POWER

DISTRIBUTION SYSTEMS

VOL: FY 2 0 1 4 0 5 JULY 2 0 1 4 ISSUE NO: 1 9

Centre for Education, Training and Development
Vijai Electricals Ltd, Hyderabad-500 082, Andhra Pradesh, INDIA
Phone: +91-40-30617791; Fax: +91-40-30617890; Email: cetd@vijai.co.in
Building a Knowledge Enterprise
Lecture Notes *
for General Guidance






TESTS ON SUBSTATION EQUIPMENT




(*The lecture notes are intended for general guidance only. In actual
execution the relevant project technical specification LOA and approved
drawings are to be followed)




Class conducted
Today i.e. 05 July 2014
Faculty: Sri.V.Neelesh, Engineer,
Project Execution & Control Dept.
D&RE Projects
TESTING OBJECTIVE, INSTRUMENT AND PROCEDURE

Objective of Testing:

To ensure that the products manufactured have met the requirement of
customer specification/standard
To prevent accidents, which may occur if a failed product is put into service
To ensure quality & that the product is fit for its intended use

Tests conducted on Sub-station Equipments:
Power Transformer and Stati on Transfor mer :

(1) Insulation Resistance Test
(2) Vector Group Test
(3) Winding Resistance Test
(4) Ratio Test
(5) Break Down Voltage of Oil
(6) Magnetic Balance Test
Vacuum Circuit Breaker:

(1) Insulation Resistance Test
(2) Closing and opening Time Measurement
(3) Contact Resistance Measurement
Current Transfor mer :

(1) Insulation Resistance Test
(2) Ratio Test
(3) Polarity Test
Potential Transfor mer :

(1) Insulation Resistance Test
(2) Ratio Test
(3) Polarity Test
Isolator :

(1) Insulation Resistance Test
(2) Contact Resistance Measurement
Lightni ng Arrestor :
(1) Insulation Resistance Test
Battery and Batter y Charger :
(1) Specific Gravity Measurement








TESTS ON TRANSFORMER

Insulation Resistance Test:

Objective:

1) To ensure proper dryness of the active parts
2) To ensure sufficient clearance between the windings and between
winding and earth

Instruments:

1) 2.5 KV rated Megger / Insulation Tester














2) Connecting cables


Procedure:
1) Before starting the test, Disconnect the PTR neutral connection.
2) One terminal of the instrument is connected to conducting part. Other
terminal is connected to earthed frame (or other conducting circuit)
3) Then IR Value between HV terminal and body of Power transformer is
to be measured & noted.
4) IR Values between HV & LV terminals are to be measured & noted.
5) IR Values between LV terminals and body of Power transformer is
measured & noted.
6) If the value is zero then there is continuity and if the value is infinity
then there is no continuity.

7) The temperature of transformer oil at which the IR Values are
measured is also to be noted. IR value depends on Temperature i.e. every
10deg. raise in temperature IR value decreases to Half.





8) Insulation resistance measurement reveals quality of the transformers
insulation and the degree of the dryness. The subsequent high voltage
tests and commissioning can be avoided if i nsulation resistance is
low.
Circuit Diagram: For three phase transformers










M Insulation Resistance Tester at 35 deg C
9) Range of Results for 5MVA PTR observed as
HV to LV = 3000 M
HV to Ground = 3000 M
LV to Ground = 4000 M



Temp.
In deg.
30 40 50 60
33KV 500M 250M 125M 65M
11KV 400M 200M 100M 50M
1U




1V






1
W

2n


2u






2v




2w



[
T/F
under
test
M
HV to Body


T/F
under
test
2n


2u






2v




2w
1U



1V





1
W
M
HV to LV
M






T/F
under
test
1U




1V






1
W

2n


2u






2v




2w
LV to Body
Vector Group Test
Objective:
To verify the phase angle difference between HV and LV winding.
Generally for 33/11KV sub-stations Dyn11 vector group PTR is used.
Instruments:
1) Three phase auto transformer








2) Voltmeter / Multimeter






3) Connecting cables
Procedure:














T/F
under
test
3
P
H

S
U
P
P
L
Y

2n

2u



2v





2w
1U








1V








1W
430 volts
AC
1) Short the terminals i.e. 1U on HV and 2u on LV side of Transformer
and apply 3-Ph voltage say 430V on any line terminals of HV side then
observe the voltage readings of various terminals 1U-1V, 1V-1W,
1W-1U, 1U-2n, 1V-2n, 1W-2w, 1W-2v, 1V-2w, 1V-2v, etc.


Voltage Across Volts
1U - 2u 0
1U - 2n 80
1V 2n 366
1U 1V 417
1V 2w 301
1U 2v 299.4
1W - 2w 303
1W 2v 438
1V - 2v 290
Vector group Diagram Voltage Conditions
Dyn11

1V to 2w =1V to 2v
1W to 2w <1W to 2v and
1U to 2n +1V to 2n =1U to
1V
Dyn5

1U to 2v =1U to 2w
1W to 2w >1W to 2v and
1U to 2n +1U to 1V =1V to 2n



















Dyn1

1W to 2v =1W to 2w
1V to 2v <1V to 2w
1U to 2n +1w to 2n =1U to 1w
Dyn7

1U to 2v =1U to 2w
1V to 2v >1V to 2w
1U to 2n +1U to 1W =1W to
2n
Winding Resistance Test:
Objective:
1) To calculate IR losses of the winding
2) Whether conductors used in winding are as per the designed cross
section or not can be verified.
Instruments:
1) Transformer winding resistance meter / Ohm meter






2) Kelvin Bridge / Wheatstone Bridge



3) Connecting Cables

Procedure:
1) The test is carried out only after ensuring that the transformer windings
are immersed in oil for at least 3 to 8 hours depending upon the rating till
the transformer oil temperature equals the ambient temperature.

2) Then the top oil temperature is taken as average oil temperature and
the temperature of the winding is the same as the average oil temperature.
The ambient temperature shall be recorded.
3) The measurement of winding resistances is done using a precision
ohmmeter.

LV side winding resistances measured phase wise
r-n =Ohm meter reading in
y-n =Ohm meter readin in
b-n =Ohm meter reading in
HV side winding resistances measured phase wise
RY =Ohm meter reading x 3/ 2
Y-B =Ohm meter reading x 3/ 2
B-R =Ohm meter reading x 3/ 2
The top oil ambient temperature is also to be mentioned along with the
winding resistances at which it is measured. The winding resistance
varies with temperature. If temperature of oil increases, the value of
resistance also increases.


Ratio Test:
Objective:
Ratio test is conducted to ensure the number of turns in HV and LV
windings on each tapping. In order to get accurate ratio measurement, a ratio
meter is used.
Tolerance for the % deviation of voltage ratio is lower should be lower than
0.5% (or) 1/10
th
of the % Impedance value.
Instruments:
1) 3-Ph Auto Transformer
2) Voltmeter
3) Connecting cables

Procedure:
1) Apply 3Ph, 430V on HV side of PTR and measure the LV side Phase to
Phase values.










2) The ratio test values of 5MVA, 33/11KV PTR are

Tap
No.
1U-1V
1V-1
W
1W-1
V
2u-2v 2v-2w 2w-2u 2u-2n 2v-2n 2w-2n

01
425 426 421 131 132 130 73 74 73
02 420 426 423 133 134 132 74 76 75
03 430 435 433 140 141 139 80 81 81
04 429 435 433 142 143 141 81 82 82
05 430 436 433 144 145 143 82 83 83
06 430 436 434 146 147 145 83 84 84
07 431 436 434 147 149 147 85 86 85
08 431 436 433 149 150 149 86 87 86
09 431 437 434 151 153 151 86 88 87
10 428 433 433 153 154 152 87 88 87
11 426 432 432 154 155 153 88 89 89
12 427 432 432 156 158 156 90 91 91
13 429 435 432 159 160 158 91 92 92
14 430 435 432 162 163 161 93 94 93
15 429 435 433 164 165 164 94 95 96
16 430 435 433 167 168 166 95 97 96
17 429 435 432 169 170 168 97 98 97






















Break Down Voltage of Oil (BDV) measurement:
Objective:

To ensure the healthiness of Transformer Oil.

Instruments:

1) BDV test Kit
















2) Connecting Cables

Procedure:

1) Oil samples from top & bottom of Power transformer main tank as
well as OLTC tank are to be collected and tested.

2) Across 2.5 mm gap test Kit, The oil shall stand for 40 to 50 KV For/
minute.













Magnetic Balance Test:

Objective:

Magnetic Balance test is conducted on Transformers to identify inter
turn faults and magnetic imbalance.

Instruments:

1) 3Ph Auto Transformer
2) Tong tester / Multimeter








3) Connecting Cables

Procedure:
1) 415V, Two phase supply is to be applied to any two phases terminals
on HV side of Power transformer and voltages in other two phase
combination are to be measured.
2) Sum of the Resultant two values shall be equal to the voltage applied.











Pre-Commissioning Checks on PTR

1) Check proper earthing of neutral & body

2) Check colour of silica gel in breather

3) Radiator valves of top and bottom should be in open condition

4) Check oil level in the conservator

5) Check for oil leakage, if any

6) Check the tapping switch is on the desired position

7) Verify that LAs are properly installed, connected & earthed

8) All drain valves are in closed position with dummy plates in position duly
fitted with bolts & nuts

9) All filter valves in closed position with dummy plates in position duly fitted
with bolts & nuts

10) The valves on either side of Buchholz relay are in open position

11) The vent pipe diaphragm is intact

12) Before charging the PTR air is to be released from air releasing points
of main tank cover of PTR, OLTC top cover, Buchholz relay, radiators and
bushings, if necessary.

13) Ensure Buchholz relay should be kept in service mode.













Tests on Current Transformer

Insulation Resistance Test:
Objective:

1) To ensure proper dryness of the active parts
2) To ensure sufficient clearance between the windings and between
winding and earth

Instruments:

1) Megger / Insulation Tester
2) Connecting cables

Procedure:
1) Measure IR value between
(i) Primary to secondary
(ii) Primary to ground
(iii) Secondary to ground
(iv) Secondary side core to core
2) If the value is zero then there is continuity and if the value is infinity
then there is no continuity.
3) 33KV, 400-200-100/1A CT

Particulars R - Phase Y - Phase B - Phase
Pri-E 9.73 G 10.2 G 11.5 G
Pri-Sec Core-I 14.2 G 10.9 G 18.4 G
Pri-Sec Core-II 16.4 G 8.51 G 17.2 G
Pri-Sec Core-III 13.00 G 13.4 G 16.5 G
Sec Core-I-E 3.22 G 6.26 G 8.4 G
Sec Core-II-E 4.75 G 5.07 G 7.14 G
Sec Core-III-E 4.69 G 5.25 G 6.28 G
Sec Core-I to Sec Core-II 3.51 G 3.50 G 4.61 G
Sec Core-I to Sec Core-III 2.80 G 3.00 G 4.37 G
Sec Core- II to Sec
Core-III
2.89 G 2.78 G 4.14 G

Ratio Test:
Objective:
This test is to ensure the proper CT connections with respected cores
and there is no mix up in the circuit (phase identification).
Instruments:
1) Primary Current Injection Kit
2) Connecting Cables
Procedure:
1) The circuit connections shall be made as shown below.
2) Single point grounding shall be verified for CT circuits, before
starting this test.
3) Inject 25% of rated primary current between one phase and earth
with all connected burden. Measure secondary current at all points of
CT circuits. It shall be done for other phases.


4) The test values are as shown below





Ratio /
Primary
injected
R(Core2/Core3) Y(Core2/Core3) B(Core2/Core3)
50 Amps. 0.498 0.501 0.499
100 Amps 1.00 1.01 0.99
Polarity Test:
Objective:
Polarity test is to confirm the polarity marking on the CT primary and
secondary.
Instruments:
1) Galvanometer
2) Battery set
3) Connecting Cables
Procedure:
1) Isolate CT secondary from the load and make circuit connection as shown
below.


2) Close and open the battery switch connected on the primary. Observe the
pointer is moving + ve direction, while closing and ve direction while opening
for correct polarity.
Particulars
(P1=+ve; P2=-ve)
R -
Phase
Y - Phase B - Phase
Core-1 Ok Ok Ok
Core-2 Ok Ok Ok
Core-3 Ok Ok Ok

Pre-Commissioning checks on C.T
1) Verify nameplate ratings are in accordance with the approved drawings
and specifications.

2) Inspect for physical damage/ defects and mechanical condition.

3) Verify correct connection of Transformers with system requirements.

4) Verify that adequate clearances exist between primary and secondary
circuit wiring.

5) Verify tightness of accessible bolted electrical connections

6) Verify that all required grounding and shorting connection provided.

7) Verify all shorting blocks are in correct position, either grounding or open
as required.

8) Verify single point grounding of each core done properly. Grounding point
shall be nearer to the CT location. However grounding shall be at relay point
in case of several CT secondaries connected together like differential
protection.











Tests on Potential Transformer
Insulation Resistance Test:
Objective:
1) To ensure proper dryness of the active parts

2) To ensure sufficient clearance between the windings and between
winding and earth
Instruments:
1) 2.5KV Megger / Insulation Tester

2) Connecting cables
Procedure:
1) Measure IR values between Measurement between primary and
secondary

2) Measurement between primary and ground

3) Measurement between secondaries and between secondary and
ground






4) The IR values for 11KV PT are shown below (Giga-Ohms)















Circuit Ref. R-Ph Y-Ph B-Ph
Primary to Earth
0.850 0.735 0.700
Primary to Sec. 1
1.60 1.70 1.84
Primary to Sec. 2
3.16 2.61 1.78
Sec. 1 to Earth
1.52 1.87 2.29
Sec. 2 to Earth
2.30 2.58 2.18
Sec. 1 to Sec.2
2.05 4.53 2.05

Ratio Test:
Objective:
To ensure secondary voltage with respect to Primary side of P.T
Instruments:
1) Auto Transformer

2) Tongtester / Voltmeter

3) Connecting Cables
Procedure:
1)A variable AC source is applied on the primary side.

2)The primary and secondary voltages are measured to determine
the ratio V2/V1

3) The values of 11KV, 11000/ 3 / 110/3 PT

Rn Yn Bn
Primary Applied
Voltage
230V 230V 230V
Sec Phase-Neutral 2.3V 2.3V 2.29V









Polarity Test:
Objective:
To ensure the Polarity of P.T and to check primary and secondary circuit
continuity.
Instruments:
1) Galvanometer

2) Battery Set

3) Connecting Cables
Procedure:
1) Connect the galvanometer leads to secondary of the P.T terminals.

2) Connect the primary terminals to the cell +ve & `N` to the cell -ve. Then
observe the meter deflection.

3) If the deflection is towards right, the P.T polarity is correct.

4) If the deflection is towards left the polarity is incorrect.








Tests on Vacuum Ci rcuit Breaker
Insulation Resistance Test:
Objective:
1) To ensure proper dryness of the active parts

2) To ensure sufficient clearance between the Contacts
Instruments:
1) Megger / Insulation Tester
2) Connecting cables
Procedure:
1) If Breaker is in Open condition, measure IR values between IN &Out
terminals. Then note down the value, it should be in M.

2) If Breaker is in Close condition, measure IR values between IN & Out
terminals. Then note down the value, it should be Zero.
























Phase
OFF Condition ON
Condition
Incoming Outgoing
R-E 15,000 13,000 12,000
Y-E 15,000 14,000 13,000
B-E 15,000 15,000 15,000
R-Y >15,000 >15,000 >14,000
Y-B >15,000 >15,000 >15,000
B-R >15,000 >15,000 >15,000
ACROSS POLE
R-R >10,000 0
Y-Y >10,000 0
B-B >10,000 0
Closing and Opening Ti me Measurement:
Objective:
To ensure the healthiness of contacts and to measure closing time
of contacts and opening time of contacts.

Instruments:

1) Battery set
2) Timer
3) Connecting Cables

Procedure:
1) Connect the instruments as shown below.


2) For measuring close time, The timer starts when the two terminals of
Start witch are shorted by closing the D.P.D.T switch. Simultaneously the
D.C supply is extended to the closing of the breaker. The timer stops
counting when the two terminals of Stop switch are shorted through the
main contact of circuit breaker, as soon as it closes and the timer displays
the time interval, which is the closing time of circuit breaker.

3) For measuring open time, The timer starts when the two terminals of
Start switch are shorted by closing the D.P.D.T switch. Simultaneously the
D.C supply is extended to the trip coil of the breaker. The timer Stops
counting when the two terminals of stop switch are opened with the
opening of the circuit breaker main contacts. The time interval displays the
time interval, which is opening time of circuit breaker.






4) The test values of 36KV, 1600A VCB in msec.

Phase Closing Time Tripping Time
R 52.6 33.4 34.7
50.4 33.9 34.7
Y 52.5 34.7 34.8
51.0 37.6 39.7


































Contact Resistance Measurement:

Objective:

To measure the resistance between fixed contact and movable
contact.

Instruments:

1) CRM kit
2) Connecting Cables


Procedure:

1) Connect CRM kit with terminals of VCB and apply the respective voltage
then meter shows the Resistance value.

2) Generally for 33KV, 1600A VCB the contact resistance values are as
shown below.


























Phase
Resistance

R 54
Y 43
B 32
Pre-Commissioning Checks on VCB

1) Tightness of all hardware, jumper bars & contact fingers.

2) Rack in and rack out the VCB inside the panel for 5 times (for i/d VCB).
Operation must be smooth during this check.

3) Charge the spring manually and ensure spring charge indication signal
appears at the end of the charge.

4) Check the limit switch (motor cut off) charge over the contacts at
the end of spring charge

5) Check manual closing & opening is possible.

6) Check whether VCB earthing contact engages to panel earth position
before contact fingers engage with spout.

7) Check mechanical ON/OFF indication appears when breaker is in closed
or open position.

8) Check the operation counter operates for every open or close operation.

9) Check proper shutter opening by engagement of VCB/finger alignment.

10) Check auxiliary switch contact change over during breaker open/close
operation.

11) Check tightness of wiring terminals before and after 25 operations.

















Tests on Isolator

Insulation Resistance Test:

Objective:

1) To ensure proper dryness of the active parts
2) To ensure sufficient clearance between the contacts

Instruments:

1) 2.5 KV Megger / Insulation Tester
2) Connecting cables

Procedure:

1) If isolator is in Open condition, measure IR values between two
terminals. Then note down the value, it should be in M.

2) If isolator is in Close condition, measure IR values between two
terminals. Then note down the value, it should be Zero.

3) For 33KV, 800A isolator the IR values as follows.









4) For 11KV, 800A isolator the IR values are as follows.





Circuit Ref. R-Phase Y-Phase B-Phase
Pole to earth
6.62 G 13.2 G 12.6 G
Phase to Phase
6.12 G 8.12 G 9.12 G
Pole to Pole
5.87 G 6.30 G 8.5 G
Incoming bus
8.15 G 7.20 G 6.35 G
Circuit Ref. R-Phase Y-Phase B-Phase
Pole to earth 8.67 G 7.07 G 9.65 G
Phase to Phase 11.0 G 10.5 G 6.37 G
Pole to Pole 9.07 G 6.38 G 2.31 G
Contact Resistance Measurement:
Objective:

To measure resistance between fixed contact and movable contact
of Isolator.

Instruments:

1) CRM kit

2) Connecting Cables

Procedure:

1) Connect CRM to respective terminals and measure the resistance value.


























Phase
Reference
Measured
Resistance ()
R-phase 155
Y-phase 150
B-phase 178
Pre-Commissioning Checks on Isolator

1) Check main earth on mechanism box, operating handles (flexible braid)
and support structure.

2) Check that earth switch earth connection is direct to the earthmat (not via a
structure).

3) Check local / remote close operation.

4) Check simultaneous operation and full travel operation of all phases.

5) Check control switches in service position.

6) Check operational nameplate and labels are in place.

7) Check phasing is correct.





























Tests on Lightning Arrestor

Insulation Resistance Test:

Objective:

To ensure proper dryness of the active parts.

Instruments:

1) 2.5 KV Megger / Insulation Tester

2) Connecting Cables

Procedure:

1) Measure IR values between Phase to Phase and Pole to Earth and the
readings are as observed below.
2) 30KV, 10KA LA readings are as shown below.
























Circuit Ref. R - Phase Y - Phase B - Phase
Pole to Earth
10,000 G 10,000 G 10,000 G
Tests on Battery and Battery Charger

Specific Gravity Measurement:

Objective:

To measure specific gravity of electrolyte.

Instruments:

1) Hydrometer
2) Connecting Cables

Procedure:




1) Collect the electrolyte of battery in a tube and by using hydro meter
measure Specific gravity. For a good electrolyte Specific gravity must be
above 1200.