form-wound coil windings built after
5
For most machines with random-wound stator coils and form-wound coils rated
below 1 kV
Notes: kV is the rated machine terminal to terminal voltage, in rms (root mean
square) kV.
Recommended minimum insulation resistance values above, in megohms, at 40°C
of the entire machine winding for over voltage testing or operation of ac and do
machine stator windings and rotor windings .
E. Dielectric absorption testing.
In a dielectric-absorption test, a voltage supplied from a source of constant
potential is applied across the insulation. The test voltage used may have to be sign
if significantly higher than the insulation-resistance test in order to obtain
measurable current readings. The potential source can be either a meg-ohmmeter,
as described above or a high-voltage power supply with an ammeter indicating the
current being drawn by the specimen under test. The voltage is applied for an
extended period of time, from 5 to 15 minutes, and periodic readings are taken of
the insulation resistance or leakage current. The test data is evaluated on the basis
that if insulation is in good condition, its apparent insulation resistance will increase
as the test progresses. Unlike the insulation-resistance test, the dielectric-
absorption test results are independent of the volume and the temperature of the
insulation under test. For the dielectric absorption test, the values recorded at each
one minute interval are plotted on log-log paper with coordinates for resistance
versus time. The slope of the resulting curve gives a good indication of the
insulation condition. A good insulation system will have a slope that is a straight line
increasing in respect to time. The characteristic slope of a poor insulation system
will be a curve that flattens out with respect to time.
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F. Polarization index testing.
The polarization index is a specialized application of the dielectric absorption test.
The index is the ratio of insulation resistance at two different times after voltage
application, usually the insulation resistance at 10 minutes to the insulation
resistance at 1 minute. The use of polarization-index testing is usually confined to
rotating machines, cables, and transformers. A polarization index less than 1 .0
indicates that the equipment needs maintenance before being placed in service.
References are available for polarization indexes for various types of equipment as
well as in table 1-2. Acceptance testing specifications for Electrical Power and
Distribution Equipment and Systems NETA 1999 and Recommended Practice for
Testing Insulation Resistance of Rotating Machinery (IEEE Std. 43-2000) are
references available for polarization indexes for various types of equipment. The
polarization index test lasts for 10 minutes. The insulation resistance is recorded
after 1 minute, then again after 10 minutes. The polarization index is the quotient of
the 10-minute and 1 minute readings as shown in the following equation:
PI = RIO/R, (dimensionless)
Where:
PI = polarization index
R = resistance.
For polarization indexes in transformers an acceptable value would be 2 or higher,
values between 2 and 1 indicate marginal condition, and values below 1 indicate
poor condition. After insulation resistance readings have been made, the test
voltage is returned to zero and the insulation is discharged.
G. High potential testing.
A high-potential test (hi-pot) consists of applying voltage across insulation at or
above the do equivalent of the 60-Hz operating crest voltage. The do equivalent of
the 60- Hz operating crest voltage is calculated using the following equation:
Vac= Vdc/42-
Where:
Vdc is the equivalent do voltage
Vac is the operating crest ac voltage
The hi-pot test can be applied either as a dielectric-absorption test or a step-voltage
test. DC high potential tests are "go no-go" tests. The cable is required to withstand
the specified voltage for the specified time duration .These tests will normally
reveal major problems due to improper field handling, improperly installed
accessories or mechanical damage. Recommended test voltages are given in
standard tables for do and ac. To perform the do Hi-pot test the input voltage to the
test set should be regulated. The current sensing circuits in test equipment shall
measure only the leakage current associated with the cable under test and shall not
include internal leakage of the test equipment. Record wet bulb and dry-bulb
temperatures or relative humidity and temperature. The wet bulb temperature is
defined as the temperature given by a thermometer bulb which is covered with an
absorbent material (linen wet with distilled water) and exposed to the atmosphere
so that evaporation will cool the water and the thermometer bulb. The dry-bulb
temperature is defined as the temperature of the atmosphere given by an ordinary
thermometer. Test each section of cable individually with all other conductors
grounded. All shields must also be grounded. Terminations shall be adequately
corona suppressed by guard ring, field reduction sphere, or other suitable methods
as necessary. Precaution should betaken to insure that the maximum test voltage
does not exceed the limits for terminations specified in IEEE Standard 48 or
manufacturers specifications. When applied as a dielectric-absorption test, the
maximum voltage is applied gradually over a period of from 60 to 90 seconds. The
maximum voltage is then held for 5 minutes with leakage-current readings being
taken each minute. In cables, high ambient temperature or
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humidity at the ends of improperly prepared cables can rais the do leakage current
to many times its normal value. When applied as a step-voltage test, the maximum
voltage is applied in a number of equal increments, usually not less than eight, with
each voltage step being held for an equal interval of time. Atypical voltage versus
time graph as shown in figure 1-2. The time interval between steps should be long
enough to allow the leakage current to reach stability, approximately 1 or 2
minutes. A leakage-current reading is taken at the end of each interval before the
voltage is raised to the next level.
Figure 1-2. Step-voltage versus time
A plot of test voltage versus leakage current or insulation resistance is drawn as the
test progresses. A nonlinear increase in leakage current can indicate imminent
failure, and the test should be discontinued. See figure 1-3.
Figure 1-3. Step-voltage high potential test current
After the maximum test voltage is reached, a dielectric absorption test can be
performed at that voltage, usually for a 5-minute period.
H. AC high potential testing.
Alternating-current high-potential tests are made at voltages above the normal
system voltage for a short time, such a 1 minute. The test voltages to be used vary
depending on whether the device or circuit is low or high voltage, a primary or
control circuit, and whether it was tested at the factory or in the field.
Manufacturers' instructions and the applicable standards should be consulted for
the proper values.
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I. Insulation power factor testing.
The power factor of insulation is a measure of the energy component of the
charging current. Power-factor testing is used to determine the power factor of an
insulation system. Power-factor testing is a useful tool in evaluating the quality of
insulation in power, distribution, and instrument transformers; circuit breakers;
rotating machines, cables, regulators and insulating liquids. The equipment to be
tested should be isolated from the rest of the system, if practical, and all bushings
or terminations should be cleaned and dried. The test should be conducted when
the relative humidity is below 70 percent and when the insulation system is at a
temperature above 32°F (0°C). The test equipment used should be such that the
power factor or dissipation factor can be read directly or such that the charging
volt-amperes and the dielectric losses can be read separately so that a ratio might
be computed. The test equipment should also have sufficient electromagnetic
interference cancellation devices or shielding to give meaningful test results even
when used in an area of strong interference, such as an energized substation.
Electromagnetic interference distorts the readings, yielding incorrect values. The
desired measurements should be performed following the operating instructions
supplied with the test equipment. The lead connections may have to be changed
several times, depending on the complexity of the apparatus and test equipment. A
meaningful evaluation will include comparison to manufacturer's results taken at
the factory and/or nameplate data. On transformer tests, obtain the power factor of
each winding with respect to ground and each winding with respect to each other
winding. In addition, tests should be made of each bushing with a rated voltage
above 600 volts, either using the power factor or capacitance tap if the bushing is
so equipped or by use of a "hot-collar" test using a test electrode around the
outside shell of the bushing. On higher voltage circuit breakers, the power factor of
each line-side and load-side bushing assembly complete with stationary contact and
interrupters, with the circuit breaker open, and each pole of the circuit breaker with
the breaker closed should be obtained. On ac rotating machines, the neutral
connection on the stator should be removed and a test of each winding with respect
to the other two windings and ground should be obtained. For cables, the power
factor of each conductor with respect to ground should be obtained and a hot collar
test should be made of each pothead or termination. Power-factor testing of
insulating oil should be performed in accordance with American Society for Testing
and Materials (ASTM)D924, Standard Test Method for Dissipation Factor (or Power
Factor) and Relative Permittivity (Dielectric Constant) of Electrical Insulating Liquids.
1-5 Switch/Circuit Breaker Testing
In addition to the insulation testing mentioned above, for large switches and circuit
breakers the following tests can be applied.
A. Circuit breaker time-travel analysis.
This test, used on medium and high-voltage circuit breakers provides information as
to whether the operating mechanism of the circuit breaker is operating properly.
This test can be used to determine the opening and closing speeds of the breaker,
the interval time for closing and tripping, and the contact bounce. The test provides
information that can be used to detect problems such as weak accelerating springs,
defective shock absorbers, dashpots, buffers, and closing mechanisms. The test is
performed by a mechanical device that is attached to the breaker. One device, a
rotating drum with a chart attached, is temporarily connected to the chassis or tank
of the breaker. A movable rod with a marking device attached is installed on the lift
rod portion of the breaker. As the breaker is opened or closed, the marking device
indicates the amount of contact travel on the chart as the drum rotates at a known
speed. With another available device, a transducer is attached to the movable rod,
and the breaker operation is recorded on an oscillograph.
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B. Contact-resistance testing.
This test is used to test the quality of the contacts on switches and circuit breakers.
A test set designed for this purpose is available with direct-scale calibration in
microhms, capable of reading contact resistances of 10 microhms or less. An
alternate method is to pass a known level of direct current through the contact
structures and to measure the do millivolt drop across the contacts. The data
obtained can then be converted to resistance by applying Ohm's Law. The alternate
method requires a source of at least 100 amperes with a mill volt meter of
approximately 0-20 mV range.
1-6 Transformer Testing
Transformers are subject to the following tests in addition to the insulation testing
mentioned above in paragraph 1-4. However, dry-type transformers would not be
subject to fault-gas analysis and insulating liquid analysis due to the fact that these
types of transformers usually feature a gaseous or dry compound insulating
medium. Cast coil transformers, which are defined as a transformer with high-
voltage coils cast in an epoxy resin, would also not be subject to fault-gas analysis
and insulating liquid analysis due to the fact that the core and coils of these types of
transformers are not immersed in an insulating liquid. Cast coil transformers are
considered to be dry-type transformers.
A. Transformer turns-ratio and polarity tests.
The turns-ratio test is used to determine the number of turns in one winding of a
transformer in relation to the number of turns in the other windings of the same
phase of the transformer. The polarity test determines the vectorail relationship of
the various transformer windings. The tests are applicable to all power and
distribution transformers. See figure 2-4 for a diagram of a typical fluid filled power
transformers. Cast coil transformers are also subject to these tests. The turns-ratio
test and the polarity test can be done on transformers of all sizes. The turns-ratio
test is also commonly performed on instrument transformers. The test equipment
used will ordinarily be a turns-ratio test set designed for the purpose, although, If
not available, two voltmeters or two ammeters (for current transformers only) can
be used. When two ac voltmeters are used, one is connected to the high-voltage
winding and the other is connected to the low voltage winding. The high voltage
winding is excited to a voltage not exceeding the rating of the voltmeter. Both
voltmeters are read simultaneously. A second set of readings should be taken with
the metering instruments interchanged. The values indicated should be averaged to
calculate the ratio. A meaningful ratio measurement maybe made using only a few
volts of excitation. The transformer should be excited from the highest voltage
winding in order to avoid possibly unsafe high voltages. Care should be taken during
the application of voltage and during the measurement. It is important that
simultaneous readings for both voltmeters be made. The voltmeters used should
have accuracy's matching with the requirements of a 0.5 %ratio calculation. When a
turns-ratio test is performed, the ratio should be determined for all no – load taps. If
the transformer is equipped with a load-tap changer, the ratio should be determined
for each load-tap changer position.
B. Fault-gas analysis.
The analysis of the percentage of combustible gases present in the nitrogen cap of
sealed, pressurized oil-filled transformers can provide information as to the
likelihood of incipient faults in the transformer. Fault-gas analysis can be performed
on mineral-oil-immersed transformers of all sizes. When arcing or excessive heating
occurs below the top surface of the oil, some oil decomposes. Some of the products
of the decomposition are combustible gases that rise to the top of the oil and mix
with the nitrogen above the oil. The test set for this test is designed for the purpose.
A small sample of nitrogen is removed from the transformer and analyzed.
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C. Insulating-liquid analysis.
Insulating-liquid analysis can be performed in the field on oil-immersed power
transformers of all sizes.
1-7 Protective Relays
Protective relays are used to sense abnormalities and cause the trouble to be
isolated with minimum disturbance to the electrical system and the least damage to
the equipment at fault. Protective relays should be set and acceptance tested prior
to being placed in service and tested periodically thereafter to ensure reliable
performance. In a normal industrial application, periodic testing should be done at
least every 2 years. The person performing the test should be given the settings to
be applied to each particular relay by the engineer. There are two types of
protective relays addressed in this manual. The first types are solid state relays.
These are electronic "black box" devices. As all electronic devices, solid state
relays should never be subject to hi-pot or megger testing. They typically come
equipped with internal testing capabilities. Any diagnostic tests shall be performed
as indicated in the manufacturer's manual. The second type is induction disk
relays . They are subject to the following tests.
A. Inspection.
If recommended or desirable, each relay should be removed from its case (if relay
design permits) for a thorough inspection and cleaning. If the circuit is in service,
one relay at a time should be removed so as not to totally disable the protection.
The areas of inspection are detailed in the manufacturer's instruction manual. These
generally consist of inspection for loose screws, friction in moving parts, iron filings
between the induction disk and permanent magnet, and any evidence of distress
with the relay. The fine silver contacts should be cleaned only with a burnishing
tool.
B. Settings.
Prescribed setting should be applied or it should be ascertained that they have been
applied to the relay.
C. Pickup test.
In the case of a time-over-current relay, its contacts should eventually creep to a
closed position with a magnitude of current introduced in its induction coil equal to
the tap setting. The pickup is adjusted by means of the restraining spiral-spring
adjusting ring. A pickup test on a voltage relay is made in much the same manner.
D. Timing test.
A timing test should be made on most types of relays. In the case of a time-over
current relay, one or more timing tests are made at anywhere from two to ten times
the tap setting to verify the time-current characteristic of the relay. One timing
point should be specified in the prescribed settings. Tests should be made with the
relay in its panel and case, and the time test run at the calibration setting.
E. Instantaneous test.
Some protective relays are instantaneous in operation, or might have a separate
instantaneous element. In this context, the term instantaneous means "having no
intentional time delay." If used, the specified pickup on the instantaneous element
should be set by test. Again referring to the relay used in the example above, at two
times pickup, its instantaneous element should have an operating time of between
0.016 and 0.030 seconds.
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F. Test of target and seal-in unit.
Most types of protective relays have a combination target and sealin unit. The
target indicates that the relay has operated. The seal-in unit is adjustable to pickup
at either 0.2 or 2.0 amperes. The pickup setting is established by the relay
coordination study. The setting for the seal-in unit should be specified with the relay
settings. It should be verified by test that the contacts will seal in with the minimum
specified direct current applied in the seal-in unit.
G. Test of tripping circuit.
A test should be made, preferably at time of testing the relays, to verify that
operation of the relay contacts will cause the breaker to trip.
1-8 Ground System Testing
In addition to the general component tests stated in the preceding paragraphs,
there are tests to be performed on the system as a whole after the components are
installed. They are as follows:
A. Equipment ground-impedance testing.
This test is used to determine the integrity of the grounding path from the point of
test back to the source panel or supply transformer. A low-impedance grounding
path is necessary to facilitate operation of the over current device under ground-
fault conditions as well as provide a zero voltage reference for reliable operation of
computers and other microprocessor-based electronic equipment. Instruments are
available to measure the impedance of the grounding path. When using these
instruments, the user should remember that, although a high-impedance value is an
indication of a problem, for example a loose connection or excessive conductor
length, low-impedance readout does not necessarily indicate the adequacy of the
grounding path. A grounding path that is found to have low impedance by the use
of relatively low-test currents might not have sufficient capacity to handle large
ground faults. Ground loop or grounding conductor impedance cannot be measured
reliably in situations where metallic conduits are used or where metallic boxes or
equipment are attached to metal building frames or interconnected structures. Such
situations create parallel paths for test currents that make it impossible to measure
the impedance of the grounding conductors; or even to detect an open or missing
grounding conductor. Visual examinations and actual checking for tightness of
connections are still necessary to determine the adequacy of the grounding path.
B. Grounded conductor (neutral) impedance testing.
On solidly grounded low-voltage system (600 volts or less) supplying
microprocessor-based electronic equipment with switching power supplies, this test
is used to determine the quality of the grounded conductor (neutral) from the point
of test back to the source panel or supply transformer. The same instruments used
to perform the equipment ground impedance tests can be used to perform
grounded conductor (neutral) impedance tests.
C. Grounding-electrode resistance testing.
Grounding-electrode resistance testing is used to determine the effectiveness and
integrity of the grounding system. Periodic testing is necessary because changes in
soil temperature, soil moisture, conductive salts in the soil, and corrosion of the
ground connectors cause variations in soil resistivity. The test set used will
ordinarily be a ground-resistance test set, designed for the purpose, using the
principle of the fall of potential of ac-circulated current from a test spot to the
ground connection under test.
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E. Neutral-current testing.
Situations exist where it is possible for the neutral current of three-phase systems
to exceed the ampacity of the neutral conductor in normal operation. This is usually
due to unbalanced phase loading, non sinusoidal load currents (harmonics), or a
combination of the two. Also nonlinear loads, such as rectifiers, computers, variable
speed drives, electrical discharge lighting fixtures, and switching mode power
supplies, cause phase currents that are not sinusoidal . The problem can be
detected using a true root mean square (RMS) ammeter to measure the current
flowing in the neutral conductor. The use of an average responding ammeter
calibrated to read the RMS value of a sine wave should not be used, as it will not
yield valid results when used on non sinusoidal waveforms. If the neutral current is
found to be excessive, the current in each phase should be measured to determine
if an abnormal condition exists. If excessive neutral current exists and the phase
currents are not excessive, harmonic content is the most likely cause. A means of
analyzing neutral current containing harmonic components is through the use of a
wave or spectrum analyzer.
2 COMPONENT TESTING
2-1 Introduction To Component Testing
The component inspection and checks are the key to the success of any
commissioning program. Each component of the system should be initially checked
for damage, deterioration, and failures by a procedure using inspections and tests
as defined by the specific equipment manufacturer. The equipment manuals from
the manufacturer identify the minimum required receipt inspections, handling and
installation procedures, drawing and wiring verification, de-energized and energized
component tests, minimum testing baseline and report requirements for on-going
maintenance, and requirements for repair and retesting if certain checks and tests
produce unsatisfactory results. After the systems components are
Interconnected, the system should be checked, using de-energized and energized
methods, to verify the proper interconnection and operation of the components
including on/off control, system process interlocks, and protective relaying
functions. Once these tests are complete, the system can be energized and
operational tests and measurements are performed. This chapter of the manual
gives a typical listing of the commissioning test and testing procedures that are
recommended (manufacturers' recommendations should always be incorporated
into component testing) for each of the following system components before the
interconnection and operation of the components as a system is verified and tested
The components/systems to be verified and tested are circuit switchers,
transformers, switchgear –low voltage, switchgear -medium voltage, transfer switch,
motors, ac/dc drives, generators, batteries, battery chargers, UPS systems, and
cables . For equipment containing electronic components, megger testing must not
be performed. However, this equipment should be tested according to
manufacturer's specifications.
2-2 Circuit Switchers
A circuit switcher is a device that consists of a disconnect switch and a circuit-
breaking interrupter. They are used for switching and protecting equipment such as
transformers, lines, cables, capacitor banks, and shunt reactors from small short
circuit currents . The first step towards acceptance of any device is verification of
nameplate data and equipment conditions. All the equipment shall be checked
against nameplate, one-line, schematic, and wiring diagrams. All equipment shall be
carefully examined upon receipt to ensure that no damage has occurred during
shipment. Upon receipt a visual inspection of the circuit switcher and associated
hardware shall be made including nameplate, parts, drawings, and Condition. Any
discrepancies should be sent to the manufacturer for a resolution. After installation,
the circuit switcher shall be checked to ensure that it has been bolted to its
permanent foundation, all shipping braces have been removed, and that it has been
properly grounded. The alignment of the
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disconnect should be checked to ensure that the blade tongue contact enters the
jaw contact on center, rotates fully and comes to rest within 1/8" of the stop. The
interrupter action should be checked for proper operation as described in the
operation manual. The circuit switcher shall be manually operated to check that the
mechanism works smoothly and correctly. The contact surfaces should be checked
for proper lubrication. The control wiring installation shall be checked per the
drawings. The low-pressure indicator should be checked by measuring the pressure
in psig and recorded along with the ambient temperature at the time the
measurement was taken and then comparing this value with the manufacturers
data. Checks shall be made to insure that the grounding connections have been
installed. Simulate a fault by activating the protective relay circuit and check
electrical operation. Check key interlocks both mechanically and electrically. Testing
shall include timing, contact resistance, contact part time, and charging motor
operation. Descriptions of these tests are found in paragraph 2-5. The timing test
shall be performed at the normal operating voltage for both trip command and close
command.
2-3 Transformers
There are two basic types of power transformers, oil-filled and dry-type. Both are
subject to many of the same tests. Therefore, the following test procedures apply to
both types unless otherwise noted. Since cast coil transformers are considered dry-
type, the following tests also apply unless the test is noted to only apply to oil-filled
transformers.
A. Inspection on receipt.
A thorough inspection for the transformer shall be completed upon arrival and
before unloading. This inspection shall include a detailed visual inspection of the
external of the transformer. Since the largest transformer we are concerned with in
this manual is 10 MVA, the transformers do not require impact recorder. The
minimum size of transformer for impact recording is approximately 20 MVA. Oil-
filled type transformers are typically shipped filled with either dry air or nitrogen.
The pressure condition, nitrogen content, and dew point shall be measured before
unloading of the transformer. A positive pressure should be maintained on nitrogen-
blanketed transformers. The oxygen content should be less than one percent. The
seals of the transformer shall be inspected to ensure that they are properly seated.
For an acceptable transformer installation it is imperative that the foundation is
level. This should be checked well in advance of receipt of the transformer. Upon
completion of the equipment inspections, the transformer shall be unloaded and set
into its final installation position. The shipping bracing shall be removed and it shall
then be anchored to its foundation. The bolts (if used) securing the transformer to
its foundation shall be checked to ensure that they are installed at the proper
torque. For large transformers (above 20 MVA approximately), a visual inspection of
the transformer internals shall be performed on air and oil-filled transformers filled
with nitrogen. Transformers shipped filled with oil will not need internal inspections
unless the electrical testing described below indicates a problem. Then the oil must
be drained, inspection performed, and repair completed. After the repair is
inspected, the transformer shall be filled with clean dielectric fluid in strict
accordance, with the manufacturer's instructions. The purpose of this internal
inspection is to determine that no displacement has occurred in transit or during
unloading. Items to be verified include the tap-changer, end braces and current
transformers. This inspection must be performed with dry air in the main tank. If the
transformer has been delivered filled with nitrogen, it must be evacuated from the
tank replaced with dry air. Personnel performing the inspection must wear clean
cotton clothing, mouth covers and oil-resistant, clean, rubber soled shoes that
contain no metallic parts. All transformer nameplates, wiring, and accessories shall
be visually inspected and compared against the drawings. These accessories
include but are not limited to radiators, fans, bushings, and instrument controls.
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B. Installation checks.
After the preceding inspections have been completed, the transformer shall be
assembled. Transformer assembly includes but is not limited to, mounting of
radiators, fans, bushings, thermometers, oil level indicators, relays and expansion
tank. Transformer assembly must be in accordance with manufacturer's instructions
and design drawings. After all of the accessories have been installed, protection
circuits shall be wired and checked. A pressure test can now be performed and the
transformer filled with oil. The alarm, control, and trip settings on temperature
indicators shall be inspected to verify that they are set as specified. The cooling
pumps shall operate correctly, and the fan and pump motors shall have correct over
current protection. Operation of all alarm, control, and trip circuits from
temperature and level indicators, pressure relief device, and fault pressure relays
shall be checked. Liquid level in all tanks and bushings shall be verified. Grounding
shall be verified. Once the above is complete the following tests shall be performed
on insulation resistance, dielectric absorption, polarization index, transformer turns
ratio test, and power factor test. Descriptions of these tests are found in paragraphs
1-4 and 1-6. Once completed and passed, the transformer is ready for energization.
2-4 Switchgear - Medium Voltage
The first step towards acceptance of any device is verification of nameplate data.
The nameplate on all equipment shall be checked against one-lines and schematics.
The Switchgear shall be checked for completeness of assembly. All equipment shall
be carefully examined upon receipt to ensure that no damage has occurred during
shipment. A visual inspection of the area where the switchgear is installed should
be performed to confirm that there is adequate aisle space at the front and rear of
the equipment for proper ventilation, service and maintenance of the equipment.
The Switchgear should be checked to insure it is properly anchored to its
foundation. Visually inspect that the high voltage connections are properly
insulated. Electrically disconnecting contacts, machined parts, shutter, etc., should
be checked or lubrication and operation. The breaker alignment and manual
operation shall be checked. All blocking, supports and other temporary ties should
be removed from breakers, instruments, relays, etc . Verify proper fuses are
correctly placed. Verify proper voltage and phase connections. Verify correct
component and installation of potential and current transformers (PTs and CTs) and
control fuse size and check continuity. Also check PT and CT polarity and
transformer turns ratio. Temporary wiring jumpers should be removed. Verify
ground connections properly made. Verify incoming primary and secondary
connections properly made and checked for shorts or undesired grounds. Verify all
equipment that has been removed during assembly has been replaced. Verify relays
are coordinated with other relays and protective devices on the system. Refer to
relay instructions before making any adjustments. Consult local utility before
making any connections to the power supply. Verify storage battery fully charged
and provided with charger.
2-5 Switchgear - Low Voltage
All equipment shall be carefully examined upon receipt to ensure that no damage
has occurred during shipment. A visual inspection of the area where the switchgear
is installed should be performed to confirm that there is adequate aisle space at the
front and rear of the equipment for proper ventilation, service and maintenance of
the equipment. The
Switchgear should be checked to insure it is properly anchored to its foundation. All
switches, circuit breakers, and other operating mechanisms should be manually
exercised to make certain they are properly aligned and operate freely. An
insulation resistance test should be performed to make sure the Switchgear is free
from short circuits and grounds. This should be done both phase-to-ground and
phase-to-phase and with the switches or circuit breakers both opened and closed.
Any electrical relays, meters, or instrumentation should be checked to determine
that connections are made properly and the devices
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function properly. Electrically exercise all electrically operated circuit breakers, and
other mechanisms (but not under load), to determine that the devices operate
properly. An auxiliary source of control power may be necessary to provide power to
the electrical operators. Test the ground fault protection system (if furnished) in
accordance with the manufacturer's instructions. Check the settings of the
adjustable current and voltage trip mechanisms to confirm that they are at the
proper values. Make certain that field wiring is clear of live bus and, where
necessary, physically secured to withstand the effects of fault currents. Check to
determine that all grounding connections are made properly. Remove all debris;
scrap wire, etc., from the Switchgear interior before closing the enclosure. Install
covers, close doors, and make certain that no wires are pinched and that all
enclosure parts are properly aligned to be tightened. Once the above is complete
perform an insulation resistance test. Before performing insulation tests precautions
should be made to eliminate damage to electronic controls/sensitive equipment
attached to the bus. The Insulation Resistance test is described in paragraph 2-4.
Once completed and passed, the switchgear is ready for energization.
2-6 Transfer Switch
The transfer switch shall be checked for completeness of assembly. All equipment
shall be carefully examined upon receipt to ensure that no damage has occurred
during shipment such as loose parts and insulation damage. The Switch shall be
checked for proper alignment and manual operation. The switch insulation
resistance (phase-to-phase and phase-to-ground) shall be measured in normal and
emergency positions. The wiring of the potential transformer to the control device
should be checked for continuity and the control fuse should be checked to confirm
size. The potential transformer should be tested as described in paragraph 3-3. The
transfer switch should be checked for proper grounding. The timer settings should
be checked against design parameters.
2-7 AC/DC Drives
has occurred during shipment. Drives are controllers used to vary the speed of a
motor. Controllers are electronic devices that should never be megger tested. They
typically come equipped with internal testing capabilities. Any diagnostic tests shall
be performed as indicated in the manufacturer's manual. A visual inspection of the
controller, enclosure, nameplates, connections, and drawings shall be performed.
After removal of the controller enclosure cover, the controller shall be checked for
physical damage and any debris from installation such as wire strands shall be
removed using clean, dry, low-pressure air. All terminal connections shall be
checked for tightness. The drive should be energized with no connection to the load
and diagnostic test should be run. Motors should be tested separately as indicated
in the motor paragraph.
2-8 Batteries
Although battery type varies (e.g., NiCad, Lead Acid), the acceptance criterion
remains generally the same. The fast step towards acceptance of any device is
verification of nameplate data. The nameplate on all equipment shall be checked
against one-lines and schematics. All equipment shall be carefully examined upon
receipt to ensure that no damage has occurred during shipment. Any apparent
physical damage shall be recorded. If the battery is delivered filled, it shall be
inspected to verify that no electrolyte has leaked during transit If the battery cells
are not delivered filled, it is recommended that they be filled according to
manufacturers recommendations before installation on racks. The individual cell
condition check shall include visual inspection of cell integrity investigating
evidence of corrosion at terminals, connections, racks, or cabinet the general
appearance and cleanliness of the battery, the battery rack or cabinet and battery
area including accessibility shall be observed. The cells shall be
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checked for cracks in cell or leakage of electrolyte as well as the integrity of the
cover. Electrolyte should be added to any cell in which the electrolyte level is below
the top of the plates. Before installation, the voltage of each cell shall be measured.
The voltage measured should be equal to or less than 0.05 V below the
manufacturers open circuit voltage. If it is not, the manufacturer shall be contacted
to determine the next course of action. The cell polarity for positive to negative
connections shall be checked. The battery shall be assembled as shown on
drawings. Each battery cell is then checked to ensure the electrolyte level is at the
maximum level. The interconnection of the battery cells shall be checked for
polarity. The connector bolts shall be checked to ensure that they have been
tightened to the manufacturers recommended torque values. The cell internal
ohmic values and the inter cell connection resistances shall be then measured. This
is accomplished by applying a load across the battery and measuring the step
change in voltage and current for each cell taken between the positive and negative
terminal posts of adjacent cells as well as the battery as a whole. The ohmic value is
the change in voltage divided by the change in current The resistance values for
each cell shall then be averaged and any interconnection that varies more than
10%or 5 AQ over the average shall be remade and then rechecked for its resistance
value. These values shall become baseline values for comparison in future tests.
The presence of flame arresters, adequacy of battery support racks, mounting,
anchorage, grounding, and clearances, ventilation of battery room enclosure, and
existence of suitable eyewash equipment shall be verified. After completion of the
above inspections the battery is ready to be connected to the charger. After
charging, the following should be measured: each cell voltage and total battery
voltage with charger in float mode of operation; ripple current; specific gravity;
electrolyte temperature; electrolyte fill level; overall float voltage measured at the
battery terminals; charger output current and voltage, ambient temperature,
condition of ventilation and monitoring equipment; and temperature of the negative
terminal of each cell of the battery. When the battery is charged, use a voltmeter to
check the polarity of the series connections. The total voltage shall be measured
both across the battery and between adjacent cells and then shall be compared to
the specified voltage. The total voltage should approximately be the resultant of the
quantity of cells multiplied by the typical cell voltage. A variation is an indication
that the battery maybe improperly assembled.
A. Discharge test.
The values for discharge time and end point voltage should be selected from the
battery manufacturer's published ratings and the values used for the acceptance
test should be approximately the same as that of the intended application. The
discharge rate should be at a constant current or constant power load equal to the
selected manufacturer's rating of the battery. The charging method used as the
basis for the published data is an important factor. For a stationary float application,
data based on prolonged constant potential charging should be used. If constant
current charging has been used to establish the published data, appropriate float
charging correction factors should be obtained from the manufacturer. Note that
the test discharge current is equal to the rated discharge current divided by the
temperature correction factor for the initial electrolyte temperature. Set up a load
and the necessary instrumentation to maintain the test discharge rate determined
in above. Disconnect the charging source, connect the load to the battery, start the
timing, and continue to maintain the selected discharge rate. If the charging source
cannot be disconnected, the current being drawn by the load has to be increased to
compensate for the current being supplied by the charging source to the battery.
Read and record the individual cell voltages and the battery terminal voltage. The
readings should be taken while the load is applied at the beginning and at the
completion of the test and at specified intervals. There should be a minimum of
three sets of readings. Individual cell voltage readings should be taken between
respective posts of like polarity of adjacent cells so as to include the voltage drop of
the inter cell connectors. Maintain the discharge rate and record the elapsed time at
the point when the battery terminal voltage decreases to a value equal to the
minimum average voltage per cell as specified by the design of the installation
times the number of cells.
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B. Capacity check.
The capacity of the battery is checked using the following equation:
Percent Capacity at the test rate at 25°C (77°F) = (ta / ts) x 100
Where: ta is the actual time of the test to specified terminal voltage as corrected for
temperatures ts is the rated time to specified terminal voltage
2-9 Battery Chargers
has occurred during shipment. A visual inspection should be performed to verify the
completeness of the equipment, correctness of installations, supports, grounding,
and wiring. The rating plate shall be checked to ensure that both the ac supply to
the charger and the battery to be connected corresponds to the charger's
parameters. Confirm that all shipping and other debris in and around the charger
cabinet have been removed. Check settings of the charger and calibrate per
manufacturer's manual to match the battery (float and equalizing levels). If the
battery charger has been factory set, check the charger float and equalizing voltage
levels against drawings and specifications. If not, set the charger float and
equalizing voltage levels to those listed on drawings and specifications. Before
connecting to the battery, measure the output voltage provided by the charger and
record. Verify that all charger functions and alarms operate correctly. Verification
that the battery is connected to the battery charger properly is extremely
important. The negative wire from the negative terminal of the battery must be
connected to the negative terminal of the charger. Similarly, the positive wire from
the negative terminal of the battery must be connected to the positive terminal of
the charger. A battery charger is an electronic device that converts ac power to dC
power. The charger supplies this dC power to the battery. As with all electronic
devices, this device should not be megger tested.
2-10 Cables
For commissioning of cables, the receipt inspection and testing is performed while
the cable is still on the reel. The exposed sections of the cables are visually
inspected for signs of physical damage, the end caps are checked for tightness. The
cable types and configuration are checked for correctness against drawings and
purchasing documents. Continuity tests are performed on each conductor and the
shield. For power cables, insulation resistance tests are performed between each
conductor, each conductor, and the shield. The cable installation shall be checked
against one-lines and schematics. After installation, the cables are inspected for
damage, proper trained bending radius, adequate spacing for ampacity, and proper
installation of fireproofing, proper size, termination, and identification. Next,
conductors are checked for continuity. The following tests shall be performed before
the cables are energized. They are the insulation resistance (Megger) test and the
do hi pot test. For medium and high voltage shielded cables the acceptance is
dependent on the do hi pot test. A satisfactory test is the exponential decrease of
current with time with a fixed do voltage applied. Non-shielded cables are not
subject to the hi-pot test because only the sections of cable in contact with ground
(such as cable tray rungs) are actually tested and therefore the test is not
meaningful, Test duration should not exceed 5 minutes for no shielded cable or 15
minutes for shielded cable. When performing a do High potential test on cables, all
precautions and limits as specified in the applicable NEMA/ICEA (Insulated Cable
Engineers Association) standard for the specific cable should be followed. Tests
should be performed in accordance with ANSMEEE Standard 400. Test voltages shall
not exceed 80 percent of cable manufacturer's factory test value or the maximum
test voltage in table 3.1 below. The test procedure should be as follows and the
results for each cable test shall be recorded. Test each section of cable individually
with all other conductors grounded. All shields must also be grounded. Terminations
shall be
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adequately corona-suppressed by guard ring, field reduction sphere, or other
suitable methods as necessary. Precaution should be taken to insure that the
maximum test voltage does not exceed the limits for terminations specified in IEEE
Standard 48 or manufacturers specifications. Reduce the conductor test potential to
zero and measure residual voltage at discrete intervals. Upon the completion of the
test, apply grounds for a time period adequate to drain all insulation-stored charge.
When new cables are spliced to existing cables, the do high-potential test shall be
performed on the new cable prior to splicing. After test results are approved for the
new cable and the splice is completed, an insulation resistance test and a shielding
continuity test should be performed on the length of the new and existing cable
including the splice. After a satisfactory insulation resistance test, a do high
potential test shall be performed on the cable utilizing a test voltage acceptable to
owner and not exceeding 60 percent of factory test value.
Insulation Type
Rated Cable Voltage
Insulation Level
Test Voltage kV (dc)
5kV
100 %
25
5 kV
133 %
25
15 kV
100 %
55
15 kV
133 %
65
Elastomeric:
Butyl and Oil Base
25 kV
100 %
80
5 kV
100 %
25
5 kV
133 %
25
8 kV
100 %
35
8 kV
133 %
45
15 kV
100 %
55
15 kV
133 %
65
25 kV
100 %
80
25 kV
133 %
100
28 kV
100 %
85
Elastomeric: EPR
35 kV
100 %
100
5 kV
100 %
25
5 kV
133 %
25
8 kV
100 %
35
8 kV
133 %
45
15 kV
100 %
55
15 kV
133 %
65
25 kV
100 %
80
25 kV
133 %
100
Polyethylene
35 kV
100 %
100
Table 2-1. Medium-voltage cables maximum field acceptance test voltages (kV, dc)
2-11 UPS Systems
has occurred during shipment. The Static UPS System consists of the battery
charger, inverter, battery, transfer switch, circuit breakers, and cables. A picture of
a typical UPS system is seen in figure 2-1. Of the UPS system, the component
testing for the battery charger, battery, transfer switch, circuit breakers, and cables
are described individually in this manual. The
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Inverter is similar in construction to the charger. It converts do power to ac power
using solid state electronics. Therefore, this device should not be megger tested.
The completeness of the assembly shall be confirmed. A visual inspection should be
performed to verify the correctness of installations, supports, grounding, and wiring.
Verify that the air inlets are not obstructed. The interconnections shall be checked
against the wiring schematic to ensure the proper phasing and voltage connections.
For example, both the battery charger connections to the battery and the battery to
the inverter should be checked to insure that they have the correct polarity.
Measure the input voltage provided by the battery and record. Measure the output
voltage and current from the inverter and record. Verify that these values
correspond to the design values.
Figure 2-1. Static UPS system 150 to 750 WA (courtesy of Liebert)
2-12 Description Of Uninterruptible Power Supply (UPS) System
The following is a sample uninterruptible power supply (UPS) system with
associated one-line and wiring diagrams for use as a guide for implementing the
test procedures described in the preceding chapters of this manual.
A. Figure description.
The uninterruptible power supply system consists of the following equipment: 480V
utility feeder breaker, 480V generator feeder breaker, 480V transfer switch, 200
kVA redundant UPS, 125 VdcNi Cad batteries and a 208/120V UPS switchboard
panel. The 200 kVA UPS consists of the following equipment: 480V incoming
breaker, 125 Vdc rectifier, redundant 120/208 VAC inverters, static switches, bypass
switches and miscellaneous breakers. The equipment, accessories, interconnection,
ratings, cabling, etc. are shown on figures 2-2 through 2-4.
B. Switching.
The utility and generator breakers are metal enclosed free standing, manually
operated, air power circuit breakers. The breakers have instantaneous, short time,
and long time trip settings with manual control and position indication on the door
of the breaker compartment. The 480V transfer switch is metal
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enclosed, break before make, dead bus transfer, automatic on loss of voltage,
solenoid operated, and mechanically held complete with microprocessor controls
and indication, four-pole switch. Transfer time and time delay settings are
adjustable. The transfer switch will supply start and stop signals to the back-up
diesel generator upon loss of and restoration of utility power. These controls are
timed and must be coordinated with the diesel generator manufacturer for start-up,
loading, and cool down times. Remote indication, control, alarm, etc. functions are
also available.
C. UPS operation.
The UPS is a static solid state system with a battery for back-up power. The
rectifiers convert ac to do power for supply to the redundant inverters and for
charging the battery. The inverters receive power from either the rectifier or
battery, and convert it from do to ac. The inverters also include power conditioning
equipment and circuits to remove harmonics developed in the system. Because the
input power is converted from ac to do to ac, power system disturbances are also
removed from the UPS output. This makes UPSs ideal for use with sensitive
electronic equipment and computers. The rectifiers and inverters are constructed
with power diodes or silicon control rectifiers along with controls and filtering
circuitry. The UPS also contains thermal magnetic molded case circuit breakers and
two bump less static switches. The switches will transfer the output of the UPS from
one redundant inverter to the other upon failure of the lead inverter. The transfer
between the inverters is accomplished with absolutely no loss of continuity of power
to the load. In the sample system, as shown in figure 2-2, the two UPS modules are
both sized to supply the entire load independent of one another. The 208/120 V
switchboard is a metal enclosed, wall-mounted distribution panel with incoming and
feeder uneducable thermal magnetic molded case circuit breakers . The
switchboard also receives a backup power supply from the utility power center for
use during the maintenance of the UPS through two bypass switches.
D. Battery description.
The nickel cadmium (NiCad) batteries are individual 1 .2 volt cells in plastic or steel
cases with nickel and cadmium plates in a potassium hydroxide solution . The cells
are sealed, maintenance free and connected together in series on racks to supply
125 Vdc. The 120/208V UPS switchboard panel contains two main and numerous
molded case thermal magnetic circuit breakers to distribute the power. The
breakers have instantaneous and over current elements trip characteristics. The
UPS systems provide normal and uninterruptible regulated power to sensitive
emergency plant loads, like computers, communications, radar, security systems,
lighting, etc.
2-13 Operation Of Uninterruptible Power Supply System
The operating modes for the UPS system are as follows:
A. Normal condition.
Utility breaker closed, diesel generator not running but in auto mode, diesel
generator breaker closed, transfer switch connected to utility, inverter A connected
through UPS static switch to UPS bus and UPS switchboard connected to the UPS.
B. Loss of rectifiers’ battery charger A.
UPS incoming breaker feeding rectifier/battery charger A opens, circuit breaker
connecting rectifier/battery charger A to battery bus opens and battery fed by
rectifier/battery charger B
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C. Loss of inverter A.
UPS static switch A switches UPS bus to inverter B and Inverter A circuit breaker
opens.
D. Loss of utility power.
Battery supplies power to UPS bus through inverter A or B, transfer switch supplies
start signal to diesel generator, diesel generator starts and ramps up to speed and
transfer switch connects to diesel generator.
E. Restoration of utility.
Utility power restored, transfer switch switches to utility bus and diesel generator
shut down by transfer switch.
2-14 Commissioning Test Plan For The UPS System
A system verification and functional performance test should be performed on the
UPS system. These tests will include installation inspections, individual component
testing, testing on wiring, control and interlock functional checks, equipment
energization and system operating measurements and functional Checks.
2-15 Installation Inspections and Component Testing Of The UPS System
The installation of the main components (i.e. utility and generator circuit breakers,
transfer switch, UPS, battery, battery charger, and UPS switchboard) will be
inspected as
Follows:
A. Utility and generator circuit breakers.
Completeness of assembly, verification of nameplate, sizes and settings against
drawings, loose parts and insulation damage, breaker alignment and manual
operation (leave circuit breaker open) and bus insulation resistance (if not
previously energized) .
B. Transfer switch.
drawings, loose parts and insulation damage, switch alignment and manual
operation (leave open), switch insulation resistance (phase-to-phase and phase-to-
ground), PT and control fuse size and continuity, ground connection and check timer
settings.
C. UPS.
drawings, loose parts and insulation damage, proper settings, control fuse size and
continuity, ground connection, proper neutral connection, proper phase and voltage
connections (incoming, battery, inverter A, and inverter B) and manual operation of
circuit breakers (leave open).
D. NiCad battery.
Completeness of assembly, verification of nameplate, sizes and connection against
drawings, loose parts, leaks, or damage, electrolyte level, vents sealed and plugs
installed, grounding and measure voltage.
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E. -UPS switchboard.
drawings, loose parts and insulation damage, ground connection, proper phase and
voltage
F. Visual and electrical wiring inspections.
The termination of each cable, shown on the cable block and wiring diagrams,
should be checked to insure each conductor matches the wiring and schematic
diagrams . This is performed by yellowing each connection from the schematic to
the wiring diagram; visually inspecting each connection for cable number, wire
number/color, and terminal; and checking point-to-point continuity or "ringing out"
each wire from end to end including grounds. For example (figure 6-3) Cable
BGATS1 from Automatic Transfer Switch to the Backup Generator should be
checked to verify that the "black" wire is terminated as follows as shown on the
schematic and wiring diagrams:
Equipment
Terminal No.
Automatic Transfer Switch
B1
Backup Generator
T1
As this is done, the wire on each drawing should be colored or highlighted to show
its termination has been checked. This process should be completed for all field
wiring as a minimum and internal wiring if not previously performed at the factory.
2-16 Energizing and Test Of The UPS System
The following steps are performed to energize and test the UPS system.
A. Initial Energization.
Individual components of the UPS system shall be sequentially energized from the
source through the loads. As each item is energized, control functions, interlocks,
and alarms should be checked for proper operation. Voltage, phasing, and current
measurements should be made at each step.
B. Utility breaker.
Verify diesel generator breaker open, verify incoming voltage, manually close the
utility breaker, measure outgoing voltage and phasing of breaker, measure
incoming voltage of transfer switch and note position of transfer switch and
manually open breaker.
C. Diesel generator breaker.
Verify utility breaker open, start diesel generator, verify diesel generator voltage,
verify diesel generator and utility voltage have same magnitude and phasing,
manually close diesel breaker, measure outgoing voltage and phasing, measure
voltage at transfer switch and note position of transfer switch, manually open
breaker and stop diesel generator and place in auto.
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D. Transfer switch.
Verify diesel generator stopped and in auto, verify utility bus energized, manually
close utility breaker. Verify position of transfer switch and indication light status,
measure input and output voltage of transfer switch, check phasing of utility bus to
output of transfer switch. Manually open utility breaker. Diesel generator should
start and switch should transfer to diesel generator. Note timing of diesel generator
start and transfer from opening of utility breaker. Manually close utility breaker.
Switch should transfer to utility and diesel generator should stop. Note timing of
transfer and diesel generator stop from closing of utility breaker. Push test switch to
simulate normal source failure. Verify diesel generator starts and transfer switch
switches to diesel generator, return switch to utility feed and verify diesel generator
stops.
E. UPS (rectifier/ battery charger/battery).
Verify UPS incoming breaker open. Verify utility feed closed through to input of UPS
and measure voltage and phasing. Verify rectifier/battery charger output A breaker
open. Verify rectifier/battery charger output B breaker open. Verify battery breaker
A open and measure battery voltage and polarity. Verify battery breaker B open and
measure battery voltage and polarity. Verify inverter A and inverter B incoming
breakers open. Close UPS incoming breaker A and measure rectifier/battery charger
A output voltage, check do output meter. Press battery "pre charge" button, if
available, and close rectifier/battery charger A output breaker and close battery
breaker A. Measure battery charger voltage. Allow unit to run until battery fully
charged or for a minimum of24 hours. Record time. Measure rectifier/battery
charger A output current and read meter every 4 hours. Open UPS incoming breaker
A. Operate UPS from battery until minimum voltage recorded (1 to 4 hours). Open
battery breaker A. Close UPS incoming breaker B and measure rectifier/battery
charger B output voltage, check do output meter. Press battery "pre charge" button,
if available, and close rectifier/battery charger B output breaker and close battery
breaker B. Measure battery charger voltage. Allow unit to run until battery fully
charged or for a minimum of 24 hours. Record time. Measure rectifier/battery
charger B output current and read meter every 4 hours.
F. UPS (inverter/static switch).
Verify UPS operational through rectifier/battery charger and battery.
(1) Verify UPS normal condition operation.
(a) Verify battery charged and on float.
(b) Measure float voltage
(c) Verify inverter A and inverter B breakers open.
(d) Verify static switch switched to inverter A.
(e) Close inverter A and B input breakers.
(f) Measure inverter A and inverter B output voltage and read meters.
(g) Verify inverter A and inverter B outputs in phase.
(h) Verify static switch in inverter A position.
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(2) Verify proper operation of static switches.
(a) Open inverter A incoming breaker.
(b) Verify static switch switches to inverter B.
(c) Measure voltage and ensure bumpless.
(d) Close inverter A incoming breaker and verify static switch switches to A.
(e) Measure voltage and ensure bumpless.
(f) Open inverter B incoming breaker and verify static switch stays connected to
inverter A.
(g) Measure voltage and ensure bumpless.
(3) Verify low voltage trip.
(a) Open rectifier/battery charger output breakers.
(b) Open battery breakers.
(c) Verify inverter A and B trip on low voltage.
(d) Close rectifier battery charger B output breaker and battery breakers.
(e) Close inverter A and B input breakers.
(f) Open UPS incoming breakers.
(g) Verify inverter A and B output (feed from battery).
(h) Measure voltage and current.
(i) Close rectifier battery charger A output breaker and battery breakers.
(/) Open UPS incoming breaker.
(k) Verify inverter A and B output present (feed from battery).
(I) Measure voltage and current.
G. Loading UPS.
Close incoming breaker to UPS bus. Verify UPS is energized through static switch .
Verify all UPS loads connected properly and ready to start Close load breaker on
UPS bus sequentially. Measure voltage and read UPS meters at each step. Add load
until UPS loads equal normal design load. Run for 4 hours and check for
overheating.
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H. Utility trip test.
Verify UPS loaded and connected to utility. Manually open utility breaker. Verify
battery picks up load. Read current. Verify diesel generator starts, transfer switch
transfers to diesel generator, diesel generator picks up load, and battery returns to
float mode. Measure voltage and current at UPS and ensure bumpless transfer.
Close utility breaker. Verify transfer switch transfers to utility, battery picks up load
during transfer, diesel generator stops, and battery returns to float after utility picks
up load. Measure voltage and current at UPS bus and ensure bumpless transfer.
I. Inverter A to inverter B loaded transfer test.
Verify UPS loaded and connected to utility. Open inverter A incoming breaker. Verify
static switch switches to inverter B. Measure voltage and current at UPS bus and
ensure bumpless transfer. Close inverter A incoming breaker. Verify that static
switch switches to inverter A. Measure voltage and current at UPS bus and ensure
bumpless transfer.
J. Battery discharge test.
Verify UPS loaded and connected to utility. Notify plant of pending UPS trip. Open
diesel generator breaker and block auto and manual start. Open utility breaker.
Verify battery picks up load. Measure battery voltage and current. Measure UPS
voltage and current and ensure bumpless transfer. Operate UPS from battery until
battery minimum voltage reached (1 to 4 hours) . Record voltage. Verify inverter A
and B trip when batteries reach minimum voltage. Notify plant of pending UPS re-
energization. Reclose utility breaker. Close diesel generator breaker and return to
auto start mode. Verify battery on float and charging, measure current. Verify when
battery fully charged and record time to charge.
Table 2-2 Possible failures and corrective actions of the UPS system
Utility and Generator Circuit Breaker Problem
Areas to Check
Breakers will not close/trip
Mechanical alignment/ interlocks
Relay and protective device setting and operation
Mis-wired circuits
Breaker trip inadvertently
Ground on cable or system
Relay and protective device setting and operation
System overload
Mis-wired circuits
Transfer Switch
Areas to Check
Switch will not transfer
Solenoid operating mechanism
Time delay settings
Control panel
Mis-wired circuits
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UPS-Rectifier/ Battery Charger
Areas to Check
No output voltage/ current
Input voltage/ breaker
Rectifier (SCR) and rectifier fuse
Input transformer
Control board
Low output voltage
Dead input phase
Rectifier (SCR) and rectifier fuse
Voltage control settings or potential
Control board
High output voltage
Input voltage high
Voltage control setting or potential
Control board
Output voltage not adjustable
Voltage control potential
Control board
High output current
System overload/ short
Current limit setting
Control board
Low output current
Current limit setting
Control board
UPS-Battery
Areas to Check
Low battery voltage/ current/ capacity
Battery and cell connections
Electrolyte level
Cell voltage
Cell condition, cleanliness, and age
Float voltage/ current
Battery room temperature
Battery design versus actual load
Battery/ system ground
Breaker trip
Battery/ system short
System overload
UPS-Inverters/ Static Switch
Areas to Check
Input voltage/ breaker
SCR or diode
Static switch
Constant voltage transformer
Control boards
Low output voltage
Input voltage
System overload
System frequency
Control board
UPS-Inverters/ Static Switch
Areas to Check
High/Low output frequency
Input voltage
Alternate source
Frequency control setting
Control board
No transfer from Inverter A to Inverter B
Primary/ alternate source
Static switch,Synchronizing circuit control board
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UPS System
Areas to Check
Incoming voltage
Circuit breakers
System components
No transfer to Diesel generator
Diesel generator equipment/ breaker
Transfer switch
Low/High output voltage/ current
Incoming voltage
System components
Battery sizing/ capacity
System sizing/ capacity
Transfers not bumpless
Battery connection
Static switch
Control board
Inadequate UPS capacity
UPS sizing/ capacity
Battery sizing/ capacity
Figure 2-2. Uninterruptible power supply system single line diagram
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Backup Generator
(BG) Automatic Transfer Switch (ATS)
Utility Power Center
(UPC)
UPS Switchboard
Panel
(UPP)
Transformer
(IT)
Battery
(BA) Uninterruptible Power Supply (UPS)
CABLE
BGATS2
CABLE
BGATS1
CABLE
UPCATS1
CABLE
UPCIT1
CABLE
UPSSUPP1
CABLE
UPSBT1
CABLE
ITUPP1
CABLE
ATS UPS1
Figure 2.3 Uninterruptible power supply system block diagram
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Figure 2-4. Uninterruptible power supply system wiring diagram
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3 Common tests
The common tests which are applicable for more than one power equipments are
listed below and explain in details in the following pages.
1. Core Insulation Resistance Test
2. Winding Insulation Resistance test
3. Polarization Index
4. Winding Resistance Test (all taps)
5. Excitation Current test
6. Insulation Power Factor test
7. Vector Relationship Test
8. Winding Temperature Indicator (WTI) test, Hot-spot Temperature Indicator
9. Oil Temperature Indicator Test
10. Percent impedance test.
11. Turn Ratio Test
12. Insulating Oil Tests
13. CT & PT Insulation resistance test
14. CT &PT Winding resistance measurement
15. CT &PT Polarity test or flick test with battery & Phase Identification Test
16. CT &PT Ratio test by current primary injection
17. CT Magnetizing (Saturation) current test
18. CT &PT Loop resistance test (Burden test)
19. CT &PT Insulation Power Factor Test
20. CT &PT Inter-core coupling Check
21. CT &PT Demagnetization of CT
22. Contact resistance test (Resistance measurement of main circuit)
23. Gas Leakage Test (Gas SF 6 Gas tightness test)
24. Moisture content measurement in SF6 Gas (Dew point test)
25. Gas density switch test
26. Air Pressure switch test (APS Calibration)
27. Operating characteristics test (Timing test)
28. MCS Test
29. Auxiliary relay test
30. VT Secondary injection (injection of voltage and measurement of voltage in LCC)
31. Function Test
32. CT Primary injection (Turn Ratio) Injection of current and measurement of
current in LCC only)
33. Bus bar stability (Injection of current and measurement of current in LCC only)
34. Interlock Test
35. 10kV insulation test on external earthling switch’s pole (10kV ES insulation)
36. Power Frequency withstand voltage test (Hi voltage test)
37. Partial Discharge Measurement
38. Phase checking for conductor and sheath every link box
39. 10. KV D.C. for sheath.
40. D.C conductor resistance measurement.
41. Capacitance measurement.
42. Earth resistance measurement.
43. Verification of cross bonding test at link boxes.
44. Zero sequence impedance
45. Positive sequence impedance.
46. Oil flow test for oil field cable
47. Oil impregnation for oil field cable
48. AC H.V.T.
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ITEM
DESCRIPTION
EXPLANATION
Definition
The core ground test verifies that the proper grounding system of the transformer
has been installed and that all of the connections are correct. There is an intentional
ground from the transformer core to the tank.
Applicable Regulation/ Rule (Standard)
IEC 76-1
Purpose
• The purpose of measuring the core-to-ground insulation is to verify that the
condition of the insulation is satisfactory and that no other core grounds exist.
• Insulation Testing (Megger Test) - A megohmmeter insulation-resistance test is
made in the field and compared with measurements made at the factory to
determine if the transformer is sufficiently dry to energize.
• This test is most important as a check for shipping damage when the transformer
arrives at the installation site that will affect the core-to-ground insulation.
Therefore, it is recommended that it be tested before unloading the transformer
from the railroad car or truck on which it was shipping.
• This test gives an overall indication of the condition of the insulating system.
Making A Test
Most transformers have one ground; others may have two grounds. The core ground
test should be performed prior to the initial energization of the transformer.
The megger test is used a lot on smaller transformers with lower rated insulation
systems (less than 5000 volts).
Grounds are accessed through removal of the covers on the top of the transformer.
To perform the test, the ground strap or straps should be disconnected from the
tank. A 1000 volt megger is then connected between the tank and the ground
straps.
The most common method of performing this measurement is to measure the
resistance of the insulation using a megohmmeter which applies a DC voltage and
indicates the resistance in megohms. The result is a function of the leakage current
which passes through either the insulation or over external leakage surfaces.
The core ground test should be performed prior to the initial energization of the
transformer.
1
CORE INSULATION RESISTANCE TEST
Test Equipments (Sets)
Meggers (mega ohm meters).
Megohmmeters can commonly be divided into three general types those with :
(1) Hand-cranked generators
(2) Motor driven megohmmeter
(3) Battery operated megohmmeter.
Megohmmeter contains a hand driven D.C generator and moving
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coil instrument which indicate the value of resistance being measured. The parts of
hand driven megger is :
(1) Crank
(2) Range switch
(3) Meter face
(4) The terminals
The scale of megger is graduated in megaohms with lowest mark zero and highest
mark infinity.
A megohmmeter has a relatively high internal resistance, making the instrument
less hazardous to use in spite of the higher voltages
Test Connections (Circuit)
A megohmmeter usually is equipped with three terminals.
The "LINE" (or "L") terminal is the so-called "hot" terminal and is connected to the
conductor whose insulation resistance you are measuring. Remember: These tests
are performed with the circuit deenergized.
The "EARTH" (or "E") terminal is connected to the other side of the insulation, the
ground conductor.
The "GUARD" (or "G") terminal provides a return circuit that bypasses the meter.
For example, if you are measuring a circuit having a current that you do not want to
include, you connect that part of the circuit to the "GUARD" terminal.
Test Readings (Results) & Acceptance Values
The insulation resistance should be 200 megaohms or more. If a low resistance is
found, the core is grounded and must be cleared before proceeding.
A reading of only several ohms suggests a dead ground that may require repair. A
reading of 300 to 400 ohms usually indicates foreign material between the core and
tank.
Safety Precautions & Test Preparations
• Make sure that the transformer is de-energized, grounded and tagged.(*1)
• Verify that the transformer is disconnected and separated from the load circuit
and all normal sources of energy.(*1)
• Restrict access to the work area which can usually be secured by placing barriers,
ropes, or warning signs around the area.(*1)
• The core ground procedures should first be compared with the manufacture's
instructions supplied with the particular megohm meter.
• Never attempt to clear a core ground unless the transformer is completely
immersed in insulating fluid. This could prevent possible tank internal explosion.
• Several factors can cause large fluctuations in megger readings.
􀂃 Equipment temperature
􀂃 Duration of the test
􀂃 External leakage due to dirty insulators and bushings
These variables must be controlled to prevent getting
confusing test data.
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Definition
Insulation Resistance is the resistance of insulation between two conducting parts or
between a conducting part and earth. It is measured in terms of applied d.c voltage
divided by total current through the insulation ,
In R = Vdc / It
IEC 76-1
Purpose
• To make sure that the current that flows through a piece of electrical equipment
does not go where it is not supposed.
• To detect problems in time to prevent failure because of factors that must be
considered like its type, thickness, age, condition, relative cleanliness of the
insulation, dirt, temperature and moisture.
To measure the condition of a major insulation system (the insulating system
between a winding and the ground (core) or between two windings.
Making A Test
The Megger tester should have a field calibration test performed as per
manufacturer’s recommendation prior to performing the test.
To measure insulation resistance:
1. Verify that the transformer is de-energized and that all devices disconnecting
sources of power are “locked-out.”
2. Verify that the transformer is properly grounded.
3. Connect together all of the bushing terminals of each winding circuit.
4. Make connections to the megohmmeter terminals (Figures 3.2.1 and 3.2.2).
5. Read the scale (or numerical display) of the megohmmeter after voltage has
been applied for one minute and record the reading.
6. Read and record the temperature of the winding temperature.
7. Record the voltage level used.
The insulation resistance values are recorded on a test data sheet or in the
appropriate Saudi Electricity Company pre-commissioning form
Insulation resistance measurements are made by applying megohmmeter voltage
to transformer windings individually and in combination (see Table 3.2.1). All
windings not under test are connected to ground. Connections are made so that no
winding “floats” at an unknown electric potential with respect to ground potential.
2
WINDING INSULATION RESISTANCE TEST
Test Readings (Results) &
The insulation resistance of a transformer can vary due to
• moisture content,
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Acceptance Values
• cleanliness,
• Temperature of the insulation parts.
Since the value of the resistance varies with temperature, all measurements are
corrected to 20°C for comparison purposes. Table 3.2 provides a list of temperature
correction factors used for liquid-filled transformers. To correct measurements to
their 20°C reference, multiply the measured value by the corresponding correction
factor shown in the table.
Example:
The megohmmeter reading for a winding insulation resistance test is found to be
256 megohms with the winding temperature at 45°C.
To correct the resistance measurement to the 20°C reference, determine the
correction factor for the measurement temperature and use it to multiply resistance
reading.
Correction Factor (45°C) = 4.5
R20°C = (R45°C)(Correction Factor (45°C))
R20°C = (256 megohms)(4.5) = 1152 megohms
Insulation resistance measurements should be compared to their factory and
historical baseline values for acceptable level. Table 3.3 provides a Rule of Thumb
that can be used as a guide for minimum acceptable insulation resistance values for
power transformers as per coil ratings and minimum DC test voltage used.
Low insulation resistance readings are usually an indication of accumulated dirt or
the presence of moisture. Dirt and other foreign materials should be cleaned from
the bushing connections.
• The benefit of using a voltage as high as possible is to enhance the sensitivity of
the test, meaning a larger megohm value can be measured. The risk of high test
voltage is that the insulation might actually begin to “break down” which would
yield a meaningless resistance reading and possibly cause damage.
• Take care to discharge the capacitance of each winding before and after each
test.
• Never perform an insulation resistance test on a transformer that is under
vacuum.
Definition
A ratio of the Megohm resistance at the end of ten minutes compared to the results
at the end of a one-minute test.
IEC 76-1
Purpose
The purpose of the Polarization Index test is to determine if the equipment is
suitable to be operated.
3
POLARIZATION INDEX
Making A Test
Perform the test in this manner using a constant DC voltage:
1. Take a Megohm reading at the end of one minute of
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operation and record the results.
2. Take the second set of readings at the end of each minute of operation (one
minute intervals) for ten minutes. Record and carefully evaluate the readings at
each one minute interval in case there is breakdown. Calculate the ratio of the 1
minute reading to the reading at the end of the ten minutes. Do this by dividing the
one minute reading by the ten minute reading.
The result is the ratio (index).
Connections are the same as part 2.
Results must be taken at a constant voltage. The megger produces a high DC
voltage that is applied to the insulation being tested. The best voltage is one that is
near the specified line voltage. This DC voltage causes a small current to flow
through and over the surface of the insulation. The total current through and over
the insulation is made up of three components:
1. Charging current due to the capacitance of the insulation being measured. This
value drops from maximum to zero very quickly
2. Absorption current due to molecular charge shifting in the insulation. This
transient current drops to zero more slowly.
3. Leakage current which is the true conduction current of the insulation. The
leakage current varies with the test voltage. It may also have a component due to
the surface leakage, particularly due to surface contamination. That is why all
surfaces must be clean.
If moisture is present, the leakage current increases at a faster rate than the
absorption current.
Under these conditions, the Megohm readings will not increase as fast as insulation
in good condition. This results in a lower Polarization Index (value).
Table 3.3.1 allows you to evaluate the condition of the insulation according to the
value of the index.
• Ensure that the DC voltage used is absolutely constant.
• There can be no variation. Any variation at the source will give different readings
and thus give false results.
Definition
Winding resistance measurements are made to determine if any changes have
occurred in the current carrying path of the transformer. The DC Winding resistance
test will indicate a change in dc winding resistance when there are short circuited
turns, poor joints or bad contacts.
4
WINDING RESISTANCE TEST (ALL
IEC 76-1 , Clause 10.2
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Purpose
• Calculation of power (I2R) component of conductor losses
• To determine the temperature rise under load and for Calculation of winding
temperatures at the end of a temperature test
• As a base for assessing possible damage
• To show changes in winding resistance due to short circuited winding turns, poor
joints, or bad contacts.
• To determine if damage to the windings and/or their connections exist.
• To calculate the resistance component of the voltage drop under load
• To ascertain that the internal connections are correct.
Making A Test & Test Connections (Circuit)
1. Wheatstone Bridge (Figure 3.4.1)
The circuit consists of four resistance arms, a source of current, and a null detector.
The measurement of the Runknown is made in terms of the three known resistances.
The three resistors RA, RB and Rvariable are adjusted for zero current in the null
detector circuit. When the bridge is balanced, as indicated by a null reading of the
detector, the unknown resistance is obtained. The formula for calculating the
Runknown resistance is as follows:
Runknown = RA Rvariable / RB
where RA and RB = Values of the ratio resistors
Rvariable = Value of the standard resistor
Runknown = Unknown resistance to be measured
2. Kelvin Bridge (Figure 3.4.2)
A four-terminal low-resistance ohmmeter that operates
on the principle of a double bridge. The Kelvin bridge is
similar to the Wheatstone bridge; however, the Kelvin
circuit contains an additional set of ratio arms. When the
bridge is balanced, the unknown resistance is given in the
following equation (if RA/RB is exactly equal to Ra / Rb):
Rx = Rs (RA / RB)
3. Modem digital low resistance ohmmeters (DLRO)
The voltage drop across the resistance under test is measured by an accurate
digital voltmeter reading directly in ohms.
4. Potential drop method (Ducter): A trade name for a four-terminal moving-coil
type low-resistance test set made by AVO International Company
5. Calculation Method
Equipments: Battery, Voltmeter and Ammeter (see Figure 4.3)
Note: This is a second method that can be used to determine
the winding resistance.
The DC battery can be a 6V or 12V car battery supply power
to the windings. When meters stabilize, take voltage and AMP
reading and calculate resistance V = IR → R = V / I (Ohms'
Law) can find resistance of primary and secondary windings
same way.
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The terminal-to-terminal resistance measurement can be made with :
1. Wheatstone Bridge (Figure 3.4.4)
2. Kelvin Bridge (Figure 3.4.5)
It measures resistance in the range of 0.01 micro-ohm to
approximately 1000 ohms.
3. Modem digital low resistance ohmmeters (DLRO) (Figure 4.6)
It measures resistance in the range of 1 micro-ohm to 60 ohms.
4. Potential drop method (Ducter) (Figure 3.4.7)
It can measures resistance in the range of 1 micro-ohm to
1 ohm.
5. Calculation Method : Battery, Voltmeter and Ammeter
When calculating the winding resistance, it is very important to note that most
manufactures report the winding resistance measurements as if all three windings
are connected in series.
• For wye connected transformers:
Take the readings from phase to neutral (A-N; B-N; C-N) and sum the readings
Or Take the readings from phase to phase (A-B; B-C; C-A), then sum the readings
and multiply by 0.5 gives total resistance value
RPhase = (1/2) R L-L
• For delta-connected transformers:
Take the readings from phase to phase (A-B; B-C; C-A), then sum the readings and
multiply by 1.5 gives total resistance value
RPhase = (3 /2 ) R L-L
The results should indicate:
• For new transformer, +/- 2 percent of factory test values
• For old transformer, Winding resistance test results should compare within one
(1%) percent of adjacent windings.
Because resistance varies as a function of temperature, the resistance readings are
corrected or normalized to one reference temperature. The normalized reference
temperature used for transformers is equal to the rated average windings
temperature rise plus 20°C.
Correction Factors:
• For transformers with a rated 55°C rise, the normalized reference temperature is
75°C.
• In a like manner, transformers with a rated 65°C rise use 85°C as the reference
temperature.
Table 3.4.1 shows the formulas used to convert winding resistance readings to their
normalized reference.
Measured resistance converted to the standard reference temperature should not
exceed the values measured during the type test by more than 10%.
• Verify that the transformer is deenergized, that power supply devices are properly
"locked-out."
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• Remove winding circuit grounds only as needed to make the measurements and
replace when finished
• To avoid possible damage from voltages induced by the DC current causing the
magnetic field to build up and collapse on being switched on and off, the winding
whose resistance is not being measured should be temporarily short-circuited (see
Figure 3.4.3)
• Cold resistance measurements should not be made on a transformer when the
ambient temperature is varying rapidly or erratically.
• After the transformer has been under oil without excitation for at least 3 hours,
the average oil temperature shall be determined and the temperature of the
winding shall be deemed to be the same as the average oil temperature.
Definition
Core excitation is the amount of energy required to excite the transformer with no
load connected to the transformers secondary.
Core Excitation = No-Load Loss
= Iron Loss
= Core Loss
IEC 76-1, Clause 10.5
Purpose
To measure current that maintain the magnetic flux excitation in the core of the
transformer
Making A Test
The primary of transformer should have an ammeter placed in a position to
measure the exciting current when the transformer is energized with the secondary
open. This can tell if excessive current is being supplied when transformer is
energized. Excessive current could be an indication of transformer internal
insulation problems and would be the determination to investigate in more detail.
The following procedures should be followed for routine excitation current tests:
1. Apply 110%, 100%, and 90% of the rated voltage to the winding under test
(normally the tertiary) with other windings open-circuited. The voltage wave shape
should be sinusoidal.
2. Measure the three phase currents and power by three watt meter method.
3. Calculate the average current.
4. Calculate the percent excitation current with respect to the power rating (MVA)
Test Equipments / Method
Core excitation tests can be performed using the same test equipment as for power
factor testing.
Others like, Average-voltage voltmeter method (Volt-Amp-Watt meter).
5
EXCITATION CURRENT
Testing (Circuit) Connections
Figures 3.5.1 and 3.5.2 illustrate the excitation current test procedures for three-
phase wye and delta connected units respectively. Note that all excitation current
tests are performed by the Under grounded Specimen Test (UST) method.
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Excitation current should not be higher than the guaranteed value by more than
30%.
The following guidelines should be followed for routine excitation current tests:
• All loads should be disconnected and the transformer deenergized.
• Winding terminals normally grounded in-service should be grounded during tests,
except for the particular winding energized for the test. For example, with a
wye/wye transformer, the neutral of the high-voltage winding would be connected
to the UST (Under grounded Specimen Test) circuit, while the neutral of the low-
voltage winding would be connected to ground.
• Test voltages should not exceed the rated line-to-line voltage for delta connected
windings or rated line-to-line neutral voltage for wye connected windings. Generally,
these tests are made at 2.5, 5, or 10 kV as the capacity of the test equipment
permits.
Definition
Power factor is a measure of the power loss through the insulation system to ground
caused by leakage current. It is equal to the circuit resistance (R) divided by the
circuit impedance (Z).
PF = W / V I or PF = (V I cosθ ) / (V I )
The power factor of insulation is the cosine of the angle between the charging
current vector and the impressed voltage vector. In other words, it is a measure of
the energy component of the charging current. The amount of charging volt-
amperes and the dielectric loss in watts, at a given voltage, increases with the
amount of insulation being tested. However, the ratio (power factor) between the
charging volt-amperes and watts-loss remains the same regardless of the amount of
insulation tested, assuming that the insulation is of a uniform quality. This basic
relation eliminates the effect of the size of electrical apparatus in establishing
"normal" insulation values and thus simplifies the problem for the test engineer.
Actually, power factor testing is more than just "a" test. It is a series of tests on
each part of the insulation system. Insulation power-factor tests can also be made
on lightning arresters, air and oil circuit breakers, current and potential
transformers, capacitors, cable (500 feet or less) and rotating machinery, such as
motors and generators.
IEC 76-1
6
INSULATION POWER FACTOR
Purpose
• To determine the relative dryness and material quality of the insulation. It is
typically used in conjunction with other dryness indicators, such as insulation
resistance and oil dielectric
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breakdown values, to determine insulation dryness.
• To measure the power loss due to leakage current through the transformer
insulation.
• To detect any measurable change in the transformer winding insulation
characteristics.
• Gives an overall indication of the condition of the insulating system.
Making A Test
To measure the winding insulation power factor, first verify that the transformer is
deenergized and "locked-out." Then check to see that the tank is properly
grounded. Short circuit each winding of the transformer at its bushing terminals.
Connect all windings to ground except the winding to be measured. Connect the
tester between the winding(s) to be measured and ground, and measure the
capacitance and power factor.
Test Equipments/Methods
The Double power factor insulation test equipment measures the charging current
and watts-loss from which the power factor, capacitance, and AC resistance can be
easily computed at a given test voltage.( see Figures 3.6.1 and 3.6.2).
Winding Insulation P.F Test:
Standard series of power factor tests applied to windings in-service shown in table
3.6.1.
CH refers to all insulation between the high voltage winding and grounded parts,
including bushings, winding insulation, structural insulating members, and oil.
CL refers to the same parts and materials between the low voltage windings and
grounded parts.
CHL refers to all winding insulation, barriers, and oil between high- and low-voltage
windings.
Typical schematic connection diagrams for measuring the insulation power factor of
single phase and three phase transformers are shown in Figures 3.6.3 and 6.4.
When measuring the power factor of transformer windings, the number of
measurements and their connections should be in accordance with Table 3.6.2.
Bushing Insulation P.F Test:
1. Underground Specimen Test (UST) Method
Bushings can be tested in several different ways without removal from the
transformer. The most effective test method utilizes the potential taps, power factor
taps, or split-mounting flanges with which most modern bushings are equipped. This
method as shown in Figure 3.6.5 is referred to as the Underground Specimen Test
(UST).
2. Hot-Collar Method
Bushings without capacitance taps may be tested by Hot-Collar test method. This
test is applied, using single or multiple collars on transformer bushings (Figure
3.6.6) if the UST method cannot be performed or to supplement the UST test when
compound filled bushings are involved. A single Hot-Collar test is also often applied
to oil-filled bushings not equipped with liquid level gauges in an effort to detect low
liquid levels.
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• Power factor readings vary with temperature; therefore, it is necessary to correct
all readings to 20°C to allow comparison with previous and factory readings. Table
6.3 provides a list of temperature correction factors to be used for liquid filled
transformers. To correct measurements to their 20°C reference, divide the
measured value by the corresponding correction factor shown in the table.
• Compare the temperature-corrected power factor with past readings taken from
the same equipment. A generally accepted industry evaluation criterion is that a
change of 0.3% over a period of one year is considered a reason to call for more
detailed testing or inspections.
• Table 3.6.4 provides the acceptable power factor values
• For Hot-Collar Test: Since relatively low dielectric losses and currents are normally
recorded, small changes in either value can result in misleading changes in
calculated power factors. Because of this, it is recommended that Hot-Collar tests
be evaluated by comparison of currents and losses obtained for similar tests on
similar bushings and potheads. Power-factor values need not be calculated. As a
general guideline, losses up to 0.05 watt at 10 kV and 3 mill watts at 2.5 kV can be
considered acceptable.
• It is very important that power factor measurement instrumentation be well
shielded if it is used in a substation area where there may be a significant level of
electrostatic interference. Using a higher frequency power supply may help solve
the interference problem.
• When performing the test, be aware that any cable or bus left connected to the
transformer will affect the overall test results.
• Due to limitations in the test set, test voltage must not exceed test set rated
voltage.
• Contamination and moisture will affect the measured losses, so be sure the
bushings are clean and dry before testing.
Definition
Measure angular displacement and phase sequence (vector group) of the
transformer.
IEC 76-1 , Clause 10.3
Purpose
To determine angular displacement and relative phase sequence
Making A Test
• Measure the vector relationship between HV and LV by exciting the HV winding
with suitable 3 voltage (such as 380V AC)
• Measure the Vector relationship between HV and LV by exciting the HV winding
with similar voltage and connecting H1 with Y1
7
VECTOR RELATION-SHIP TEST
Test Equipments / Methods
• Phasor diagram
• Ratio bridge
• Excited voltage
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Test Readings (Results) And Acceptance Values
Vector diagram should be drawn and confirmed. Vector group shall be as per
contract.
Purpose
To monitor the transformer hottest-spot temperature and provide the most accurate
temperature reading for proper loading and operation of the transformer.
Making A Test
There are two types of hot spot indicating circuits:
• Thermometer heat-well type
• Bridge type
For oil-filled power transformers the rated maximum hottest spot winding
temperatures are 95°C and 110°C without any loss of service life of transformer.
The internal winding hot-spot temperature of the transformer winding is determined
by the load it carries, its thermal characteristics, and the temperature of its cooling
liquid and the ambient temperature around the transformer.
Typical indicators used on transformers have scales that begin at 0°C and go to
120°C maximum, some have 160°C maximum and the scales can be even higher
scales dependent on the type of transformer.
8
WINDING TEMPERATURE INDICATOR (WTI) TEST, HOT-SPOT TEMPERATURE
INDICATOR
See Figure 3.8.1
Purpose
To protect the transformer from excessive temperature and also to permit it to be
loaded to its maximum safe-operating temperature.
9
Oil Temperature Indicator Test
Making A Test & Test Readings (Results) & Acceptance Values
To determine the nominal expected temperatures that might be read from the
indicator, consider that liquid-filled transformers are rated to have either a 55°C or
a 65°C average winding temperature rise above ambient when measured by
resistance. Using a 65°C rise with a 30°C ambient means that the transformer
winding should not exceed 95°C when operated at nameplate rated kVA. Since all of
the heat generated by the windings is transferred to the liquid, the liquid will
gradually approach the temperature of the windings, but with a time lag. As a
result, when the transformer is operated within its rating, the liquid temperature
should never exceed 95°C.
Definition
The definition of impedance volts is the percent of rated high-voltage impressed on
the high-voltage winding to produce rated full-load current in the short-circuited
low-voltage winding.
This percentage is the same percentage of rated low voltage impressed on the low-
voltage winding to produce rated full-load current in the short-circuited high-voltage
winding.
10
PERCENT IMPEDANCE TEST
IEC 76-1, Clause 10.4
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Purpose
To indicate the transformer’s ability to support a given secondary load with a
prescribed primary voltage drop.
Making A Test
Transformer impedance is measured by short circuiting the secondary winding and
applying a low voltage to the primary winding until rated current is circulating in the
primary winding.
Test Equipments / Methods
Ammeter, Voltmeter and Wattmeter.
The impedance is then calculated using the following formula:
Z _= Impedance = V Measured (Primary)/I Rated (Primary) ohms
The percent impedance shown on a transformer nameplate is the “impedance
voltage drop” of the transformer. The manufacturer calculates the percent
impedance (%Z) using the following formula:
%Z = (V Measured (Primary)/V Rated (Primary)) x 100
See Table 3.10.1
See Figure 3.10.1
The test must be done quickly since the windings heat-up and change the
resistance of the windings.
Definition
The turn’s ratio test uses the principle that the no-load voltage ratio on a
transformer nameplate is equal to the ratio of the number of turns in its primary
winding to the number of turns in its secondary winding. The turn’s ratio test does
not give the actual number of turns on the primary or secondary windings. It only
gives the ratio of primary to secondary turns.
IEC 60076
Purpose
• To determine if a transformer is providing the desired ratio of primary to
secondary voltage.
• To test each phase winding turn-to-turn insulation system in a transformer.
• To detect shorted or opened windings, conduct polarity checks or tap changer
failure and alignment problems.
• To verify the no-load voltage ratio of all transformer tap positions.
• To verify that the internal connections are correct and that a transformer meets
the nameplate ratings.
• The test may possibly detect high resistance due to loose connections or
grounded conductors if exciting current is also measured.
• To identify short circuited turns, wrong tap settings, errors in turn count or
mislabeled terminals
11
TURN RATIO TEST
Making A Test
A simple TTR test can be done by applying a known voltage on one winding
(primary) and measuring the voltage that is induced in the secondary.
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The TTR test set must be balance before reading the dials. The test set is balanced
when the following conditions occur:
• The test set crank is being turned.
• The voltmeter reads 8 volts.
• Ammeter (excitation current meter) reading decreases
toward zero.
• Null detector has no deflection.
To perform this test, first step is checking the test leads are connected properly.
• If needle on the null detector deflects→left = test leads are connected
• If needle on the null detector deflects→right = test leads are not connected
The next step in the testing procedure is balancing.
There are two different starting points to consider in interpretation of TTR test data.
These are balanced and unbalanced readings.
Balanced Readings: A balanced reading that is + 0.5% of the calculated turn’s ratio
is the normal indication. In this case, the transformer is fine.
Unbalanced Readings: If a balanced reading cannot be obtained, several problems
are possible. These are:
• Wrong connection or test method
• Open circuit in windings
• Short circuit in windings
Open-circuit indications are as follows:
• Normal exciting current
• Normal generator voltage
• No deflections of the null detector
Short-circuit indications are as follows:
• High exciting current
• Low generator voltage
TTR test set (Biddle). See figure 3.11.1
The basic parts of a typical turns ratio test set are:
• An AC generator coil and a hand crank
• A tapped reference transformer with LV winding and HV winding
• Three meters (an ammeter, a voltmeter and a null detector)
• Two pairs of test leads
See Figure 3.11.2.
The key to determining where to make the connections is on the transformer’s
nameplate.
• For a two winding transformer:
there is only one combination LV to HV
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• For a three winding transformer:
there are three combinations
• LV to HV
• HV to TV
• LV to TV ;
LV =low-voltage winding, HV = high-voltage
winding, TV = tertiary-voltage winding.
• For transformers with a no-load tap changer:
The turn ratio is measured between the high voltage
winding on each tap position and the rated low voltage
winding.
• For transformer with a load tap changer:
The test is repeated at different tap settings without changing the test connections.
Figure 3.11.3 is a typical test connection chart that can be used for connection of
turn ratio test of various transformer configurations. The Connection of AVO Multi
Amp Model TR-700 and TR-800 is illustrated in the figure.
When calculating the ratio, be certain to use:
R = High Voltage (L-L) / Low Voltage(L-L)
After one phase of the transformer has been tested, the test leads are removed to
the next phase until all three phases have been tested.
The following equation shows the ratio of transformer:
Expected turns ratio = High voltage rating / low voltage rating
Vp / Vs = Calculated Turns Ratio
Vp is Primary Phase Voltage
Vs is Secondary Phase Voltage
The winding voltage, phase to ground, not the system voltage, phase to phase, is
the low voltage rating that is used in the turns ratio calculation.
The voltages used depend on whether the winding is wye or delta connected and
whether the transformer has a tap changer. If the transformer has a tap changer,
the position of the tap changer must be taken into consideration.
The expected turn’s ratio value is equal to the calculated value +/- 0.5% of
nameplate values. If the value that is measured is not in this range, there is a
problem with the transformer or the test set.
• Before starting the test ensure that the TTR tester is calibrated or has been
calibrated within the past 6 months. If it has not, perform a quick calibration test
according to TTR manufacturer’s requirements.
• Make sure the test leads are connected to the appropriate terminals on the power
transformer.
• Make sure the turn ratio test set is grounding.
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Purpose
To verify the integrity of the liquid insulating system.
12
INSULATING OIL TESTS
A brief of acceptance values are shown in table 3.12.1.
Definition
The dielectric breakdown voltage of an insulating liquid is important as a measure
of its ability to withstand electric stress without failure. The dielectric breakdown
voltage is the voltage at which breakdown occurs between two electrodes under
prescribed test conditions. The voltage level where the electrodes spark over is
recorded as breakdown voltage of the oil being tested.
i. ASTM D 877
ii ASTM D 1816
Purpose
The dielectric breakdown voltage test serves primarily to indicate the presence of
contaminating agents such as water, dirt, carbon, or any other conducting particles
in the liquid. It does not detect acids or sludges.
A
DIELECTRIC STRENGTH
(ELECTRICAL TEST)
Application / Making A Test
This test is performed by applying an AC voltage between two electrodes immersed
in an oil sample. When the current arcs across the gap between the electrodes, the
voltage at that instant is the dielectric breakdown strength.
The test cup is first cleaned, using a dry hydrocarbon solvent, then dried and filled
with the sample fluid to a prescribed level. The liquid is gently agitated to remove
air bubbles, and then allowed to stand for 3 to 5 minutes. An oil dielectric tester set
is connected to the test cup and voltage is applied at either 3 kV/second for ASTMD-
877 test cups, or 500 volts/second for ASTM-D1816 test cups until the sample
breaks down.
The test is repeated a total of five times, with one filling of the test cup. The final
value is the average of the five readings and must not vary by more than 3 kV from
any one reading top be considered valid.
• ASTM D 877
This test method uses thin flat-faced cylindrical electrodes with a 2.5 mm gap.
Applied for OCB(Oil Circuit Breaker), Tap Changer, LPOF (Low Pressure Oil Filled)
Applied Voltage = 3 KV
• ASTM D 1816
This method uses spherically shaped electrodes with a 1 mm gap.
Applied for Power Transformer
Applied Voltage = 0.5 KV
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These are kV values for the various conditions of oil:
• Old oil > 25 kV is good oil
• Oil with 24 kV is bad oil
• New oil 35 kV
This test should be done by Oil Tester in the laboratory of the company.
The acceptance values for this test vary with the test method and operating
experience.
• For KV = 69 , 115, 230
Acceptance Result = 22 KV
• For KV = 380
Acceptance Result = 25 KV
The ASTM-D1816 test is more sensitive to small amounts of contamination and is
therefore primarily used to test new fluid.
Definition / Purpose
The neutralization number is a measure of the acidic constituents of the oil.
Transformer oil becomes acidic due to oil oxidation. In new oil, any acid present is
likely residual from the refining process. In a service-aged liquid, the NN is a
measure of the acidic byproducts of the oxidation of oil.
The test specifically determines the number of milligrams of potassium hydroxide
(KOH) required neutralizing the acid in one gram of the liquid sample.
ASTM D 974
Making A Test
Acidity can be measured in the field using a spot test. The spot test is made by
applying drops of an acidity buffer solution to a piece of filter paper, and allowing it
to soak in. Two drops of oil are then added to the same place, followed by one drop
of an indicating solution. This combination causes a color change that is compared
to a standard color chart.
B
NEUTRALIZATION NUMBER (ACIDITY)
(CHEMICAL TEST)
The results of the test are expressed in mg KOH/gm. The rating of the standard
color chart are as follows:
_ Green and yellow - 0.3 mg KOH/gm
_ More green than yellow - less than 0.3 mg
_ More yellow than green - more than 0.3 mg
_ Orange or brown - high acidity
_ Blue – alkaline
• The maximum acceptance test is 0.12 mg KOH/gm
• The minimum acceptance test is 0.25-0.35 mg KOH/g max
Typical neutralization numbers for insulating liquid when new are 0.01 to 0.03 mg
KOH/gm.
Good = Green & Yellow , max 0.03 mg KOH/gm
New = 0.01-0.03 mg KOH/gm
Bad = Orange, brown, high acidity
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Be aware however that orange or brown always means high acidity. This does not
mean that the oil is good or bad, but it is a good candidate for further laboratory
tests.
Definition
The interfacial tension between an electrical insulating oil and water is the measure
of the molecular attractive force between the unlike molecules at the interface. The
test generally measures the soluble contaminants or deterioration products in the
insulting fluid.
ASTM D 971
Purpose
• This test is extremely sensitive to the presence of oil decay products, and soluble
polar contaminants from solid insulating materials.
• The test provides a reliable means of detecting deterioration of the insulating
fluid.
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INTERFACIAL TENSION
(PHYSICAL TEST)
The results of the test are expressed in dynes/centimeter or millinewwtons per
meter (mN/M).
The minimum acceptance test is 22 dynes/centimeter.
Good - 40 dynes/cm min.
Bad -18 dynes/cm
• Interfacial tension for new insulating fluid is typically 40 to 45 dynes/cm.
• Insulating fluids with IFT measurements of 24 dynes/cm or greater are judged
suitable for continued service.
• Fluids with IFT measurements below 24 dynes/cm should be reconditioned or
reclaimed.
Definition
The color of insulating oil provides an indication of oil deterioration or
contamination.
• ASTM D-1524 is the standard field test for color of oil.
• ASTM D-1500 is the lab test for color of oil.
Purpose
• The purpose of the color test is to establish a baseline measure of the insulating
fluid color for a specific transformer, and then observe the rate of change in color
between inspections.
• The color of insulating oil provides an indication of oil deterioration or
contamination.
D
COLOR
(PHYSICAL TEST)
Making A Test
The color test is performed by placing a sample of the fluid in a hand-held device
referred to as a color wheel. Light is transmitted through the sample and its color is
compared with a set of standard colors mounted on a wheel. Each color is
expressed as a number and the color that most closely matches the fluid sample is
recorded as the measure of the sample. This test consists of comparing a sample of
oil against a series of standard colored disk filters, in a specially built comparator.
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New insulating fluid has a very light color identified by a low number (typically 0.5).
Color had to be compared with IFT and acidity.
Definition
The test is called the Karl Fischer Method. The water content test is performed to
determine the total water, as well as soluble water content of the oil.
It is difficult to measure, because most of the moisture in a transformer is absorbed
by cellulose winding insulation. It does not stay in the oil.
ASTM D 1533
Purpose
It detects moisture in the oil in parts per million (ppm). The reason it is important to
detect moisture is that it is absorbed by the cellulose winding insulation limiting its
insulating ability.
E
Moisture (Water) Content
(Chemical Test)
The tests for moisture content find the ppm (parts per million) water content of the
oil. This value is then used to approximate how wet the insulation is. The moisture
content for new insulating fluids is typically 20 to 35 ppm. The critical and
maximum value for this test is 22 ppm. To get acceptance values, you can find
results in Table 3.12.e.1.
The units of measure of water are mg/kg. New insulating oil received from the
manufacturer normally contains less than 25 mg/kg.
Definition
Power factor is the ratio of the power (in watts) dissipated in the oil to the product
of the effective voltage and current (in volt-amperes). The power factor measures
the leakage current through an oil
ASTM D 924
Purpose
• This is a measure of contamination or deterioration of insulating oil because of its
sensitivity to ionic contaminants.
• The drawback of the power factor test is that it is not specific in what it detects.
• A high value of power factor in oil is an indication of the presence of contaminants
or deterioration products such as oxidation products, metal soaps, charged colloids,
etc.
The Double power factor insulation test equipment
F
POWER FACTOR TEST
(ELECTRICAL TEST)
Oil samples are tested for power factor by the UST method as shown in Figure
3.12.f.1.
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• See table 6.4
• The power factor of new oil is normally 0.05% or less at 25°C. When the power
factor exceeds 0.5%, more investigation should be done.
• With consideration of other fluid parameter measurements, insulating fluids with
power factors of 1.0% at 25°C are judged satisfactory for continuous service.
Insulating fluids with power factors of 1.2% and above should be reconditioned or
reclaimed.
Definition
This test is the most used for gas-in-oil analysis and is called a dissolved
combustible gases (CG) analysis (CGA.). This test which is specified in ASTM D3612
contains the method of testing to determine the amount of dissolved gases in
insulating oil and the total amount of gases.
The key gases that are generated as a result of the electrical and thermal stresses
include hydrogen (H2), carbon monoxide (CO), carbon dioxide (CO2), methane
(CH4), ethane (C2H6), ethylene (C2H4), and acetylene (C2H2).
This gas-in-oil analysis is accomplished according to ASTM D3284, which is a field
test. A gas-in-oil test tests total gases in the oil and is accomplished according to
ASTM D3612. It is done in the laboratory.
ASTM D3284 (Field Test)
ASTM D3612 (laboratory Test)
Purpose
• To determine the amount of dissolved gases in insulating oil and the total amount
of gases.
• To determine faults caused by combustible gas.
Making A Test
ASTM D3284 ( Field Test):
The meter registers in mill amperes which can be calibrated to read directly in
percent of total combustible gases. A standard reference (baseline) gas is used. The
standard calibrating gas is a mixture of methane in nitrogen. The sample is mixed
with a fixed ratio of air and introduced into the tester through an orifice at a
pressure of one atmosphere. The meter then reads the percentage of combustible
gas in the sample. Ensure that the instrument is calibrated according to the
manufacturer’s instructions.
G
DISSOLVED GAS IN OIL ANALYSIS
ASTM D3284 (Field Test):
• A portable Combustible-gas Meter.
• The Gas Analyzer
ASTM D3612 (laboratory Test):
Two methods are used for detecting and analyzing the combustible gas content in
blanket gas samples and insulating fluid samples. The two methods are:
• The Gas Analyzer, and
• The Gas Chromatography.
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The only responsibility of the engineer is to ensure proper collection and submission
of the samples to the laboratory.
This test only requires that nine gases be analyzed during the process. It measures
the range of gases in ppm. In evaluating the total combustible gas, use the tabular
data (Table 12.g.1) below for your analysis.
A list of the types and amounts of gases in oil at normal temperature is shown in
Table 3.12.g.2.
In order to know if there is excessive CG's in the oil, you must first have a base line
for the normal solubility of gases in transformer oil.
Table 3.12.g.3 shows how much the gases will dissolve into the oil. It indicates that
normal total combustible gas detection could not detect combustible gases in these
types of transformer:
• Free breathers
• Conservator type transformers
• Transformers without air space
Gases generated in a transformer can be explosive and may cause personal injury
or death. Strict precaution should be observed when drawing samples of blanket
gas from the transformer.
Purpose
To determine any organic material in the oil.
Making A Test
The oil is drained, filtered and centrifuged to separating sediment. The sediment
samples are dried and weighed. Then, the sample is ignited and any organic
material is burned. The sample is weighed again. The difference in the weight
(weight loss) determines the amount of organic material in the insulating oil. The
presence of organic matter indicates deterioration such as sludge or contamination.
The remainder of the sample is inorganic matter which indicted contamination such
as rust.
The portion of the liquid that remains after the solubles are filtered is also tested to
determine soluble sludge and organic sludge. There are two other tests steps in this
series:
1. Soluble sludge is determined by diluting it with N-pentane, which is a
hydrocarbon. This will precipitate the sludge because it is not soluble in this
solution.
2. Identify organic sludge by determining if a sample will dissolve in acetone. If it
dissolves, it is organic, not inorganic.
H
RESISTIVITY, SEDIMENT AND/OR PRECIPITABLE SLUDGE
There are no good or bad values in the results of the test. There are three
categories of degree of organic matter in the oil; slight, moderate, and heavy.
• Moderate indicates other tests should be performed or the condition should be
investigated.
• Heavy indicates the oil should be reconditioned by filtering but other types of test
should confirm this decision.
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Definition
CURRENT TRANSFORMER: An instrument transformer that is intended to have its
primary winding connected in series with the conductor that carries the current to
be measured or controlled.
VOLTAGE TRANSFORMER: An instrument transformer that is intended to have its
primary winding connected in shunt with a power supply circuit, the voltage of
which is to be measured or controlled.
Insulation resistance tests are made to determine the insulation resistance from
individual windings to ground or between individual windings.
Insulation resistance may be measured using the following equipment:
• A variable-voltage dc power supply with means to measure voltage and current
(generally in microamperes or mill amperes).
• A megohmeter.
Insulation-resistance tests shall be made with all circuits of equal voltage above
ground connected together.
Circuits or groups of circuits of different voltage above ground shall be tested
separately. Examples of procedures include the following:
a) High voltage to low voltage and ground, low voltage to high voltage and ground.
b) Voltage should be increased in increments of usually 1 kV to 5 kV and held for 1
min while the current is read.
c) The test should be discontinued immediately if the current begins to increase
without stabilizing.
d) After the test has been completed, all terminals should be grounded for enough
time to allow any trapped charges to decay to a negligible value.
Making A Test (Procedure)
Remove the ground from the CT circuit. If relays are left connected to the CTs
during the test, the relay manufacturer should be consulted before test values
above 500V are used. A 500V megger should be connected from the CT circuit to
ground for the test readings. If a fault is detected, the cables should be
disconnected from the CTs secondary in order to determine the source of the lower
reading.
13
CT & PT INSULATION RESISTANCE TEST
The generally accepted minimum insulation resistance is 1 Megohm, but resistance
should be compared with those of similar devices or circuits. One of the most
common reasons for low readings is the presence of moisture. Drying out the
equipment and retesting should be considered before it is dismantled.
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Definition
The resistance is defined as the open-circuit voltage across the potential terminals
divided by the current entering and leaving the current terminals.
Purpose
These measurements are made on instrument transformers for the following
reasons:
• To calculate relaying accuracy of type C or K current transformers
• To establish the winding resistance at a known temperature for use in
temperature rise tests
• To calculate winding temperatures and temperature rises at the completion of
temperature rise tests
14
CT &PT WINDING RESISTANCE MEASUREMENT
Test Methods and Connections (Circuit)
1. Voltmeter-ammeter method
The voltmeter-ammeter method is sometimes more convenient than the bridge
method. It should be employed only if the rated current of the transformer winding
is 1 A or more. Digital voltmeters and digital ammeters of appropriate accuracy are
commonly used in connection with temperature-rise determinations.
To use this method, the following steps should be taken:
a) Measurement is made with direct current, and simultaneous readings of current
and voltage are taken using the connections of Figure 3.14.1. The required
resistance is calculated from the readings in accordance with Ohm’s Law. A battery
or filtered rectifier will generally be found to be more satisfactory as a dc source
than will a commutating machine. The latter may cause the voltmeter pointer to
vibrate because of voltage ripple.
b) To minimize errors of observation,
1. The measuring instruments shall have ranges that will give reasonably large
deflection.
2. The polarity of the core magnetization shall be kept constant during all resistance
readings.
c) The voltmeter leads shall be independent of the current leads and shall be
connected as closely as possible to the terminals of the winding to be measured.
This is to avoid including in the reading the resistances of current-carrying leads
and their contacts and of extra lengths of leads. To protect the voltmeter from
injury by off-scale deflections, the voltmeter should be disconnected from the circuit
before switching the current on or off. To protect test personnel from inductive kick,
the current should be switched off by a suitably insulated switch. If the drop of
voltage is less than 1 V, a potentiometer or mill voltmeter shall be used.
d) Readings shall not be taken until after the current and voltage have reached
steady-state values. When measuring the cold resistance, preparatory to making a
heat run, note the time required for the readings to become constant. That period of
time should be allowed to elapse before taking the first reading when final winding
hot resistance measurements are being made. In general, the winding will exhibit a
long dc time constant. To reduce the time required for the current to reach its
steady-state value, a non-inductive external resistor should be added in series
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with the dc source. The resistance should be large compared to the inductance of
the winding. It will then be necessary to increase the source voltage to compensate
for the voltage drop in the series resistor. The time will also be reduced by
operating all other transformer windings open-circuited during these tests.
e) Readings shall be taken with not less than four values of current when deflecting
instruments are used. The average of the resistances calculated from these
measurements shall be considered to be the resistance of the circuit. The current
used shall not exceed 15% of the rated current of the winding whose resistance is
to be measured. Larger values may cause inaccuracy by heating the winding and
thereby changing its temperature and resistance. When the current is too low to be
read on a deflecting ammeter, a shunt and digital mill voltmeter or potentiometer
shall be used.
2. Bridge methods
2.1. Whetstone Bridge
The Wheatstone bridge consists of a pair of ratio arms,
an adjustable resistance arm for achieving balance, and
an arm containing the resistance to be measured. In the
commercial versions, the ratio arms are equipped so that
any one of several ratios can be readily selected. Thus,
resistances can be measured over a wide range with
maximum resolution available from the adjustable arm.
2.2. Kelvin Bridge
The double-ratio arm bridge is more complex in both its
design and its operation. Text books in electrical
measurements contain excellent discussions of the bridge
in addition, should be consulted. Generally speaking, the bridge
measures a four-terminal resistance in such a way that its
points of attachment to the measuring circuit and its lead
resistances do not enter into the measurement.
To avoid errors due to the time required for the bridge current to become constant,
the time required shall be determined during the measurement of the winding
resistance reference temperature.
All secondary leads to the devices should be disconnected for this test.
Measurements should be performed at the full tap and all other multiple ratio taps
and recorded. Upon completion of this test, the CT should be demagnetized as
described in the SATURATION TEST, because of the DC applied with the resistance
bridge.
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Definition
The designation of the relative instantaneous directions of the currents that enter
the primary terminals and leave the secondary terminals during most of each half
cycle. Phase-relation tests are made to determine angular displacement and
relative phase sequence.
Purpose
To prove that the indicated polarities that are marked on the CT are correct.
An analog DC meter shall be used for this test.
While testing for polarity of the CT, it should be noted that there are additive and
subtractive polarities involved with CT’s.
• Subtractive is the normal case, in which H1 on the high side would be the same
polarity in respect to X1 secondary.(Figure 3.15.1)
• Additive polarity would have H1 polarity on the high side the same polarity in
respect to X2 secondary.(Figure 3.15.2)
When testing polarity by using a battery, a battery of 6 to 12 volts, with terminals
for connections, is preferred. This is also referred to as a DC flick test. See Figure
3.15.3 and 3.15.4 for a typical connection. If a bushing current transformer installed
in a power transformer is being tested by connecting the battery to the power
transformer terminals, the other windings on the same phase of the power
transformer may be short circuited in order to obtain a reading. It is necessary to
demagnetize any current transformer that is tested by using DC voltage across a
winding.
To determine the polarity of instrument transformers using this method, do the
following:
1. Connect terminal 1 of the high-turn winding to terminal 1 of the low- turn
winding. In most cases, the high turn winding of a current transformer is the X1-X2
winding, and the high-turn winding of a voltage transformer is the H1-H2 winding.
2. Connect a dc voltmeter across the high-turn winding.
3. Connect a battery across the high-turn winding so that the voltmeter will read up
scale.
4. Disconnect the voltmeter from terminal 2 of the high-turn winding and connect it
to terminal 2 of the low-turn winding.
5. Break the battery circuit and observe the direction of kick on the voltmeter. If the
voltmeter kicks down scale, terminal 1 of the high-turn winding and terminal 1 of
the low-turn winding are of the same polarity.
6. Check the results by remaking and breaking the battery circuit. If both terminals
1 are of the same polarity, the voltmeter will kick up scale on make and down scale
on break.
• When the pointer swings in the opposite direction (negative), the polarity is
subtractive. (Battery is disconnected)
• When the pointer swings in the same direction as before (positive), the polarity is
additive. (Battery is connected)
15
CT &PT Polarity Test Or Flick Test With Battery & Phase Identification Test
• It is preferable to apply the battery voltage to the high-turn winding in order to
minimize high inductive kicks that might injure personnel or damage equipment.
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• A dangerous voltage and arcing may be generated while disconnecting the
battery from the transformer winding. Therefore, if a knife switch is not used, a hot
stick or rubber gloves must be used for connecting and disconnecting the battery.
Definition
The CT ratio is defined as the number of turns in the secondary as compared to the
number of turns in the primary.
Purpose
To verify that the CT is within its specified accuracy.
This method uses heavy cable and some type of current source, such as a generator
or a low-voltage, high-current test set.
When testing in-line CTs, the primary voltage reading can be taken across the
conductor, while the breaker bushing type will require the breaker to be closed to
take a reading across the bushings. When taking primary readings with the bushing
type CT in power transformers or reactors, correct voltage readings can be taken at
the appropriate external winding connections. To test a donut CT where it is not
possible to read across the primary conductor, pass a test lead one time through
the core of the donut CT and take a reading across the test lead for the primary
reading.
Figure 3.16.1 shows the current method of testing for ratio. The current method
uses a high-current source to pass current (up to the full rated value) into the
primary of a CT, and the amperage of the secondary is measured.
An exception is, for CT's in the delta winding of a power transformer, because the
impedance limits any significant current. Current can be injected in the Delta if the
bushings are not installed and the transformer is not filled with oil by looping test
leads though the core of the CT. Breakers that have bushing CTs must be closed to
produce primary current.
For testing CTs in the Delta of a Power transformer, a special consideration should
be taken into account. See Figure 3.16.2 for taking the measurements for the
primary. The phase to phase voltage will read 2/3 of the expected voltage. To test
the other taps on a multiple ratio CT, apply across the full winding and take
readings at each tap for calculation of other ratios. Compare tap section voltage
with the impressed voltage across the full winding.
16
CT &PT RATIO TEST BY CURRENT PRIMARY INJECTION
When injecting current into a circuit containing a Bus Differential relay, ensure the
relay manufacturer’s instructions are followed, such as jumpering a thyrite to
prevent damage to the relay. Precaution should also be taken to prevent tripping of
the bus.
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Purpose
To ensure that a CT will maintain its integrity under fault conditions. The test
verifies the integrity of the transformer windings and core.
Refer to Figure 3.17.1 for the correct connection. To perform this test, AC voltage is
applied to the secondary winding with the primary winding open. Before performing
the following test, the voltage should be increased slightly beyond the knee point
and gradually decreased to zero (to demagnetize the CT).
A variable voltage source is connected to the secondary of the CT. As the voltage is
increased in equal increments, the current should be recorded and the slope should
be plotted. The slope of the curve should remain constant until the saturation point
is reached. As the saturation point is approached, a small change of the voltage will
cause the amperage to rise rapidly. The point at which this occurs is the “knee” of
the curve. The curve plots the secondary excitation current (horizontal) against the
secondary excitation voltage (vertical).
For current transformers with taps, the secondary tap should be selected to assure
that the CT can be saturated with the test equipment available. The highest tap
which can accommodate that requirement should be used. CTs should not remain
energized at voltages above the knee of the excitation curve any longer than is
necessary to take readings.
Test results should be recorded on the data form with approximately 8 points on the
curve, with a minimum of 2 points above the knee. To determine the knee, the
manufacturer’s or reliable past test results may be used. Any substantial deviation
of the excitation curve, Figure 3.17.2, for the CT under test should be investigated.
If there is a lack of information on the curves for the CTs under test then
comparison of CTs of same model or curves of similar CTs can be used to determine
the normal readings. Deviation from expected results may indicate a turn to turn
short circuit, distortion of test supply voltage wave form, the presence of a
completed conducting path around the current transformer core or if the core is
magnetized due to a previous DC voltage test. After readings have been recorded, a
curve can be drawn by using the graph provided in the data sheet.
17
CT MAGNETIZING (SATURATION) CURRENT TEST
• During saturation and excitation tests, applied voltage should be increased and
decreased gradually. Turning off the applied voltage abruptly will magnetize the CT
core, and will affect the test results.
• The most hazardous condition is when the secondary is open with the primary
energized from the normal source. This induces a high voltage in the secondary
which is hazardous to human life and may also destroy connected apparatus and
leads.
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Definition
The part of the circuit of the secondary that is connected to the secondary winding
that determines the active and reactive power at the secondary terminals. The
burden is expressed either as total ohms impedance with the effective resistance
and reactive components or as the total volt-amperes and power factor at the
specified value of current, voltage, and frequency.
The total burden of the circuit, which is the sum of the internal CT burden and the
external connected burden, must be determined.
Purpose
To verify that no noticeable change in the CT ratio within its burden rating has
occurred. A noticeable change in CT ratio is an indication of shorted turns.
Measurements can be made of the external burden on the CT. Apply rated nominal
secondary current at the first CT shorting block after the CT. Measure the secondary
voltage across the CT circuit and multiply the current to voltage to obtain the VA.
This should not exceed the VA rating of the CT under test. See Figure 3.18.1
The following reminders have been found useful in obtaining correct burden data:
1. While performing the burden test, all parallel current transformers should be
disconnected, and all relays and other external devices must be on the operate tap.
If desired, the circuit impedance can be calculated by dividing the voltage
measured by the current applied.
2. Phase-to-neutral measurements in relay circuits can be high, particularly if
ground relays with sensitive settings are involved.
3. Phase-to-neutral and phase-to-phase measurements of bus differential circuits
can be high because of the impedance of the differential relay operating coil.
18
CT &PT LOOP RESISTANCE TEST (BURDEN TEST)
If this value is exceeded, PED should be notified to confirm circuit burden calculated
values. Burden measurements, when compared with calculated values, help to
confirm circuit wiring and satisfactory contact resistance of terminal blocks and test
devices.
Definition
Insulation power factor is the ratio of the power dissipated in the insulation in watts
to the product of the effective voltage and current in volt-amperes when tested
under a sinusoidal voltage and prescribed conditions.
Insulation power factor may be measured by special bridge circuits or by the volt-
ampere-watt method. The accuracy of measurement should be within ± 0.25%
insulation power factor.
The test specimen shall have the following:
1. All windings immersed in insulating liquid,
2. All windings short-circuited,
3. All bushings in place,
4. Temperature of windings and insulating liquid near the reference temperature of
20 °C.
Insulation power-factor tests shall be made from windings to ground and between
windings as shown in Table 3.19.1.
19
CT &PT INSULATION POWER FACTOR TEST
Test Readings (Results) and
Temperature correction factors for the insulation power factor depend upon the
insulating materials and their structure, moisture
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Acceptance Values
content, etc. Values of correction factor K listed in Table 19.2 are typical and are
satisfactory for practical purposes for use in the following equation:
where
Fp20 is the power factor corrected to 20 °C,
Fpt is the power factor measured at T,
T is the test temperature (°C),
K is the correction factor.
Definition
Intercore coupling occurs when a spurious metallic conducting path is established
which encircles more than one current transformer. It may not be detectable with
the excitation test if enough resistance is present in the conducting path.
To determine if there is coupling between cores, the excitation test should be
repeated, and the voltage across the full winding on each of the adjacent cores
should be measured one at a time with all other current-transformer secondary
windings shorted.
20
CT &PT INTERCORE COUPLING CHECK
A high-impedance voltmeter (20 000 _/V or greater) will read less than 1 or 2 V if
there is no intercore coupling. If there is coupling, the voltage will be substantially
higher.
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Three methods are presented below for demagnetizing current transformers:
1. Method1
Connect the current transformer in the test circuit as shown in figure 3.21.1. Apply
enough current to the high-turn winding (usually X1-X2) to saturate the core of the
transformer as determined by the ammeter and voltmeter readings, then slowly
reduce the current to zero. Rated current of the transformer must not be exceeded.
2. Method 2.
Connect the current transformer in the test circuit as shown in figure 3.21.2. Pass
rated current through the low-turn winding, (usually H1-H2). Increase the resistance
R in the high-turn winding, (usually X1-X2), circuit until the transformer core is
saturated; then slowly reduce the resistance to zero and disconnect the current
source. Saturation of the core is indicated by a reduction of current in the high-turn
winding circuit.
3. Method 3.
The method presented here applies only to multi-ratio CTs, since a controlled direct
current must be passed through a separate secondary section from that connected
to a flux meter, as shown in figure 3.21.3. The method requires the core to be
saturated with dc in both positive and negative directions, and then to be left in a
magnetic state midway between the two extremes. The procedure follows:
1. With the primary winding of the CT open-circuited, connect the secondary section
to a dc source and a flux meter or operational integrator, as shown in Figure 3.21.3.
2. Make certain there are no common conductors in the dc and flux meter circuits.
3. Set the flux meter pointer at about the center of the scale and smoothly increase
the direct current until the drop in the flux meter pointer speed indicates that the
region of saturation has been reached.
4. Observe the level of dc at this point and the corresponding flux meter indication,
F1.
5. Reverse the dc, maintaining the same level, and obtain another flux meter
indication, F2.
6. Now apply a trial value of dc in the opposite direction to demagnetize the core.
7. Open the dc circuit and observe the flux meter indication.
8. Repeat this operation until by successive trials the flux meter finally indicates the
arithmetic mean of F1 and F2.
21
CT &PT DEMAGNETIZATION OF CT
Safety Precautions &Warning
A continuously variable resistance must be used to avoid opening the high-turn
winding circuit when resistance values are changed, since, as the resistance is
increased, the voltage across the resistance will approach the dangerous open
circuit value.
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Purpose
The purpose is to appreciate the status of internal fabrication and dimension of
conductors which lie in GIS indirectly ensure good contact and good tied.
Test Equipment
Micro ohm meter
DC 0 ~ 600A
Test Method
Applying DC current of (100-400A) to main circuit normally and closing or opening
each earthing S/W, the resistance of each section (CB, DS, Bus, etc) shall be
measured buy voltage drop method. Injection and measurement point should be
almost same as factory test records (see diagram 1) R= V/I
22
CONTACT RESISTANCE TEST (RESISTANCE MEASUREMENT OF MAIN CIRCUIT)
Criteria
The measured value of teach section shall not exceed 1.2Ru, where Ru means the
factory test record.
Purpose
To ensure whether is any leak of SF6 gas in test object.
Test Equipment
Gas leak detector.
Test Method
Remarks 1.: should be check test equipment before start test.
Remarks 2. Should be check pressure before and after test.
After filling the reassembled sealing of point of GIS at site and inspection holes to
related gas density with SF6 gas, and wrapping the test object with finyl, it is
checked whether there is any leak in the envelopment, using halogen detector.
The checking time shall be at least 24 hours later, after wrapping the test object.
23
GAS LEAKAGE TEST (GAS SF 6 GAS TIGHTNESS TEST)
Criteria
SF6 Gas leak rate per year shall be less than 1% (no continuous leakage sound).
Purpose
This test is performed to ascertain moisture contents in SF6 gas.
Test Equipment
Dew point tester which shall be indicated temperature.
Test Method
After filling SF6 gas in test object related to rated pressure, check the moisture
content in SF6 gas using equipment.
In let valve will be connected test object and out let valve will be adjusted properly.
The moisture content and dew point temperature in SF6 gas shall have the following
criteria at rated pressure.
24
MOISTURE CONTENT MEASUREMENT IN SF6 GAS (DEW POINT TEST)
Criteria
-CB Gas Section : Less Than-30 oC
-Other Gas section: Less Than-25 oC
Purpose
The purpose is to ensure whether these switches are set to alarm and lock out
pressure correctly according to following criteria.
25
GAS DENSITY SWITCH TEST
Test Equipment
• Calibration Gauge (standard meter)
• Buzzer
• Gas filling hose between SF6 Gas cylinder and Test equipment.
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Test Method
Controlling gas pressure in test equipment, alarm and lock pressure shall be
checked with buzzer and gas gauge. Also, gas density switches together with
calibration gauge to ensure the correctness of the settings and indicators.
After completion of cabling between GIS and LCC, alarm shall be checked again
from pressure switches contact only.
Criteria
0.2 bar.
± 0.2 bar as following table.
Operation (Bar)
Gas Section
CONDITION
On
Off
High Pressure Alarm
Low Stage 1’st Stage Alarm
CB
Low Stage 2’nd Stage Alarm
High Pressure Alarm
Low Stage 1’st Stage Alarm
Other
Low Stage 2’nd Stage Alarm
Tolerance ± 0.2
Purpose
The purpose is to ensure whether these switches are set to alarm and lockout
pressure correctly according to following criteria.
Test Equipment
• Buzzer
• Calibration gauge
• Gas filling hose between SF6 Gas cylinder and test.
Test Method
Using SF6 Gas instead of air, closing lock out and tripping lock shall be checked
calibration gauge. After completion of cabling between GIS and LCC, alarm shall be
checked again from pressure switches contact only.
The pressure switch contacts of pressure switches move shall be within the value
shown in the following table, with tolerance of ± 0.2bar at each condition.
Operation (Bar)
Condition
On
Off
Closing lock out
26
AIR PRESSURE SWITCH TEST (APS CALIBRATION)
Criteria
Tripping lock out
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Purpose
The purpose is to ensure operating characteristics and to check operating time of
CB, DS and ES.
Breaker Analyzer system
CB
The operating time of 100% closing at 80% and Tripping at 60% and differential
time between each phase shall be checked at normal condition as following table.
Check with factory test.
Control Voltage
Air Pressure
Operation
Condition
%
Vdc
%
BAR
Closing
Normal
Opening
C-O
DS & ES
The operating time shall be checked at normal condition as following table. Also, it
is checked the busbar protection CTs switching scheme is satisfied or not. This test
shall be carried for only GIS excepted protection panel
Control Voltage
Operation
Condition
%
Vdc
Closing
Opening
Normal
27
OPERATING CHARACTERISTICS TEST (TIMING TEST)
Criteria
CB at normal condition
Closing Time according to factory test
Tripping time according to factory test
Differential time between each phase < 3mS
DS/ES at normal condition
Closing time according to factory test result
Opening time according to factory test
The busbar protection CTs switching scheme shall be satisfied with approved
specification.
Purpose
This test is performed to check whether MCB should be tripped or not at applied
over current time of trip inside the limit according to curve and ensure of auxiliary
contact is ok or not.
28
MCS TEST
Test Equipment
Current injection (up to AC/DC), Multi digital tester secondary injection (current)
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Test Method
After applying over current (2-3 In) of MCB, tripping time shall be measure and
compared with specification (factory test) and limit from curve.
100% will be checked as pre check after installation of LCC and 20% will be
witnessed at site.
Criteria
Shall be complied with specified MCB data or curve.
Purpose
This test is performed to check whether relay could be operated or not at applied
voltage.
Test Equipment
Secondary Voltage injection, Multi digital tester.
Test Method
After applying voltage to relay, operating time shall be measured and compared
with specification. 100% will be checked as pre-check after installation of LCC and
20% will be witnessed at site.
29
AUXILIARY RELAY TEST
Criteria
Shall be compiled with specified relay data.
Purpose
The purpose is to check looping VT circuit of all point and equipment which is
related voltage in control panel.
Injection of voltage from GIS and measurement of voltage up to LCC and control
panel.
Test Equipment
Secondary Voltage injection , Multi digital meter (Voltage)
Test Method
Applying voltage of each phase (different voltage of each phase) from VT, it is
measured voltage all point (terminal block at VT and terminal block in LCC) and
control panel
30
VT SECONDARY INJECTION (INJECTION OF VOLTAGE AND MEASUREMENT OF
VOLTAGE IN LCC)
Criteria
Measured voltage shall be same as injected voltage.
Purpose
This test is to check all GIS function including wiring which is satisfied with approved
schematic drawings.
Test Equipment
Multi digital meter
Test Method
It is to check all point including wiring, alarm, operating of device for GIS/LCC with
approved schematic drawing
31
FUNCTION TEST
Criteria
Shall be matched with approved schematic drawings.
Purpose
The purpose is to check CT turn ratio in LCC and equipment which is related current
in control panel
Test Method
Injection of current from GIS and measurement of each CT secondary current in LCC
only. Testing in control panel.
32.A
CT PRIMARY INJECTION (TURN RATIO)
INJECTION OF CURRENT
Test Equipment
• Current injection (upto 70% of rated primary current),
• Multi digital meter (Ampere)
Test Method
Applying current of each CTs from GIS ES bushing, it is measured secondary current
in LCC.
Please refer to the attached format as CT primary injection.
32.B
MEASUREMENT OF CURRENT IN LCC ONLY
Criteria
%error shall be less than 10%
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Purpose
Bus bar stability: The test is related to equipment of control panel (Accuracy,
sensitivity).
Bus bar stability: This test is checked balance of current for each CTS.
Scope Of GIS
Bus bar stability: Injection of current from GIS only.
Bus bar stability: Injection of current from GIS and measurement of secondary
current in LCC and control panel.
Test Equipment
• Current injection (upto 70% of rated primary current)
• Phase angle meter.
• Multi digital meter (Ampere)
Test Method (Bus Bar Stability)
Applying current of each CTs from GIS ES bushing, it is measured looping current (2
feeders, one is for object and other is for reference) & angle between voltage and
ampere in LCC
33
BUS BAR STABILITY (INJECTION OF CURRENT AND MEASUREMENT OF CURRENT IN
LCC ONLY)
Criteria
In coming current & out going current shall be equal.
Purpose
This purpose is to ensure whether the interlocks between CB, DS and ES will be
subjected to approved interlock table.
Test Content
Electrical interlock.
Test Method
As per approved interlock table, it will be checked whether operating will correctly
or not.
34
INTERLOCK TEST
Criteria
Shall be complied with approved interlock table
Purpose
The purpose is to ensure the dielectric strength is ok or not.
Test Equipment
High voltage applying equipment (up to 15Kv)
Test Method
Applying voltage through test bushing, this test shall be done under the normal
condition.
The test voltage shall be raised up to 10kVrms and kpt for 1min with removal of
earthing bar. Each phase and their phase earthed.
35
10KV INSULATION TEST ON EXTERNAL EARTHING SWITCH’S POLE (10KV ES
INSULATION)
Criteria
The test object is considered to be accepted, if no disruptive discharge occurs
during test.
Remarks. 1 This test should be done before H.V.T.
2. Should be discharge and earthed after finish.
Purpose
The purpose is to ensure the dielectric strength of GIS is ok. And no defective
Test Of Equipment
High voltage applying equipment and multi digital meter.
36
POWER FREQUENCY WITHSTAND VOLTAGE TEST (HI VOLTAGE TEST)
Preparation
• Consider all safety regulation
• Valid test certificate for the equipments used and check calibration during routine
test VT’s
• All tests must be ok.
• Start test with VT’s
• 10KV A.C. for ES before HVT
• CT’s shorted and earthed.
• VT’s are not included in HVT for GIS
• Link between power transformer & GIS should be removed. No power cables
included the test.
• Apply 5000V Megger before and after HVT
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• Check corona shield
• Check pressure
• Check pressure position for OB CDC
• Check PD before and after HVT
Test Method
AC test voltage level shall be equal to 80% of the factory test.
- A) Test frequency : 60Hz
- Test duration : 1 Min
- Gas pressure: Rated pressure
- Test condition
All CB & DS: Close
All ES : Open
Enclosure : Earthed
All VT DS : Open
- Under above condition, test shall be done next sequence.
In case of R phase injection: Y, B phase earthed together.
In case of Y phase injection: R, B phase earthed together
In case of B Phase injection: R, Y phase earthed together
Or through resonance test range 30 to 300hz
B) through GIS voltage transformer according to TCS – B 105 – Ro,
Criteria
Withstand
Purpose
The purpose is to ensure the dielectric strength of VT
Test Equipment
High voltage applying equipment Multi digital tester (Voltage)
Test Method
During the AC HV test on GIS, this test will be done under normal operation
condition. At 76KV secondary voltage shall be measured in LCC and 114KVrms will
be applied for 1 mint.
- Gas pressure : Rated pressure.
Test Condition
All CB & DS : Close
All ES : Open
Enclosure : Earthed
All VT DS : Close
Under above condition, test shall be done next sequence.
In case of B phase injection: R, Y phase earthed together.
36.1. GIS HI VOLTAGE TEST
Criteria
At 76kV, secondary voltage will be equal to VT specification
At 114 kV according to VF.
Purpose
Before and after Hi voltage test, it shall be checked in order to verify healthy
condition of GIS.
Test Equipment
5000V Megger
Preparation
- Gas pressure : Rated pressure.
Test Condition
All CB & DS : Close
All ES : Open
Enclosure : Earthed
Under above condition, test shall be done next sequence.
In case of B phase injection: R, Y phase earthed together.
36.2 VT HI VOLTAGE TEST
Criteria
Shall be more than 10 G Ώ
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Purpose
The purpose is to ensure the dielectric strength of long term in test object.
Test Equipment
High voltage applying equipment,
Partial Discharge Measuring System, PC meter.
Test Method
The PD test shall be performed in the place which is a shield against ambient
disturbance (etc. windy) and which has a ground system.
This test shall be done under the same condition of GIS HV test and rated pressure
before and after the AC HV test on GIS. The partial Discharge is measured at 92kV
(145/√ 3 x 1.1)1 min.
Also this test shall be done according to bellow sequence.
• In case of R phase injection: Y, B phase earthed together.
• In case of y Phase Injection: R, B Phase Earthed Together.
• In case of B phase injection: R, Y phase earthed together.
Remark: IEC-60517, clause CC 4 of Annex CC.
Voltages
Check PD
92kV
Time (duration)
37
PARTIAL DISCHARGE MEASUREMENT
Criteria
Shall be less than 10pC
Scope
After complete installation, the cables are to be identified with respect to their
phases and to be ensured the marked correctly or not and this test is very
important.
Test Equipment
Megger.
38
PHASE IDENTIFICATION
Test Procedure
One phase will be earthed while the others are unearthed.
Each Phase will be check when it is own phase is earthed and other are unearth
Through a switch ground the other end of this conductor of the cable under test and
measure the resistance.
If the resistance is negligibly very small the phase identifications is OK and check
the correct color coding is applied or not.
Other phases must be check if the resistance very high that is ok.
The method will be repeated for each phase one by one.
The test results have to be recorded in the test format.
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Pre Caution
During the test period all necessary safety measures must be strictly applied.
Calibration
Calibration must be made according to calibration procedure see Figure 3.38.1
Scope
The purpose is to ensure the sheath is Ok or not Ok and no damage.
Test Equipment
High Voltage test equipment range from 0-15 KV DC
Or 0 – 20Kv.
Preparation
Remove the semi conductive layer around 3 Cm from both end of each phase.
Place the instrument at one end of the cable 2m away from the test point.
Connect the instrument HV terminal bushing to the copper wire screen of the outer
sheath other terminal of the instrument must be connected to a good around.
Test Method
Insulation resistance with Megger
Apply 10 KV DC voltage step by step on the cable 1 min.
If there was not any break down during this period test is ok.
Insulation resistance with Megger
During the test period all necessary safety must be considered.
Calibration
Calibration must be made according to calibration procedure.
39
DC SHEATH TEST
Remarks
The leakage current has to be recorded in the DC sheath test form.
One phase under test other two phases ground see Figure 3.39.1
Scope
The resistance of conductor of the cables to be measured before any other test and
the values are to be computed at 20Co.
Reference
IEC 228
Test Equipment
• Thermometer, to measure the ambient temperature.
• Micro Ohm meter.
40
DC CONDUCTOR RESISTANCE TEST
Test Procedure
The DC current and voltage is measured
R=V/A Ohm
the conductors are Short circuited at the far end.
The other ends of the cable are connected to the bridge according to equipment
instruction.
Substituting the values in the formula, the resistance of conductor at 20o C/km will
be obtained.
The measurements are recorded in the test form.
For Copper R
R 20 =------------------------ Ohm/km
L [ 1 +0.00393,(T-20)]
For Copper
R20 Conductor resistance at 20o C(Ohm/km)
R Measured resistance of one phase (ohm)
L Exact Length (Km)
* Temperature coefficient at 20o (for copper 0.00393/K)
T Temperature of conductor when measured in oC
The conductors are short-circuited at one end, other and connected to suitable
bridge with two cables in order to measure the resistance of the conductor. Values
which may be compared with those given in
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a resistance table based on a conductor temperature of 20 o C can be determined
from above formula as resistance per kilometer. See Figure 3.40.1
Scope
The capacitance shall be measured between conductor and metallic screen.
According to IEC, the measured value shall not exceed the nominal value specified
by the manufacturer by more than 8%.
Reference
IEC 840
Test Equipment
• Capacitance Meter
• Bridge capable of measuring capacitance
Test Procedure
All metallic parts (conductor, sheath, etc) will be connected to the earthing system.
Capacitance will be measured between conductor and metallic screen.
Capacitance value will be calculated in order to get capacitance value per km
C=C/L (μf/km)
Capacitance in μF/km
Measured capacitance in μF
Cable length in km
The capacitance is measured between each individual conductor and metal sheath.
A capacitance bridge is used for this measurement. The values obtained can be
converted to μF/km.
Precautions
Calibration
Calibration must be made according to calibration procedure.
41
MEASUREMENT OF CAPACITANCE
Recording
The test result have to be recorded in the test form see Figure 3.41.1
Scope
The measurement of earth resistance is to ensure the value inside limit < 20.Ώ or
not.
Objective
It is a guideline for the test engineer to carry out the test according to the
instructions.
Test Equipment
Earth resistance tester.
Frequency Of Testing
After finishing of complete earthing.
Test Procedure
􀂙 Check the battery voltage and check all connection.
􀂙 Connect the green test cord to the terminal “E” of the instrument. Yellow test
cord to terminal “P” and rest test cord to terminal “C” respectively.
􀂙 Make sure to stick the auxiliary earth bars deep into the moist part of the earth so
that they may be aligned at an interval of about 5-10 meters from the earthed
equipment under test.
􀂙 Connect the auxiliary earth bars to the terminals of the earth resistance tester by
means of the respective test cord.
Precautions
Calibration
Calibration must be made according to calibration procedure and schedule.
42
EARTH RESISTANCE MEASUREMENT
Recording
The earth resistance has to be recorded in the earthing resistance measurement
test form. See Figure 3.42.1
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Scope
The purpose is to be ensuring the power cables, link box and sheath is OK. After
complete erection and result inside the limit.
Test Equipment
• Generator three phase min 100A-220/380V power cable + MCB
• Two multi meter
• Two telephone
Preparation
• Check supply volt and current from generator is ok or not ok
• check the cross section of supply power
• Check all connection and position for L-Box tired and short other side.
• Check contents of sheath.
• Check all safety
• Check the far and of the cable circuit
• Check good connection of testing point and the ground
• Check good solid earthed connection
43
VERIFICATION OF CROSS BONDING TEST
Test Procedure
A three-phase current between 100-150 is injected in all 3 phases. At the remote
ends the conductors are shorted with substantial shorting bars (300mm 2 copper)
All links is the link boxes are in the “as energized position
Current measured at terminations and at each link box location.
Current should not be more than 3% -- 5% of the injected valve if all the cross
bonding links are properly placed. See Figure 3.43.1
Test Equipment
• Power meter for measurement of current, voltage and power factor.
• Three phase variable transformer
Preparation For O And + Sequence
• all safety must be considered
• check stable power supply test certificate
• check position power cable from both sides
• check position for C.B. and DC and earth switch
• check good solid earthed connection
• Check rated of generator supply cable test and MCB for earth.
• Check good connection of the test point and the far end of the cable circuit and
cross section.
Calculations & Formulas
The arrangement of measurement is shown in the attached diagram. The zero
sequence impedance is given by the following formula.
Z0 = 3U0/Iph
For writing the zero sequence impedance in complex form the cos ø must be
measured.
Zo = Z0 cos ø0 + j Zo sin ø0
44
ZERO SEQUENCE IMPEDANCE
Test Procedure
3 phase power are to be injected in the cables and 3 phase measurements are to be
taken and recorded.
We are measuring the voltage (U) current I and power factor (Cos ø)
To be able to get a good measurement results, the following should be observed:
Good connection at the testing point and at the far end of the cable circuit
Solid good earthing connection.
Stable power supply. See Figure 3.44.1
Usually 100A injected current is sufficient to get a good result but
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depending on the length of the cable to be tested.
The cable circuit to be tested should be in NORMAL or ACTUAL condition like it is
ready for energization. In this case all earthing connections, link boxes earthing
connections are in NORMAL setting.
The actual measurement of zero and positive sequence will be made first and
calculations of each entity will be done based on the given formula in the test
procedures and on the test sheets.
Test Requirement
The measured values must be recorded in the test forms.
Since the measured actual values in general can substantially deviate from
calculations no guarantee values can be indicated.
Test Equipment
• Power meter for measurement of Current voltage and power factor.
• Three phase variable transformer.
Test Procedure
The arrangement of measurement is shown in the attached diagram. The positive
sequence impedance is given by the following formula.
Z + = Uo/Iph
For writing the positive sequence impedance in complex form the cos ø must be
measured.
Z+ = Z+ cos ø + + j Z + sin ø+
45
POSITIVE SEQUENCE IMPEDANCE
Test Requirement
The measured values must be recorded in the test forms.
Since the measured actual values in general can substantially deviate from
calculations no guarantee values can be indicated.
Test Instrument
Mass cylinder (1,000cc), stop watch.
Procedure
1. open the value at oil feeding side and record the pressure of test Phase.
2. Open the valve at testing side and measure the oil valve and time.
3. Same method of test for each phase.
46
OIL FLOW TEST
Measurement value is not less than theoretical value.
Theoretical oil flow:
Q= Pr 4
2.5 nL
Q Oil Flow (ℓ/sec)
P Pressure difference on the section
r Radius of oil duct (mm)
L Length of cable section (m)
n Viscosity of oil at the testing temperature (cp)
X 10E (-1)
C

Test Instrument
Mass cylinder (1,000cc), stop watch.
Procedure
1. open the value at oil feeding side and record the pressure of test phase and close
the valve.
2. Open the valve at testing side and measure the oil valve and time.
3. Same method of test for each phase.
47
OIL IMPREGNATION TEST
K is less than 4.5 X 10E(-4)
K= dV 1
V dP
V Volume of oil when installed (ℓ).
dV Volume of Oil withdrawn
dP Drop of oil pressure (kg/cm2)
Purpose
AC H.V.T. at site for power cables to be ensure the P.C. is Ok or defective after
erection
Test Equipments
AC HVT equipment as drawing, supply, control unit, step up transformer, HV
Reactor, Divider, HV Leads, Earthing system, Voltmeter.
The single component are as following:
Power Supply
Voltage: 230/400V 50-60 Hz 3 phase
Power > 200kVA
Control & Feeding Unit
The control and feeding unit contains all modules needed to feed the resonance
circuit with variable frequency. This includes an AC inverter with variable out put
frequency. Test sequence control; peak value measuring instrument and all needed
control and display elements.
The control unit allows entering all test parameter using an operator panel before
starting the automatic test sequence. A personal computer can be connected to the
serial interface to set or read the most important test parameters.
Exciter transformer
This transformer steps up the output voltage of the frequency converter (feeding
unit. to a level necessary to produce the test voltage considering the expected
quality factor of the HV circuit of both reactor and load.
HV Reactor
The HV Reactor is the heart of the resonant system.
The reactor is an oil-filled tank, characterized by its fixed value of inductance. A
special design of the core and the windings guarantees that a high quality factor
can be achieved. Variable frequency systems have the advantage of no mechanical
drive system and hence no moving parts to service. Elimination of the drive system
reduces weight as the high quality factor is doing.
48
HIGH VOLTAGE TEST
Preparation
• Consider all safety regulation
• Test certificate for the equipments.
• V.T’s must be isolated and also link. See Figure 3.48.1
• S.V.L must be isolated from all Link Box.
• Check pressure of gas.
• Position of power cable from both sides.
X
C

• Position of all L.B. according to drawings and correct position
• Position of C.B and DC from both sides
• Insulation resistance before H.V.T.
• One phase under test and other phases earthed.
• Check test equipment.
• Check earths and connection
• calculation for resonance test f = 1
2П√LC
• Check adaptor or test bushing
• Connections of phase have to be tested. See Figure 3.48.1 and Figure 3.48.2.
(*1): These safety precautions and test preparation have to be done for most types
of tests.
Table 3.2.1: Megohmmeter Connections for Testing Two Winding and Three
Winding Transformers
C

Table 3.2.2: Temperature Correction Factors for Winding Insulation
Resistance
Table 3.2.3: Rule of Thumb Test Values
C

(Megger is shown connected for measuring the insulation resistance
of the high voltage to low voltage winding and ground)
Figure 3.2.1: Schematic Diagram for Measuring the Insulation-Resistance of a
Typical Single-Phase (Two-Winding) Transformer
C

(Megger is shown connected for measuring the insulation resistance
of the high voltage to low voltage winding and ground)
Figure 3.2.2: Schematic Diagram for Measuring the Insulation-Resistance of a
Typical Three-Phase Delta-Wye Transformer
Table 3.2.4: Insulation Condition according to the value of the index.
C

Table 3.4.1: Formulas to Convert Winding Resistance to Reference
Temperature
Figure 3.4.1: Wheatstone Bridge
Note:
The connections to bridge network to the component being tested. The test leads to the
component should be as short as possible and as close to the same length as possible to
minimize errors.
C

Figure 3.4.2: Kelvin Bridge
Figure 3.4.3: Connections for Measuring Transformer Winding Resistance
C

Figure 3.4.4: Bridge Network Connections
C

Figure 3.4.5: Front Face of a Kelvin Bridge
C

Figure 3.4.6: Top View of a Digital Low-Resistance Ohmmeter
Figure 3.4.7: Top View of a Ducter
C

Figure 3.5.1: Measurement of Ie in a Wye-Connected Transformer Winding
(Routine Method)
Figure 3.5.2: Measurement of Ie in a Delta-Connected Transformer Winding
(Routine Method)
85 - 116
C

Figure 3.6.1: Typical Two-Winding Transformer Simplified Diagram
Figure 3.6.2: Dielectric Loss of Each Capacitor Divided by Capacitive Volt-
Amperes is Equal to Power Factor
C

Table 3.6.1: Standard series of power factor tests applied to windings in-
service.
Figure 3.6.3: Schematic Diagram for Measuring the Capacitance and
Insulation Power
factor from the High-Voltage Winding to the Low-Voltage Winding and
Ground for a Two-Winding, Single-Phase Transformer
(Method 1, Table 6.1)
C

Figure 3.6.4: Schematic Diagram for Measuring the Capacitance and
Insulation Power
factor from the High-Voltage Winding to the Low-Voltage Winding
and Ground for a Three-Phase Delta-Wye Transformer
(Method 1, Table 6.1)
C

Table 3.6.2: Measurements for Insulation Power-Factor Tests
(Reference: ANSI/IEEE C57.12.90-1999)
C

Figure 3.6.5: Ungrounded Specimen Test on Transformer Bushings
C

Figure 3.6.6: Hot-Collar Test Method for Testing of Bushing Insulators
Table 3.6.3: Temperature Correction Factors for Insulation Power Factor
(Reference: ANSI/IEEE C57.12.90-1999)
C

Equipment Class
% P.F Acceptance Values at 20°C
New Insulating Oil
0.05
Dried and/or New HV Transformer
0.2
Dried and/or New EHV Transformer
0.3
Paper-insulated power cables
0.3
Condenser & Oil filled bushings
0.5
Silicon Insulating fluid
0.5
New oil-filled transformers
0.5 to 1
In-Service oil-filled transformers
1 to 2
Compound-filled bushings
2.5
Askarel(Insulating Liquid)-filled power Transformer
3 to 5
Rubber-insulated power cables
4.0 to 5.0
Varnish-cambric insulated power cables
4.0 to 8.0
Synthetic Insulating fluids
12
Table 3.6.4: Acceptable Power Factor Values
Figure 3.8.1: “Hot-Spot” Indicating Circuit
C

A = Ammeter (Rated Primary Current)
V = Voltmeter (Impedance Voltage Drop)
WM = Wattmeter (Watt Loss in transformer)
Figure 3.10.1: Impedance Measurement for Transformer
Table 3.10.1: Three-Phase Power Transformer Percent Impedance (Typical
Values)
C

Figure 3.11.1: Front Panel and Leads of a TTR Test Set
Figure 3.11.2: Schematic Diagram for Transformer Turns-Ratio (TTR) Test Set
C

Figure 3.11.3: Transformers turns ratio test connection chart
C

Table 3.12.e.1: Recommended maximum limit of water content in mineral
insulating oil
of operating gas blanketed, sealed, or diaphragm conservator transformers
Figure 3.12.f.1: Liquid Insulation Cell Connected for Ungrounded Specimen
Testing
Range of Combustible Gases (ppm)
Indications
0 - 500
Satisfactory
500 - 1000
Decomposition exceeds normal aging
> 1000
Decomposition significant; requires more frequent sampling and analysis;
determine rate of trend, if increasing
> 2500
Decomposition getting extreme; monitor by frequent samples and analysis; if
any increase in trend, schedule shut-down inspection, testing and
determination of repair
Table 3.12.g.1: Evaluation of the total combustible gas
C

Table 3.12.g .2: A list of the types and amounts of gases in oil at normal
temperature.
Table 3.12.g.3: Solubility of Gases in Transformer Oil
C

A*
B*
C*
Values for voltage class
Values for voltage class
Test and method
Limit value
≤ 69kV
> 69-<230 kV
≥230kV-<345kV
≥345 kV
≤ 69kV
> 69-<230 kV
≥ 230kV
Dielectric strength
ASTM D1816-97
kV minimum,
1 mm gap:
2 mm gap:
20
35
25
45
30
52
32
55
35
60
23
40
28
47
30
50
Dissipation factor(power factor),
ASTM D924-99e1
25°C, % maximum:
100°C, % maximum:
0.05
0.30
0.05
0.40
0.05
0.40
0.05
0.30
0.05
0.30
0.5
5.0
0.5
5.0
0.5
5.0
Interfacial tension
ASTM D971-99a
mN/m minimum:
40
38
38
38
38
25
30
32
Color
ASTM D1500-98
ASTM units maximum:
0.5
1.0
1.0
1.0
0.5
Neutralization number(acidity),
ASTM D974-02
Mg KOH/g maximum:
0.015
0.015
0.015
0.015
0.015
0.20
0.15
0.10
25
20
10
10
10
27
12
10
35
20
12
Water content,
ASTM D1533-00
Mg/kg maximum:
50°C:
60°C:
70°C:
55
30
15
A*: Test limits for shipments of new mineral insulating oil as received from
the
supplier
B*: Test limits for new mineral insulating oil received in new equipment, prior
to
energization
C*: Test limits for continued use of service-aged insulating oil
Table 3.12.1: Acceptance Values of Insulating oil Tests
C

Figure 3.14.1: Connections for voltmeter-ammeter method of resistance
measurement
Figure 3.15.1: Windings: subtractive polarity Figure 3.15.2: Windings:
additive polarity
+ - +-S E C O N D A R Y PRIMARYX 1 H1CTma or mv
Figure 3.15.3: Polarity Test with Dc Voltage
C

Figure 3.15.4: Polarity by Inductive Kick
A AA C S O URC E VA R I A B L E AU T O TR A N S F O R M E R LOADINGTRANSFORMERPR O T
E C T I V E GR O U N D O N BU S H I N G C T U N D E R T E S T SECONDARY
PRIMARYREFERENCECTH1CTX1I T IR
Figure 3.16.1: Ratio Test by Current Method
H31_3V1_3VHH211_3V1.0 V120VV1_3V1_3V1_3V3V_2H21.0 VH1H3
Figure 3.16.2: Voltage Readings inside the Transformer Delta Windings
C

VAHIGH VOLTAGETEST
SOURCESECONDARYPRIMARYOPENCIRCUITX1H1
Figure 3.17.1: Excitation Test
Figure 3.17.2: Excitation Curve for Current Transformer
C

Figure 3.18.1: CT Burden Test
C

Table 3.19.1: Measurements to be made in insulation power-factor tests
C

Table 3.19.2: Temperature correction factors for insulation power factors
Figure 3.21.1: Method 1: Circuit for demagnetizing current transformers
C

C

Figure 3.38.1: Phasing check
PHASE CHECK
Switch
AV
Power Cable
RYB
Megger
C

Figure 3.39.1: 10KV D.C. Sheath Test
A
V R Y B B Y R S/S A S/S B
E.L.B
Earth Link Box
Power Cable
H.V.T
C

Figure 3.40.1: Measurement of Dc Resistance Of Conductor
+I +U -U -I
C1 P1 P2 C2 B Y R L
MICRO ohm Meter
C

Figure 3.41.1: Capacitance Measurement
……….μF
RYBBYR
……..μF
C

Figure 3.42.1: Earth Resistance Measurement
RED TEST CORD
YELLOW TEST CORD
GREEN TEST CARD
EPC
C P E MEASURING EARTHING
SYSTEM C1
EARTH RESISTANCE
METER
10-15m 10-15m
The individual ground resistance at each earthing point shall not exceed 20hm
C

Figure 3.43.1: Verification of cross bonding test at link boxes
C

Figure 3.44.1: Zero Sequence Impedance Measurement
C

Figure 3.45.1: Positive Sequence Impedance Measurement
HV Reactor
Step-up Transformer
3ø Supply
Divider Test
Object
Figure 3.48.1: Schematic Diagram of a resonant circuit with variable
frequency
Control Unit
C

R2 Out put 320 Kv
160kv
50A 50A
R1
Frequency Converter Exciter Transformer
Out put
160kv 160 kv
50A 100A
R1
Frequency Converter Exciter Transformer
Figure 3.48.2: Circuit diagram of AC H.V.T
F1
F2
F1
F2
C

Example for calculation
F=1
2П √LC
L inductance for reactor = 17 H or 18 H
Suppose Power cable 800 mm and length 5 km
Cross Section
Resistance at 20Co Ώ/KM
Cμf/km
800mm
0.0221
0.19
C is measured before during test and according to cross section up is = 0.19
μf/km
:- C = 0.19x5 = 0.95 μf
:- f = 1 = 1 1x10 6
2П√LC 2II 17x0.95
= 1000 = 1000 = 39.62
2П x 4.01871 25.2375 Hz
And also from curve same value almost
Other example
for use 2 reactor to arrive freq to 60 Hz almost
f = 1 106
2П 8.5 x 0.95
= 1 106
2П 8.075
= 56.036
TEST PROCEDURE
Planning and connection of the equipment
The AC test equipment is composed of two trailers. Trailer A contains control
unit, exciter transformer, one HV reactor and HV test cable. Trailer B contains
one HV reactor and insulation support for series arrangement 320kV.
These 2 trailers can be connected in one of three configuration with a frequency
range 30—200Hz (max 300Hz)
Configuration
Connection Mode
Rated
Maximum
Voltage
Inductance
Current
Test Power
1
Trailer A Only
160KV
17H
50A
8000Kva
2
Trailer A//B
160KV
8.5H
100A
16000kVA
3
Trailer A+B
320KV
34H
50A
16000kVA
Two reactor panel
C

The configuration depends on the system capacitance and the test voltage
required and can be deducted from the load diagram in appendix A. the
dimensions and connection method of the different configuration can be found
in appendix B.
Test Equipment Connection
Depending on the type of terminations in the system, one of the following
connection methods can be used.
Connection to Outdoor Termination.
In order to perform the test HV test instrument has to be connected to the
outdoor termination depend on the situation of the outdoor gantry and the place
required for the test trailer.
􀂙 The far end of the cable must be insolated from the other parts of the system.
􀂙 If there is a GIS termination, the cable chamber must be disconnected from
the bus—bar and filled with SF6 gas up to 4 bars.
􀂙 If there is a transformer termination, the cable chamber must be disconnected
from the bus—bar and filled with oil.
Connection to GIS – Switchgear
In order to perform the test HV test instrument has to be connected to the GIS
switchgear test bushing SF6/air or the to the test cable with SF6. T004 depends
on the kind of test bushing.
􀂙 If there is a GIS termination the cable chamber must be disconnected from the
bus—bar and filled with SF6 gas up to 4 bars.
􀂙 If there is a transformer termination, the cable chamber must be disconnected
from the bus –
bar and filled with Oil.
􀂙 The far end of the cable must be isolated from the other parts of the system.
AC Testing
According to tcs-p-105-RO(T-PRECOM-1000-R0) and recommendation from Cigre
working Group the test voltage has to be 2Uo for the period of 1 hour. No break
down should occur 152 Kv.
Precautions
During the test period all necessary safety measures must be considered.
Calibration
All used equipment must be calibrated according to calibration procedure.
Recording
The test voltage and the test frequency shall be recorded versus the test time in
the test report Format.
Electrical System
Commissioning
Manual
SECTION - B
FACTORY TESTS
TRANSMISSION
INDEX
Paragraph
page
SECTION B
FACTORY TEST
Introduction
1 - 21
Test Guidelines
1
1 - 21
Routine Tests
1–1
2 - 21
Type Tests
1–2
5 - 21
Special Requirements
1–3
5 - 21
380 KV & 132 KV Shunt Reactors
2
7 - 21
Routine Tests
2-1
7 - 21
Special Tests
2–2
8 - 21
SEC Special Requirements
2–3
8 - 21
132 KV XLPE Power Cables
3
9 - 21
Routine Tests
3–1
9 - 21
Sample Tests
3–2
9 - 21
Type Tests
3–3
10 - 21
132KV / 380KV oil filled and paper insulated cables and accessories
4
11 - 21
Type Tests on Cables
4–1
11 - 21
Routine Test on Cables
4-2
11 - 21
Special Test on Cables
4–3
11 - 21
Routine Test on Accessories
4–4
12 - 21
Type Test on Accessories
4–5
12 - 21
132KV and 380KV Gas Insulated Switchgears (GIS)
5
13 - 21
Routine Test
5–1
13 - 21
Type Tests
5–2
13 - 21
Paragraph
page
132KV and 380KV Electromagnetic Voltage Transformers for Gas
Insulated Switchgear.
6
17 - 21
Routine Tests
6–1
17 - 21
Type Tests
6–2
17 - 21
Special Tests SEC Special Requirements
6–3
17 - 21
132KV and 380KV Capacitor Voltage Transformers
7
17 - 21
Routine Test
7–1
18 - 21
Type Tests
7–2
18 - 21
Special Tests SEC Special Requirements
7–3
18 - 21
Current Transformers
8
19 - 21
Routine Tests
8-1
19 - 21
Type Tests
8–2
19 - 21
Oil/SF6 Transformer and Oil Impregnated Paper High Voltage Bushings
9
20 - 21
Tightness Test
9-1
20 - 21
Outdoor Surge Arresters
10
21 - 21
Tightness Test on Each Individual Unit
10 - 1
21 - 21
Outdoor Insulators
11
21 - 21
Visual Examination
11 - 1
21 - 21
FACTORY TESTS
Section B - Page 1 of 21
INTRODUCTION:
Purpose of this document is to verify that the factory tests being performed by the
manufacturers on the contractual electrical equipment are in line with latest IEC
standards read with SEC specifications. It is also a guideline for SEC inspectors to
check and approve the factory procedures submitted prior to the tests executions.
Factory Inspection is carried out to ensure that various equipments ordered are
manufactured/assembled with good engineering work meeting contract
specifications and design and all related tests prior to shipment are performed.
It is full responsibility of manufacturer to deliver zero defect equipment. This also
needs to be supported by all documentation which includes ‘Factory Test Records’.
SEC exercises right to do factory inspection & witness the tests and ask to fulfill deficiencies
pointed out prior to shipment of equipments. This inspection may be by SEC engineers or their
appointed Consultants/Inspecting agency.
PURPOSE:
The purpose of this section is to specify the guidelines for witnessing of factory
routine, special and type tests on the new equipments used in Saudi Electricity
Company transmission network.
NOTE:
Factory tests would be consisted of following kind of tests:
􀂉 Routine tests (to be performed on all units manufactured for client)
􀂉 Type tests (to be performed on one identical or same sample for design
confirmation purpose)
􀂉 Special tests (to be performed on few unit as agreement with client)
􀂉 SEC Requirements (to be provided with all units for client)
FACTORY TESTS
1 TEST GUIDELINES
NO
EQUIPMENT TEST DESCRIPTION
CHECKS, TEST LEVELS AND ACCEPTANCE CRITERIAS
REFERENCE
STANDARD AND REMARKS
1.0
POWER TRANSFORMERS
IEC 60076-1
IEC 60076-2
IEC 60076-3
IEC 60076-4
IEC 60076-5
1.1
ROUTINE TESTS
1.1.1
Visual inspection and dimensional checks.
Quality of paint and welding, serial no, height, width, wheels, name plate data, fans
radiators, valves open close positions, etc.
1.1.2
Measurement of insulation resistance (IR) and polarization index (PI) tests.
Measurements by 5kv megger between phase-ground and phase- phase with guard
used.
PI = insulation resistance (IR) at ten minutes value / one minute value.PI should be
greater than 1.1and IR at 10 minutes value not less than 1000 mega ohms at room
temperature.
1.1.3
Measurement of voltage ratio and vector relationship.
Turn ratio error within ± 0.5% at principal tap.
Vector group shall be as per contract.
1.1.4
Measurement of winding resistance of all taps and all windings.
Resistance shall increase or decrease with regular steps along the taps. Any abrupt
change indicates loose connection.
1.1.5
No load loss and magnetizing current measurement at 90%, 100 % & 110% rated
voltage and at rated frequency (60hz)
At 100% rated voltage, no load loss deviation shall be within ± 15% to the
guaranteed value and for no load current within + 30% of the declared value.
1.1.6
Short circuit impedance and load loss test.
Tolerance limit at principal tap for short circuit impedance volts shall be within ±
7.5 %, for load loss within ± 15 % and for overall total losses including auxiliary
power within ± 10 %.
Load losses can be asked to be referred to 105ºc instead 75ºc.
FACTORY TESTS
1.1.7
Switching impulse test (SI).
380/132/33 kv Power Transformer
SI (250/2500μs impulse shape) at test voltage 1050kv.
1.1.8
Lightening impulse test (LI).
Test with lightening impulse chopped on tail.
380/132/33 kv Power Transformer
LI (1.2/50μs) test levels 1425kv
LI test level at 1425kv
132-115-110/33KV/8.8 KV Power Transformer
Li (1.2/50μs) test levels 650 kv. Three impulses of –ve polarity to be applied
1.1.9
Separate source voltage withstand test.
38kv for graded insulation
1.1.10
Long duration induced ac voltage test (ACLD) with partial discharge measurements
as per IEC-60076-3 (2000) clause 7.4 (3 phase test)
Test sequence (um = 420kv)
raise from zero to
1.1um/√3=266kv for 5 minutes
u2 = 1.5um/√3= 364kv 5 minutes
u1=1.732um/√3=420kv 5 sec
u2 = 1.5um/√3= 364kv 60minutes with pd measurements, pd < 500pc pd at
1.1um/√3 (266kv-5minutes) < 100pc switch off to zero kv. Run eight complete
cycles. No breakdown shall occur.
Make sure induced voltage test (ACLD) with pd measurements shall be performed
at the end of all tests on windings.
1.1.11
Operation tests on on-load tap changer.
Eight complete cycles without voltage. On local controls.
AC/DC supply supervision checks.
Outputs for AVC panel.
1.1.12
Insulation resistance tests and 2kv ac withstand test on auxiliary wiring and
secondary circuits in local control panel (mkbox.)wiring function checks
Check cooler fans scheme, ac/dc supply supervision
Check functions of bucholze, oil/wdgs. Temp. Indicators, oil level indicators,
pressure relief devices etc. at mk box terminals. By using 2.5 KV megger, IR > 100
Mega Ohms
1.1.13
Insulation resistance tests on windings.
By 5kv megger, ir > 1 gegga ohms
1.1.14
Capacitance and power factor (pf) test on windings and bushings
pf < 0.4%
1.1.15
No load loss and exciting current measurement, after all dielectric tests finished.
Loss within ±15% deviation
Current within ± 30% declared vale.
FACTORY TESTS
Gas
max limits (ppmv)
hydrogen (h2)
100
methane (ch4)
70
Carbon monoxide (co)
700
Carbon dioxide (co2)
5000
Ethane (c2h6)
70
Acetylene (c2h2)
5
Ethylene (c2h4)
90
Total combustible gas continents
500
1.1.16
Complete oil analysis for dissolved gas analysis (dga)
“ppmv = part per million volume”
note:
serious or danger level s starts when the gas contents are 5 to 10 times the values
given in the above table
ASTM d3612
1.1.17
Leakage test by vacuum and overpressure test
Vacuum better than 1mbar for 30 minutes. Maximum permanent deflection 0.1% of
the horizontal length of the tank wall allowed.
Over pressure test 0.35 bars (35kpa, 5psi) above atmospheric pressure with all
radiators and accessories connected position applied on top of conservator for
24hours.
No deformation shall take place
1.1.18
Bushings current transformers tests for ratio, polarity, magnetizing characteristics
and verification of terminals markings after completed assembly.
This test is performed for verification of correct ct ratio and class as per approved
protection schemes and drawings
Carry out prim. Inj. And check sec. currents at mk box terminals
1.1.19
Core ad clamp megger test by 2kv megger.
IR value shall be more than 10 mega ohms.
1.1.20
Separate source voltage withstand test.
33/8.8 KV Power Transformers
Test voltage for 8.8kv winding at 38kv for one minute.
Test voltage for 33kv windings at 75kv for one minute.
1.1.21
Short duration ac withstand voltage test (ACSD) as per clause 7.2.1- IEC-60076-3-
(2000) to the uniformly insulated HV windings
ACSD test performed by balanced three phase injection on LV side and voltage
raised, and not exceed double the phase-phase voltage on line (66kv for 33kv
windings and 27.5kv for 8.8kv windings). No pd measurements required normally.
1.1.22
Capacitance and power factor test on windings and bushings.
Pf < 0.5%
FACTORY TESTS
1.2
TYPE TESTS
1.2.1
Gas analysis, before, during and after temperature rise tests
For analysis and comparison of gas results before and after temperature rise test
1.2.2
Temperature rise tests ONAN and ONAF conditions at rated powers.
In case of prior agreement with contractor / manufacturer, the temperature rise test
can be performed at an ambient temperature of 55ºc.
1.2.3
Pressure test
Tank pressure limit ≤ 203kpa (2.03bar) absolute
IEEE
c57.7.00.1993
1.2.4
Lightening impulse test.
33/8.8 KV Power Transformers
Li test for 33kv = 170kv PK and for 8.8kv = 95kv PK. Thee –ve polarity impulses to
be applied with no failure.
1.2.5
Gas analysis, before, during and after temperature rise tests
1.3
SPECIAL REQUIREMENTS
1.3.1
Short duration ac withstand voltage test (ACSD) as per clause 7.3- (a) & (b) IEC-
60076-3- (2000) phase to earth and phase to phase tests. If this test is specified as
routine test then switching impulse test no 7 as routine test above shall be
cancelled.
380/132/33KV Power Transformer
ACSD test sequence (um = 420kv)
• raise from zero to
• 1.1um/√3=266kv for 5 minutes
• u2 = 1.3um/√3= 285kv 5 minutes
• u1=test level 570kv – 36 sec
• measure pd level at u2 = 1.3um/√3= 285kv- 5minutes, pd < 300pc
• 1.1um/√3 =266kv-5minutes.
Lower voltage and switch off
raise from zero to
u1=1.75um/√3=253kv 5 sec
u2 = 1.5um/√3= 125kv 60minutes
pd at 1.1um/√3 (92kv-5minutes) <
FACTORY TESTS
Long duration induced ac voltage test (ACLD) with partial discharge measurements
as per IEC-60076-3 (2000) clause 7.4.
Test certificates of all auxiliary protection devices like winding and oil temperature
gauges, bucholze relays. Pressure relief devices. Bushings, bushing CTs, fan motors
and any other device installed on the test object.
Name plate, all labels, wiring ferrules, terminal blocks, paints, wheels, and control
panel shall be as per sec approved and prequalified materials.
500pc
switch off to zero kv
Run eight complete cycles.
No breakdowns
raise from zero to
u1=1.75um/√3=420kv 36 sec
measure pd level at u2 = 1.5um/√3= 364kv- 5minutes,
1.1um/√3 =266kv-5minutes
lower voltage and switch off
1.3.2
Acoustic sound level measurement.
Maximum sound level shall not be more than 65 db (a)
IEC-60076-10
1.3.3
Zero sequence impedance tests.
1.3.4
Measurement of harmonics on the no load current.
1.3.5
Tank wall vibration measurement.
Vibration amplitude less than 100 micro meter (peak to peak
1.3.6
Measurement of cooling equipment power consumption.
FACTORY TESTS
2.0
380 KV & 132KV SHUNT REACTORS
IEC 60076
2.1
ROUTINE TESTS
2.1.1
Visual inspection and dimensional checks.
Quality of paint and welding, serial no, height, width, wheels, name plate data, fans
radiators, valves open close positions, etc.
2.1.2
Measurement of insulation resistance
Measurements by 5kv megger between phase-ground and phase- phase with guard
used.
Pi = ir (10 minutes value)/one minute value > 1.1. Ir at 10 minutes value not less
than 1000 mega ohms.
2.1.3
Measurement of tan delta and capacitance of bushings and winding.
Pf less than 0.4%
2.1.4
Measurement of winding resistance and inductance.
2.1.5
Separate source withstand test.
38kv for hv neutral graded insulation
2.1.6
Full wave lightening impulse test at line and neutral.
Refer to IEC 60076
2.1.7
Short duration ac withstand voltage test (ACSD) as per clause 7.3- (b) IEC-60076-3-
(2000) phase to phase tests with partial discharge measurements.
Refer to IEC 60076
2.1.8
Acoustic noise level measurement
Noise level < 85 db (a)
2.1.9
Tank vibration measurement test.
Vibration amplitude less than 100 micro meter (peak to peak
2.1.10
Measurement of loss and reactance.
2.1.11
Impedance measurement test
2.1.12
Zero sequence measurement tests.
2.1.13
Mutual reactance measurement test.
FACTORY TESTS
2.1.14
Leakage test by tank overpressure and full vacuum.
Vacuum better than 1mbar for 30 minutes. Maximum permanent deflection 0.1% of
the horizontal length of the tank wall allowed.
Over pressure test 0.35 bars (35kpa, 5psi) above atmospheric pressure with all
radiators and accessories connected position applied on top of conservator for
24hours.
No deformation shall take place
2.1.15
Insulation resistance tests on auxiliary wiring. in mk box
Wiring functions check in mk box.
By 1kv megger.
Ir > 100 mega ohms
Check - ac/dc supply supervision
Check functions of bucholz, oil level indicators, and oil/wdg. Temp. Indicators,
pressure relief devices etc. At mk box terminals
2.1.16
Complete oil analysis tests.
Refer to clause 1.1.16 above
2.1.17
Bushings current transformers tests for ratio, polarity, and mag curve & verification
of terminals markings after completed assembly.
Carry primary inj. And check sec currents in mk box terminals, check ct short &
isolate facility
2.2
SPECIAL TESTS
2.2.1
Harmonics & magnetic characteristics measurements.
2.2.2
Measurement of power taken by cooling fans if applicable.
2.3
SEC SPECIAL REQUIREMENTS
2.3.1
Test certificates of all auxiliary protection devices like winding and oil temperature
gauges, bucholze relays. Pressure relief devices. Bushings, bushing CTs, fan motors
and any other device installed on the test object.
2.3.2
Name plate, all labels, wiring ferrules, terminal blocks, paints, wheels, and control
panel shall be as per sec approved and prequalified materials.
FACTORY TESTS
3.0
132KV XLPE POWER CABLES
IEC-60840
1999
3.1
ROUTINE TESTS
3.1.1
Partial discharge test 1.5uo with prestress voltage 1.75uo-10sec
Pd less than 10 pc
3.1.2
Power frequency voltage test at tests voltage 2.5uo-30 mints
Test level = 190kv ac
3.1.3
25 kv dc withstand test on sheath insulation
No break down
3.2
SAMPLE TESTS
3.2.1
Measurement of electrical resistance of conductor.
3.2.2
Measurement of thickness of insulation and non-metallic sheath
3.2.3
Measurement of thickness of metallic sheath
3.2.4
Measurement of diameters for all metallic parts.
3.2.5
Hot set test xlpe insulation
3.2.6
Measurement of capacitance.
3.2.7
Void contaminant determination and screen protrusion test
3.2.8
Cable core eccentricity checks
3.2.9
Swellable tape tests as
a. Tensile strength
b. Swelling height
c. Swelling speed
d. Volume resistivity
e. Thickness measurements
3.2.10
Aluminum foil test
a. Thickness measurement
b. Tensile strength and elongation
c. PE peeling strength
Overlap peeling strength.
FACTORY TESTS
3.3
TYPE TESTS
3.3.1
Bending test followed by pd test
3.3.2
Tan and Measurement
3.3.3
Heating cycle voltage test followed by pd test
3.3.4
Impulse withstand test followed by pd test.
3.3.5
Bending test followed by pd test
3.3.6
Tan and Measurement
FACTORY TESTS
4.0
132KV / 380KV OIL FILLED & PAPER INSULATED CABLES AND ACCESSORIES
IEC 60141-1
4.1
TYPE TESTS ON CABLES
4.1.1
Dielectric loss angle/temperature test
(Clause 17 IEC 141-1).
4.1.2
Dielectric security test (clause 18 IEC 141-1).
4.1.3
Lightening impulse voltage test (clause 19 IEC 141-1)
4.1.4
Ac voltage test after impulse test.
4.2
ROUTINE TEST ON CABLES
4.2.1
Conductor resistance test.
4.2.2
Capacitance test.
4.2.3
Dielectric loss angle test.
4.2.4
Ac high voltage test 1.67uo+10kv –15 minutes.
4.2.5
Sheath 25kv dc –1 minute hv test (IEC 229)
4.3
SPECIAL TEST ON CABLES
4.3.1
Measurement of insulation thickness.
4.3.2
Measurement of metal sheath thickness.
4.3.3
Measurement of thickness of sheath covering.
4.3.4
Bending test.
FACTORY TESTS
4.4
ROUTINE TEST ON ACCESSORIES
4.4.1
For joint and sealing ends
Each joint and sealing end assembly shall be tested hydraulically at ambient
temperature for 15 minutes at twice the maximum design pressure and no leakage
shall occur.
4.4.2
Pressure tank –hydraulic test
Times the max design pressure applied for 8 hours and no leakage shall occur
4.4.3
Pressure gauges
Test certificate required from manufacturer
4.4.4
Alarm pressure gauges
Test certificate required from manufacturer
4.4.5
Special test on accessories
Pressure tank -pressure/volume test as per clause 25 of IEC 141-1.
4.5
TYPE TEST ON ACCESSORIES
4.5.1
Dielectric security test (clause 29 IEC 141
4.5.2
Lightening impulse test (clause 28 IEC 141
FACTORY TESTS
5.0
132KV & 380KV GAS INSULATED SWITCHGEARS (GIS)
IEC 51-2
IEC 517
IEC 694
5.1
ROUTINE TESTS
5.1.1
Visual and constructional checks.
5.1.2
Resistance measurement on main circuit.
5.1.3
Power-frequency voltage tests on main circuit.
5.1.4
Dielectric tests on auxiliary and control circuits.
5.1.5
Partial discharge measurements
5.1.6
Pressure test on enclosures.
5.1.7
Gas tightness tests.
5.1.8
Mechanical operation tests.
5.1.9
Circuit breaker open / close timing tests.
5.1.10
Interlock tests
5.1.11
Tests of auxiliary electrical, pneumatic and hydraulic devices
5.1.12
Verification of correct wiring
5.1.13
Current transformers tests
5.1.14
GIS VT tests.
5.2
Type tests
As per clause 6.1 to 6.109 of IEC 517.
5.2.1
Switching impulse tests for 380kv GIS
SI 1050kv for 380kv
5.2.2
Lightening impulse tests
Li for 380 kv = 1425kv
Li for 132kv = 650 kv
5.2.3
Power frequency high voltage test with pd measurements.
Power frequency withstand test for 380 kv = 550kv ac ad for 132kv = 275kvac one
minute.
5.2.4
Short circuit making and breaking tests for circuit breakers.
5.2.5
Three phase peak and short time withstand current tests of main circuit and Earthing
circuits.
5.2.6
Three phase temperature rise test at rated normal current at 55 deg- c for all main
circuit.
FACTORY TESTS
5.2.7
AC POWER FREQUENCY VOLTAGE WITHSTAND LEVELS
System Rate
d Voltage
U (KV)
Highest Syst
em Voltage
Um (KV)
One Minute R
ated Power Freq
Withstand Test
Levels
(KV)
380
420 550
230
245 460
132
145 275
115
123 230
110
123 230
ASSESSMENT OF THE TESTS
1. The switchgear shall be considered to have passed the test, if each section has
withstood the specified test voltage test voltage mentioned above in table-above
without any disruptive discharge.
2. In the case of flashover, the test can be repeated to find the discharge location.
3. If the flashover occurs during the test period and voltage still holds, then test
should be completed by keeping the test voltage fully one minute after flash over in
self-restoring insulation as gas.
FACTORY TESTS
5.2.8
BASIC IMPULSE LEVELS (BIL)
Basic i
mpulse levels (BIL) System
Rated
Voltag
e
U (KV)
Highes
t
System
Voltag
e
Um (KV
) Lighte
ning Impulse
1.2/50
μsec
Withstand
Level P
eak (KV) Switch
ing Impulse
250/25
00 μsec
Withst
and Level Peak
(KV)
380 420 1425 1050
230 245 1050 NA
132 145 650 NA
115 123 550 NA
110 123 550 NA
69 72.5 325 NA
34.5 36 170 NA
33 36 170 NA
8.8 17.5 95 NA
11 14.5 75 NA
TEST CRITERIA FOR VARIOUS EQUIPMENTS INCLUDING GIS & SWITCHGEARS
No of impulses to be applied
Test criteria
Test object
For
Um < 300kv
For
Um >= 300kv
For
Um < 300kv
For
Um >= 300kv
IEC
Ref.
Current and Voltage
Transformers
Fifteen each
Positive and Negative
Polarities
Three each
Positive and Negative
Polarities
No disruptive discharge in the solid insulation.
No more than two Flashovers, in gas insulation
No disruptive discharge.
IEC-185 and 186
Bushings
Five each
Positive & Negative
Polarities
NA
No disruptive discharge
NA
IEC-137
Medium and High Voltage
Switchgears Air and
Gas Insulated
Fifteen each
Pos & Neg
Polarities
Three each
Pos & Neg
Polarities
No disruptive discharge In the solid insulation.
No more than two Flashovers in gas Insulation
No disruptive
Discharge.
IEC - 694
Power Transformers
& Reactors
Three full wave, each of Pos and
Negative Polarities after gradual
As per Clause
14 IEC 76-3
IEC 76-3
& 722
FACTORY TESTS
increase by 50% and 75%, till 100%
Chopped wave as per clause
8.3 IEC 76-3
5.2.9
REQUIREMENTS OF NEW SF6 GAS
SF6 which is delivered in cylinders in liquid phase, contains impurities with in the
limits imposed by IEC 376 as under.
IMPURITIES
MAX LIMIT
Carbon Tetra fluoride (Cf4)
0.03%
Oxygen + Nitrogen (Air)
0.03%
Water
15ppmM
Carbon dioxide (Co2)
TRACES
HF
0.3ppmM
SF6 should be 99.9% pure
FACTORY TESTS
6.0
132KV & 380KV ELECTROMAGNETIC VOLTAGE TRANSFORMERS FOR GAS INSULATED
SWITCHDEAR.
IEC-186
IEC 44-4
6.1
ROUTINE TESTS
6.1.1
Verification of terminals markings
6.1.2
Power frequency tests
6.1.3
Partial discharge test
6.1.4
Tests for accuracy
6.2
TYPE TESTS
6.2.1
Temperature rise test
6.2.2
Ferro-resonance tests
6.2.3
Transient response test
6.2.4
Tests for accuracy
6.3
SPECIAL TESTS
SEC-SPECIAL REQUIREMENTS
6.3.1
Windings resistance
6.3.2
Megger test
6.3.3
Vt primary isolation device operational tests
6.3.4
Verification of primary isolation gap to withstand rated power frequency high
voltage withstands tests.
FACTORY TESTS
7.0
132KV & 380KV CAPACITOR VOLTAGE TRANSFORMERS
IEC-186
IEC 44-4
7.1
ROUTINE TESTS
7.1.1
Verification of terminals markings
7.1.2
Power frequency tests
7.1.3
Partial discharge test
7.1.4
Tests for accuracy
7.2
TYPE TESTS
7.2.1
Temperature rise test
7.2.2
Ferro-resonance tests
7.2.3
Transient response test
7.2.4
Tests for accuracy
7.3
SPECIAL TESTS SEC-SPECIAL REQUIREMENTS
7.3.1
Dissipation factor and capacitance measurement tests
7.3.2
4kv insulation test on hv neutral terminal with ground.
FACTORY TESTS
8.0
CURRENT TRANSFORMERS
IEC-185
IEC-44.4
8.1
ROUTINE TESTS
8.1.1
Determination of error according to the requirement of the appropriate accuracy
class.
8.1.2
High voltage power frequency dry withstand test between primary winding and
secondary winding at 3kv –1 minutes (sec winding grounded).
8.1.3
High voltage power frequency dry withstand test between secondary winding and
earth at 3kv –1 minutes. All other windings grounded.
8.1.4
High voltage power frequency dry withstand test between primary winding and
earth at 3kv –1 minutes (all other windings grounded).
8.1.5
Inter turn insulation test
8.1.6
Verification of terminal marking and polarity test.
8.1.7
Composite error test
8.1.8
Magnetizing characteristic curve test to know knee point voltage
8.1.9
Primary/secondary winding resistance test
8.1.10
High voltage test with pd measurements as per IEC 44.4
8.2
TYPE TESTS
8.2.1
Temperature rise test in case primary conductor is part of ct
FACTORY TESTS
9.0
OIL/SF6 TRANSFORMER AND OIL IMPREGNATED PAPER HIGH VOLTAGE BUSHINGS
IEC 137
9.1
TIGHTNESS TEST
9.2
Measurement of dielectric dissipation factor and capacitance
Df < 0.4%
9.3
Power frequency voltage withstand test with partial discharge measurements
Pd< 5pc
9.4
Repeat dielectric dissipation factor and capacitance measurement test.
Df < 0.4%
9.5
Lightening impulse voltage withstand test 1.2/50μs
5 full wave negative polarity impulses to be applied with no flashover.
9.6
Repeat power frequency voltage withstand test with partial discharge
measurements
Pd< 5pc
9.7
Repeat again dielectric dissipation factor & capacitance measurement test
Df < 0.4%
9.8
Measuring tap test by 3kv ac one minute along with capacitance meant by tan delta
set
No short circuit
FACTORY TESTS
10.0
OUTDOOR SURGE ARRESTERS
IEC 99-4
10.1
Tightness test on each individual unit
10.2
Residual voltage measurement test at current impulse of 10KA (8/20μs) on each
individual unit and for complete arrester.
10.3
Reference voltage measurement test at a resistive current of 5 mill amperes on
each individual unit and for complete arrester.
10.4
Partial discharge measurement test on each individual unit and for complete
arrester.
Pd < 5pc
10.5
Power losses and grading current test at cove on each individual unit and for
complete arrester.
11.0
OUTDOOR INSULATORS
IEC 233
11.1
VISUAL EXAMINATION
11.1.1
Verification of dimensions with tolerance
11.1.2
Porosity test
11.1.3
Temperature cycle test
11.1.4
Ultrasonic test
11.1.5
Galvanizing test
11.1.6
Mechanical tests
• Tensile test.
• Bending test
• Torsion test
11.1.7
Internal pressure test
11.1.8
Electrical tests
• Puncture test
• Voltage withstand test with partial discharge measurents.
• Impulse tests
11.1.9
Tests for crack indication of ground end surface
Electrical System
Commissioning
Manual
SECTION - C
DRAWINGS
TRANSMISSION
INDEX
Paragraph
page
SECTION C
DRAWINGS
INTRODUCTION
1-1
1 - 10
PURPOSE
2-1
1 - 10
PROTECTION SECTION RELATED POINTS
3
1 - 10
Drawings Quality
3-1
1 - 10
SEQUENCE OF DRAWINGS SUBMISSION
4
3 - 10
Single Line Diagram
4-1
3 - 10
Logic Diagram
4-2
3 - 10
Schematic Diagrams
4-3
3 - 10
Alarms
4-4
4 - 10
C.T. Shorting and Isolating Arrangement
4-5
4 - 10
V.T. Circuit
4-6
5 - 10
Internal Wiring and Cable Connections
4-7
5 - 10
Equipment Labeling
4-8
6 - 10
General Points
4-9
6 - 10
TESTING SECTION RELATED POINTS
5
9 - 10
Power Transformers
5-1
9 - 10
Metal Clade Switchgears and GIS
5-2
9 - 10
Test Adapters
5-3
10 - 10
Measurands
5-4
10 - 10
General Requirements
5-5
10 - 10
DRAWINGS
Section C - Page 1 of 10
1 INTRODUCTION:
Drawings are very important and play vital role in activities of commissioning and other related
S.E.C. Departments. So it is equally important to have correct drawings covering all aspects of
Scheme and details of connections.
2 PURPOSE
Objective of this section of the manual is to have Guidelines on major points of checking
drawings at each stage of commissioning activities i.e. For approval, Approval after
implementing various comments, As Built during commissioning and Final As Built after
incorporating all corrections etc. to represent truly all correct drawings.
3 PROTECTION SECTION RELATED POINTS:
3.1 DRAWINGS QUALITY:
3.1.1 Each sheet of the drawing to be marked as ‘FOR APPROVAL’, ‘APPROVED’,
‘AS-BUILT’ and ‘FINAL AS-BUILT’, as the case may be.
3.1.2 The drawing to be submitted in A3 size in a proper binder. The folding of any drawing
sheet would not be acceptable. The contents detail to be available outside the binder.
3.1.3 The Feeder/Bay name/number to be available on each sheet. The separators to be
provided to enable an easy access to each bay drawing from the index sheet.
3.1.4 Each sheet to contain the number of the following sheet invariably if numbers are not
symmetrical otherwise the sheet # oblique total # of sheets must appear on each sheet.
3.1.5 Each drawing sheet to be divided in columns and rows. The columns to be assigned by
numbers viz. 1, 2, 3… and the rows to be assigned letters viz. A, B, C… etc.
3.1.6 Proper inter-references to be added for each primary and secondary equipment and
these inter-references should include the column and row reference of the location e.g. 2E, 5D
and 4C etc. For reference, the same method should be used throughout the drawing. More than
one method for the purpose is not acceptable.
3.1.7 The date of issue of the drawing to be available on each sheet. In case of modification,
the modifications detail with date also to be added. Additionally, the name and signature of the
engineer responsible for checking and approving the drawing should be available.
3.1.8 The drawing index to be available at the beginning of each set of drawings describing the
subject of each sheet or a group of sheets and its status as 1st issue, 2nd issue and 3rd issue etc.
DRAWINGS
3.1.9 Each sheet to be titled as per the functions contained in that sheet e.g. main protection
C.T. circuit, Tripping relay-1, trip circuit for trip coil # 2, DC distribution, A.C. distribution, local
alarms and SCADA alarms, etc.
3.1.10 Each set of drawings to be assigned one and only one number. Two drawing numbers
(one from the main Contractor and one from the Sub-contractor) would not be used in any case.
3.1.11 In case of main/auxiliary relays, the detail of contacts (NO and NC) with proper
reference to the relevant drawing sheets to be available. The contacts which are not used, to be
marked as spares. Additionally, the reverse references on the relevant drawing sheets should
also be available. Indicating the relay coil and its contacts detail with reference at the end of the
drawing only would not be accepted in any case. Each reference to include some identification
mark having close resemblance with its function.
3.1.12 In case of involvement of the equipment from more than one manufacturer, the inter-
references are normally missed. This situation is not acceptable at all.
3.1.13 The exact relay model # to be indicated on the drawing.
3.1.14 The protection IN/OUT relay must be indicated in the Out Position with a note to this
effect at the bottom of the sheet.
3.1.15 The C.T., V.T. ratio and the other relevant details must appear on each drawing sheet
wherever the same are indicated.
3.1.16 All the drawing relating to a particular bay viz. GIS, LCC, Control Panel, Relay Panel,
Schematic, internal connection diagram and cable connection Schedule etc. must be contained
in one binder.
3.1.17 The drawing set for each bay must be independent. Typical drawing for any device/bay
whatsoever type it may be would never be accepted.
3.1.18 At the beginning of each set of drawings, an equipment list to be added and this should
furnish full information about each device in respect of type, rating make, the number of ‘NO’
and ‘NC’ contacts, the sheet #, location on the sheet containing that device and ordering
information etc.
3.1.19 The inter-reference would follow the contacts location and not the coil location.
DRAWINGS
4 SEQUENCE OF DRAWINGS SUBMISSION:
4.1 Single Line Diagram:
The single line diagram for the Substation to be the 1st submission and it should indicate the
positioning of each CT, VT and all devices viz. C.B’s., disconnectors, earth switches,
transformers, O.H.L. feeder, U.G. cable feeder and spare/future feeders etc. The bays to be
indicated as per physical positions. Future bays would be indicated with dotted lines.
4.1.1 The VT to be indicated clearly in respect of its being single phase or three phases. In case
of single phase, the VT phases also to be correctly indicated.
4.1.2 The designation of CT and VT if any, must be added. The ratio and other particulars of
each CT & VT core will be added.
4.1.3 SEC-CRB Standard Numbers to be added for each device, as per relevant Specifications.
Circuit label should include SEC (CRB) Bay no. also.
4.1.4 The rating of each equipment BB, CB disconnect and Earth Switch etc. to be indicated.
4.2 LOGIC DIAGRAM:
The logic diagram to follow the single line diagram. For each bay/feeder a functional logic
diagrams to be furnished. This logic diagram is to indicate the CT/VT ratio, rating, class, and
connections to the protective devices and the measuring instruments. Further, it should indicate
the IN/OUT relay, if any, trip relay and all the output functions of the trip relay viz. Trip CB # …
trip coil # … initiate CBF protection, initiate AR, block AR, alarm, auto reset circuit and inter-trip
send etc. Respective Channel no. to be indicated for Protection Signaling Equipment. Output to
local ann. Alarms & to ECC to be indicated.
4.3 SCHEMATIC DIAGRAMS:
4.3.1 All the various drawings relating to a bay viz. Schematic, GIS, LCC, relay panel, control
panel, AC distribution, D.C. distribution and SCADA interface panel, etc. along with the single
line diagram and the logic diagram (already approved under ( 1 & 2) above to be submitted for
each bay at the same time.
4.3.2 In case of various devices viz. CB, isolator, Earth switch and relay etc., the internal detail
of AC/DC circuits to be indicated. All the contacts to be indicated properly. The black box used
for representing any device is not acceptable. In case it is not possible to indicate such details,
the internal detail to be indicated up to the possible extent and a separate drawing with
complete internal detail to be attached with.
4.3.3 The typical drawing for any device whatsoever may be would not be submitted.
4.3.4 The contact # and terminal # would be available in the drawing.
DRAWINGS
4.4 ALARMS:
4.4.1 Each alarm relating to the GIS would be available in the LCC panel. In case the alarm is
related to each phase, then independent alarm would be provided for each phase. SF6 Stage-I
and Stage- II alarms would also be provided.
4.4.2 The alarms and their litra to be strictly as per SEC-CRB Specifications 15-0-10. Latest
revision.
4.4.3 Each individual alarm would be available in the FMK interface panel.
4.4.4 The alarm terminals to provide the facility for the alarm isolation without the use of screw
driver by a hand operated knife switch isolating type terminal with test sockets on both sides.
4.4.5 The detail of all the alarm terminals would be available in the panel on a metallic sheet
fixed in the panel.
4.4.6 The availability of the necessary spare alarm windows fully equipped would be checked.
4.4.7 The plug in relay/connections would not be allowed in any alarm circuit.
4.4.8 In addition to DC supply, AC supply with AC/DC converter would also be used for the
alarms and it would work as backup in case of failure of DC alarm supply.
4.4.9 In case of AC or DC supply fail alarm, a little bit delay would be introduced in order to cope
with transient jerks.
4.4.10 Each supply MCB would be equipped with an alarm contact which would alarm when the
MCB gets switched off automatically on fault or is switched off manually and such an alarm
contact would be connected to the annunciator System.
4.5 C.T. SHORTING AND ISOLATING ARRANGEMENT:
4.5.1 An 11/14 terminals arrangement would be provided in LCC Panel for C.T. shorting and
isolation. This arrangement should allow the isolation of neutral and earth connection. The relay
and Control Panels to be equipped with 8 terminals arrangement for such functions. The
arrangement should allow the insertion of 4 mm size banana plug on each side of the terminal
to measure the in service current. This arrangement should allow the shorting and isolation of
each phase individually 3-phase simultaneous shorting would, in no case, be used. This facility
would also be extended to auxiliary C.T. and those installed in LV, AC. Panels. If the same C.T.
is feeding more than one equipment e.g. a relay and fault recorder then a series type shorting
and isolating arrangement shall be used.
4.5.2 The C.T. star point would never be made directly on the C.T. secondary terminals. It
should be made on terminal block.
DRAWINGS
4.5.3 The C.T. terminals would always be covered with a Caution label as ‘Caution C.T. Circuit
short before isolating’. The label should describe the shorting and isolation process briefly. The
shorting and isolating terminals would be lapelled for their functions. It is worth mentioning that
in no case, MCB would be used for such functions.
4.5.4 For the C.T. connections, a cable having colored cores with Red, Yellow, Blue and Black
colors for Red Phase, Yellow Phase, Blue Phase and Neutral respectively would invariably be
used.
4.5.5 In case of unit protections like BBP, REF etc., the C.T. neutral in no case would be
connected to earth at more than one point.
4.5.6 The plug in type connections would never be accepted in any C.T. circuitry.
4.6 V.T. CIRCUIT:
4.6.1 Each V.T. circuit would be equipped with isolating links just before feeding any device. A
plastic cover and a label to this effect would be provided.
4.6.2 Each V.T. circuit would be properly monitored with the MCB of proper rating.
4.6.3 The V.T. secondary circuit would always be protected from the V.T. to its M.K. with proper
protection and this protection would be properly graded with the other branch protections. Each
V.T. circuit would be independently protected with MCB having alarm contact.
4.6.4 A cable containing colored cores would be used for V.T. circuit.
4.6.5 In case of open delta connection for DEF relay, the delta connection would be made in the
relay panel to allow directional on load test of DEF relay with V.T. circuit manipulation before the
delta circuit.
4.6.6 For V.T. MCB associated with Synchro check & closing Scheme, additional aux. contacts
shall be provided for the required interlocking scheme.
4.7 INTERNAL WIRING AND CABLE CONNECTIONS:
4.7.1 The Terminal Board layout drawings should indicate the external cables terminated on one
side and the internal connections made on other side of a terminal block.
A separate sheet titled ferruling methods and materials to be included. Each internal wire and
the cable termination would be ferruled as per IEC standard IEC-391 (Fig. 14d). Moreover, the
ferruling system all over the substation will be kept uniform.
4.7.2 Each of terminal block would be designated properly and this designation would be
according to the function and as simple as possible so as to facilitate the ferruling. No
DRAWINGS
terminal number should have more than 2 digits. The terminals to be grouped according to their
functions and labeled accordingly.
4.7.3 Each wire would be terminated by using an appropriate insulated lug.
The minimum size of the internal wires for C.T. and Control circuit should never be less than 2.5
mm2 and 1.5 mm2 respectively in any case.
4.7.4 The plug in type connections would not be used, in any circuit but alternately, the screwed
connections would only be used.
4.8 EQUIPMENT LABELLING:
4.8.1 Each equipment would be labeled properly and a schedule of labels would be submitted
and got approved by the Contractor from SEC. The label would include the equipment
designation and function.
4.8.2 In case of duplex type protection and control panels, the bay/feeder name/number would
be labeled outside and as well as inside the panel. The same principle would be applied to the
relays and measuring instruments. If panel has been given any designation, the same would
also be available inside and as well as outside the panel, as per schematic diagram.
4.8.3 Each piece of equipment inside a panel would be properly labeled and the detail with the
function would be available inside the panel on a metallic sheet.
4.8.4 Each trip isolation link would be properly labeled with red sleeve.
4.8.5 The paper labels would not be used in any case.
4.9 GENERAL POINTS:
4.9.1 The trip circuit supervision scheme would be provided for each C.B. irrespective of its
voltage level and this scheme should ensure continuous supervision of the C.B. trip circuit (not
only trip coil) whether the C.B. is ‘ON’ or ‘OFF’ and whether the trip signal is present or not. A
supervised trip isolation link would be provided in each trip circuit for each Protection. One
common trip isolation link for all the Protections is not acceptable.
4.9.2 The gas monitoring system would be arranged in a fail safe manner. Similarly, the C.B.
operating medium viz. air pressure or oil pressure etc. also to be monitored in a fail safe
manner.
4.9.3 The independent SF6 monitoring gauge contact to be available for trip circuit-1, trip circuit-
2 and closing circuit etc. of the C.B.
4.9.4 The measuring transducers for SCADA purposes would be located in the SCADA panels.
4.9.5 The C.T. shorting and C.T./V.T. isolation facilities would also be provided in the SCADA
panels.
DRAWINGS
4.9.6 If SEC-CRB organization of alarms allows for grouping of some alarm, each individual
alarm must be flagged to enable to know the exact initiator.
4.9.7 The C.T. and V.T. cables should be segregated core-wise. More than one core in one
cable is not acceptable in any case, whether these cables are between the equipment and its
M.K. or between two equipment. This shall be reflected in respective cable tables.
4.9.8 The direct auxiliary contacts of the various devices to be used in the interlock circuit rather
than the contacts of the interface auxiliary relays.
4.9.9 All the abnormalities must be alarmed. No abnormality should be such which does not
show its appearance. Moreover, the alarm to ECC must follow the initiating contact i.e. on
resetting the alarm initiating contact the alarm to ECC must get reset.
4.9.10 Consistency would be maintained throughout the S/S in various respects viz. equipment
number, equipment designation, wiring, cabling, ferruling, labeling, the arrangement of the
terminal blocks and their designation, termination standard and method even if the different
equipment have been supplied by different suppliers.
4.9.11 The SEC specifications would be strictly followed in all respects. In case of doubt about
any point, the Contractor must get it clarified from SEC and SEC decision would be considered
final in such cases. The benefit of the doubt would be SEC privilege.
4.9.12 The relays would be selected from the SEC approved list of relays. If the Contractor is
interest to introduce a relay which is not covered by the SEC approved list of relays, the
Contractor must get it Pre-qualified through the formal Pre-qualification procedure.
4.9.13 The Acknowledgement, Reset and test facility for each Panel to be independent for the
Annunciator System.
4.9.14 Each relay and instrument to be equipped with an independent test block. It equally
applies to synchro-check relay, synchronizer and auto reclose relay etc. A common test block
for more than one relay is not acceptable. In case a scheme uses more than one relay, each
relay to have its independent test block. Each terminal of the test block to be marked with its
function viz. ‘+’, ‘-’ trip, close, Alarm R, Y, B, N etc. Each relay out put e.g. alarm, close and trip
etc. to pass through the test block.
4.9.15 The terminals to be used for C.T., V.T., control, trip and alarm circuit etc. would be
subject to SEC approval for their type and materials.
4.9.16 In case lamps are used in LCC to indicate the status of various devices viz. C.B. isolator
and Earth Switch etc. this should be done with one lamp only. Two lamps for one function would
not be accepted.
4.9.17 The plug in type auxiliary relays would not be used in any circuit unless their locking
arrangement is provided.
4.9.18 The auxiliary relays would be of high quality/standard. The industrial type auxiliary relays
would not be used in any case.
DRAWINGS
4.9.20 The drawing should never be approved with comments. But rather, the approval should
be accorded only and only after the comments are incorporated in the drawing.
4.9.21 Each modification done in the drawing during Pre-commissioning stage must be reflected
on the drawing in colored ink.
4.9.22 One copy of the temporary as built drawing, test results and all the catalogues to be
provided at the Substation in a pad lockable cupboard and another copy to be provided to P&T
Office. The same would be replaced with final as built drawing at a later stage.
4.9.23 For the tripping function, a proper trip relay would invariably be used. The use of auxiliary
relays for such functions is totally prohibited.
4.9.24 The protection equipment existing at the remote end of each circuit would be upgraded
by the Contractor to bring it in line with the one being used at the local end so as to meet SEC
latest Specifications or vice versa.
4.9.25 The remote/local switch and inter-locking over-ride switch etc. should be pad lockable
and to be reflected in the drawings.
4.9.26 Every relay to be equipped with a flag which should drop with the issue of trip signal from
the relay.
4.9.27 For Busbar Protection scheme, the closing of line earth in any feeder, should initiate
automatic shorting and isolation of the BBP C.T. for that feeder in order to avoid mal-functioning
of the BBP. If the BBP c.t. get included in the fdr. Earthling's circuit.
4.9.28 he inter-trip wires (receive + send) from pilot box up to the relay terminals should be of
15 KV insulation.
4.9.30 In case two unit type Protections (Main-1 & Main-2) are connected to the same set of
C.T. bus wires, a provision should be made to isolate each one of them in respect of C.T., trip
and alarm circuit leaving the other in service.
4.9.31 The Panel to Panel wires must be protected with PVC or rubber grummets and to be
reflected in Panel View drawings.
4.9.32 During open/close operation, of any isolator, if A.C. supply is interrupted, the operation
should not be completed automatically in case of restoration of supply for the A.C. operated
drives.
4.9.33 In case of involvement of a new Contractor in any Project a little bit more time should be
spent for the drawings review due to possibility of non compliance with SEC Specifications as a
result of his being unfamiliar with SEC System.
DRAWINGS
5 TESTING SECTION RELATED POINTS:
5.1 POWER TRANSFORMERS:
5.1.1 Check following points in the nameplate diagram.
5.1.1.a Confirm the transformer HV side R, Y, B phases are connected to GIS in the same
correct phase sequence.
5.1.1.b Serial no same as on body engraved.
5.1.1.c Tap positions increase say 1 to 21 or 8L, 7L,,,,,,,,,2L, 1L, N, 1R, 2R,,,,,,,,12R shall
corresponds to decrease in the voltage ratio.
5.1.1.d Vector group shown graphically and symbolically both.
5.1.2 Following points in the marshalling kiosks of power and cooling circuits diagram to
be considered as.
5.1.2.a Check for each of Fan motor protection MCBS shall have 30% extra overload setting
range available to avoid unnecessary tripping in hot season when the MCBS are de-rated due
to high temperature in the cabinets.
5.1.2.b Check for each of the fan group shall have its own main MCCB. All the fan groups shall
not be controlled by only one MCCB.
5.1.2.c Check the Cooler Control Cubicles are supplied with suitable wiring size to carry the fan
motor current without overheating.
5.1.2.d Check auxiliary transformers installed over the main transformers shall have primary
fuses installed. Direct connection from main transformer to auxiliary transformer is not
acceptable.
5.2 METAL CLADE SWITCHGEARS AND GIS
Check following points in the MV and HV switch-gear layout diagrams.
5.2.1 13.8kv and 33kv VTs shall have primary fuses installed in a separate compartment. VTs
directly installed without primary fuses are not acceptable.
5.2.2 G.I.S. VTs shall have primary isolating device manually operated externally with on off
indication on the mimic diagram.
DRAWINGS
5.3 TEST ADAPTERS:
5.3.1 Check drawings for suitable three phase test adapter + bushing for performing and Cable
AC HV tests.
5.3.2 The test adapter shall be suitable to select any phase and earth the other two at same
time.
5.3.3 One side of the test adapter to be fitted on GIS but other side should have gas to air
bushing to connect wire in air to apply ac high voltage from any test set.
5.4 MEASURANDS:
Following points shall be considered while checking drawing containing measurands.
5.4.1 Check all the Transducers shall be installed in SCADA Panels. Only meter driving
transducers should be installed in Control Cubicles.
5.4.2 Confirm all feeders shall have zero centered MW, Mvar indicating meters with clearly
written import and export on dials.
5.4.3 MMLG or RMLG type test terminal block shall be available for meter calibration purpose.
5.4.4 Confirm all the indicating meters shall have long scale readings. Short scale meters
should not be acceptable.
5.5 GENERAL REQUIREMENTS:
5.5.1 Check in the auxiliary supply drawings that a separate earth terminal and a supply point
(220v-200amp-60hz) has been provided in all Switchgear and GIS halls near the main doors for
future testing purpose.
5.5.2 Check in the S/S layout drawings that access to a big van shall be available on metalloid
ground on big door side of every Switchgear Rooms for Testing and Fault location purpose.

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