Instruction and Maintenance Manual for

CAPACITOR VOLTAGE TRANSFORMER

Type : CVE - 72.5kV.......800kV

Index

Topic

Page No.

Description

Packing Transport and Unloading

Erection

Electrical Connections

Commission & Maintenance

Checklist

Safety Clause

BRIEF DESCRIPTION
High Voltage Capacitor Unit : (Ref. Fig. 1)
The high Voltage Capacitor unit comprises of one
capacitor unit upto 170 KV and two or more Capacitor Units
for higher KV classes. The Capacitor Unit comprises of HV
Capacitor (C1) and Intermediate Voltage Capacitor (C2).
These capacitors consist of oil impregnated series
connected capacitor elements housed inside oil filled
porcelain insulators. Each capacitor unit is independently
hermetically sealed. Stainless steel bellow is provided
inside each capacitor unit to compensate volumetric
changes in oil due to ambient temperature changes.
Aluminium HV Terminal is provided on capacitor unit as
shown in Fig. 1. Bottom cover of the lowest capacitor unit
forms the cover of the EM unit tank. Lifting Lugs are
provided on the tank to lift the lowest capacitor unit and the
EM unit together.
Intermediate Voltage Tap and high frequency Carrier
Terminal (NHF) are brought from capacitor unit to EM unit
through bushings.
Electro Magnetic Unit (EMU) (Ref. Fig. 2)
The EMU comprises of following electrical components:
- Compensating Reactor (L)
- Intermediate Transformer (Tr)
- Damping Device (Zd)
- Varistor (V)
- HRC Fuses (F) / MCBs (M).
The Varistor (V) and the damping device (Zd) are
connected across an auxillary secondary winding (f-g). The
varistor mounted inside secondary terminal box
suppresses over voltages which may occur due to
transients on the High voltage side or Low voltage side;
whereas the damping device mounted inside EMU tank
damps the transient oscillations. The secondary winding
leads and LV lead of the capacitor (NHF) are taken into
secondary terminal box through a multilead epoxy block
(monoblock). Surge Arrester is provided across NHF and
earth which is rated at 1kVp.
The compensating reactor (L) and intermediate
transformer (Tr) are mounted inside the oil filled
hermetically sealed EMU steel tank. A suitably
dimensioned air cushion is provided in EMU tank to
accomodate expansion of oil. For all service temperatures
the oil level must be within min. and max. levels. On the
bottom side of the terminal box a removable undrilled
gland plate is provided in which suitable holes can be
drilled at site. The HRC fuses (F) / MCBs (M) are fitted in
the secondary terminal box.
Optional Accessories
1) Terminal Connector
2) Cable Glands
3) Three Element Carrier protection device comprising of
a) Drain Coil b) Lightning Arrester c) Earth Switch
Items 1, 2 are packed seperately and 3 is mounted inside
secondary terminal box.

PACKING, TRANSPORT AND UNLOADING

CVTs upto 170 kV are packed in a single wooden packing
crate.
For higher kV classes base unit (comprising of lowest
capacitor unit and EMU) and each capacitor unit is packed
seperately.
WARNING : BASE UNIT AND UPPER CAPACITOR
UNITS SHOULD ALWAYS BE TRANSPORTED/ STORED
IN VERTICAL POSITION. IT SHOULD NEVER BE
TRANSPORTED/ STORED IN HORIZONTAL POSITION.
(Except upper capacitor units of 800kV)
For unloading, the packing crate should always be lifted
from bottom.
Immediately on receipt, the goods should be checked for
transportation damage (if any). In case of externally visible
damages, inform CGL and the insurance company
immediately, preferably with photographs. Also mark the
position of damage / oil leakage, if any on the CVT outline
drawing enclosed with this manual and send it to CGL.
Use nail puller while unpacking. While unpacking utmost
care should be taken to prevent any damage to the CVT.
Store the CVT only in vertical position on a hard, dry and
even surface.
For taking the base unit out of packing use lifting lugs
provided on the EMU cover (Refer Fig. 3)and for taking top
capacitor unit out of packing case, tie the rope in the neck
of
porcelain of this unit below Al. flange
For lifting upper unit or middle unit, arrangement as shown
in
Fig.4 to be followed
.
CAUTION : 1) AVOID DAMAGE TO THE HV TERMINAL
WHILE LIFTING THE UPPER CAPACITOR UNIT.
2) WHILE LIFTING THE BASE UNIT SAFETY ROPE HAS
TO BE TIED AS SHOWN IN FIG. 3

ERECTION
Upper Capacitor units belonging to the same CVT are marked
at our works by the same serial number suffixed by U.

For example
: Serial number on the main rating plate fixed on the base
unit - 1000
: Serial Number on the number plate fixed on upper
capacitor unit - 1000/U
: Similarly middle capacitor unit is marked by same serial
no.
suffixed by M. For example -1000/M.
CAUTION : ENSURE CAPACITOR UNITS WITH SAME
SERIAL NUMBERS ARE COUPLED DURING
ERECTION OF CVT WITH TWO OR MORE CAPACITOR
UNITS.
The hardwares necessary for assembly of upper capacitor
unit on the base unit are packed seperately. (Refer Fig. 4)
for this assembly.
Initially the base unit has to be mounted and fixed on the
support structure. For fixing the base unit, four holes are
provided on the bottom plate of EM Unit. (for mounting
details refer to general arrangement drawing supplied
against order)
The threaded studs used for coupling have to be first held
into the through holes of the flanges, before the units are
placed one above another. This assembly has to be done
with utmost care, to prevent damage to the porcelain
sheds. For handling of the base unit and upper capacitor
unit during this erection process, use of crane is necessary.
The studs used for coupling the capacitor units have to be
tightened with a torque of 6 kg-m.

A
C1
C2
NHF
L
Tr
F
Zd
V
S

- HV Terminal
- Pri. Capacitor
- Sec. Capacitor
- HF Terminal
- Compensating Reactor
- Intermediate Voltage Transformer
- HRC Fuse
- Damping Device
- Varistor
- Surge Arrestor

Fig. No. 2

CAUTION : 1) UPPER AS WELL AS THE LOWER

CAPACITOR UNIT HAS TO BE SHORT CIRCUITED AND
CONNECTED TO EARTH UNTIL THE ERECTION AND
COMMISSIONING WORK IS BEING DONE ON THE CVT.
(The capacitors get charged by the electrical fields in the
vicinity and they keep these charges for a long time, which
will be dangerous to human life. Hence the shorting and
earthing of capacitor units is necessary.)
2) DO NOT UNSCREW ANY OTHER SCREWED JOINTS
OF THE CAPACITOR UNITS AND THE BASE UNIT.

Secondary Connection :
While connecting the measuring instruments & protective
relays to the secondary terminals, ensure the burden on
respective secondary winding does not exceed.
CAUTION : CVT SECONDARY WINDING SHOULD
NEVER BE SHORT CIRCUITED.

COMMISSION AND MAINTENANCE

ELECTRICALS CONNECTIONS

The short circuit connection provided across the capacitor

units has to be removed prior to commissioning. The CVTs
do not require maintenance for a long period of time, owing
to the foolproof hermetic sealing. Checks specified in the
checklist given on page no. 4 are to be strictly followed.
OUR CVTS DO NOT REQUIRE ANY ADJUSTMENTS AT
SITE FOR MAINTAINING ACCURACY FOR THE
SPECIFIED BURDENS. CVTS ARE CONSTRUCTED IN
SUCH A WAY THAT THE REQUIRED ACCURACY
CLASS
IS MAINTAINED OVER THE ENTIRE BURDEN RANGE.
CAUTION :
1) NEVER OPEN THE CAPACITOR UNIT AS WELL AS
THE CLAMPING BETWEEN THE EMU AND THE
CAPACITOR UNIT.
2) THE NHF TERMINAL WHEN NOT USED FOR
CARRIER COMMUNICATION SHOULD BE FIRMLY
CONNECTED TO EARTH.
3) THE TERMINAL BOX COVER SHOULD BE CLOSED
USING NUT & BOLT SO AS TO COMPRESS THE DOOR
GASKET ADEQUATELY THIS WILL ENSURE
WEATHERPROOF SEALING.

Earthing :

Important Checks from Checklist

The CVT has to be firmly connected to earth by fixing

substation earthing flat to the earthing pads provided on
theEMU tank.
The end (N) of high voltage winding of the intermediate
voltage transformer which when brought inside the
secondary terminal box has to be connected to the earthing
screw provided in the terminal box has to be connected to
the earthing screw provided in the terminal box. As
despatched, the LV terminal of the capacitor unit (NHF) is
connected to earthing screw by a cable link.
CAUTION : ENSURE FIRM EARTHING OF (N) & (NHF).IF
NOT EARTHED FIRMLY THESE LEADS AND OTHER
LEADS IN THE TERMINAL BOX WILL ATTAIN
EXCESSIVE VOLTAGES WHICH WILL LEAD TO
PRODUCT FAILURE.
One end of the secondary windings can also be earthed
inside the terminal box by using the earthing screw.

a) Secondary Voltage : (item 5) Significant deviation in the

secondary voltage from the rated value indicates that there
is a fault. The product should be taken out of service
immediately. Inform CGL for corrective action.
b) Varistor : (item 6) Visual inspection of varistor (viz.
check for bulging, burning) will indicate healthiness of the
varistor. In case of any abnormality inform CGL
immediately.
c) Oil level Indicator : (item 7) : Since oil inside the
indicator is directly exposed to the sunlight, a uniform or
spotty brownish sediment can appear on the sight glass
after few years of operation. However the oil should remain
clear and become insignificantly darker. Otherwise check
temperature rise of EMU as in d) and check oil
characteristics as in e) below.
d) Temperature Rise of EMU : (item 12) : if any fault
develops in the EMU, the EMU tank temperature will rise.
In
such cases the temperature shall be measured below the
within five minutes of taking the shut down. The recorded
temperatures should be informed to CGL.
e) Checking of oil in EMU : (item 13) : Owing to the
foolproof hermetic sealing, the ageing of the oil is
considerably reduced. An oil sample should be taken after
first 10 years of service and subsequently every 5 years.
Nevertheless the test on oil should be carried out when the
oil becomes brownish in colour. The oil in the EMU should
have a maximum dissipation factor of 10% at 40 deg. cent.
and BDV of 40 kv (min.) For oil sampling procedure for this
test and analysis of the test results contact CGL.

ESSENTIAL CHECK BEFORE COMMISSIONING :

Low Voltage Ratio Check :
For low voltage ratio check apply a voltage of 100 to 2000
volts between HV terminal and NHF, measure the voltage
across the secondary terminals. The ratio should not
significantly deviate from the rated value. In case of
substantial deviation in this ratio, there is a possibility of an
internal damage / loose connection during transport and
apparatus must not be put into operation.
Report the abnormalities to CGL immediately giving
following details
1) Customer Site
2) Type designation
3) S. O. No. (On rating plate)
4) Sr. No. (On rating plate)
5) Date of receipt at site
6) Testing details
7) Contact person and Telephone number.

HV Connection :
After confirming the low voltage ratio, connect the HV
terminal to the line by terminal connector . While clamping
the terminal connector proper torques should be applied to
ensure firm connection.
CVT HV TERMINAL BEING OF ALUMINIUM,BIMETALLIC
STRIP IS NOT REQUIRED IF AL. TERMINAL
CONNECTOR IS USED.

f) Inspecting the CVT for oil leakages : (item 8) :

The CVT should be checked at following places for likely oil
leaks.
- Below each porcelain flange.
- On EMU tank below and above.
- On EMU tank at all welded joints.
- Around monoblock in the terminal box.
g) Check for capacitance : (item 14) : This should be
conducted after 10 years of service at a temperature
between + 15 and 30 deg. centigrade The capacitance
value should not differ significantly from the routine test
results, taking into account the accuracy of the capacitance
meter.
IN CASE OF DAMAGES AND FAULTS THE FOLLOWING
SHOULD BE COMMUNICATED TO CGL :
a) Customer Site
b) Type designation of the CVT
c) S. O. No. and serial number of the CVT
d) Date of receipt and the date on which it is noticed
e) Details of damage and the date on which it is noticed.
f) Details of the Low voltage ratio check before
commissioning and results of other tests recommended
by us
00

Check list
Checks, which should definitely be carried out at specified times.
.Additional checks, if further information is required, or if considered necessary.
Checking Times :
F When EMU oil is dark.
E After change of burden or of connections.
Before reconnection to high voltage system.
D If secondary voltage is doubtful
C Before commissioning after transport of apparatus
B After 10 years
A Routine checking every year.

Check Items :
1.

Check of Earthing

A
EMU tank, NHF (L V terminal of capacitor)

N (Neutral end of HV winding of Int. VT)

2.

Low voltage ratio

Check for correctness

3.

Secondary circuits

Check if not short circuited

4.

Connections

Check for firmness of connections

Check for corrosion .

5.

Secondary Voltage

Check with regard to rated value

6.

Varistor Visual

check (Bulging or burning)

7.

Oil Level Indicator

Check if completely filled with oil

Check oil colour

8.

Oil leaks

Check for oil traces

9.

Terminal Box

Check for cleanliness and

door gasket sealing

10.

Porcelain Insulator

Check for dust accumulation

11.

Metal Parts

Check for corrosion

12.

Temperature rise

Check for tank temperature

13.

Oil in Tank

Checks on the oil

14.

Capacitor

Check capacitance)

Fig. No.3

SAFETY :
7.1 Instructions for Disposal of Material
Material used in Instrument Transformers & Condenser
Bushings to minimize depletion of natural resources :
After unpacking of product at site, packing wood & steel
to be recycled. Keep wood & steel at dry place to avoid
soil & water pollution.
After the useful life of product is over, disassembled the
job. Collect oil & oil soaked paper to avoid soil & water
contamination.
The disposal action for various materials is as follows :

For disposal of Hazardous waste, refer to local regulation.

7.2 Instructions for Mitigation Control

In case of abnormal & emergency conditions during life
cycle of Instrument Transformers & Condenser Bushings to
minimize environmental pollution :
Storage of packing wood for long duration in humid
condition will cause land pollution. Incinerate / bury
the Infected wood as per local regulation.
Rusting of steel used in packing will cause
contamination of water & soil. Take action as per
local regulation. In case of rusting of steel
component used in product, clean the rust with
suitable solvent & apply paint to prevent further
rusting.Ensure masking of insulating surfaces while
painting.Contact manufacturer & refer local
regulations for use of solvent & procedure for
painting.
During transportation / storage / operation, if any oil
leakage is detected suspected, following actions are

to be taken :
If the product is in operation, de-energized &
disconnect the suspected product. Clean the product.
Find out source & severity of leakage. If leakage is at
bolted joint, ensure tightness of bolt. If the leakage is
minor on surface, apply sealant to stop the leakage. If
the leakage is major, raise the level of leaking portion to
reduce leakage. Avoid spreading of oil. Arrange for oil
collection. Collect the leaked oil, oil soaked soil, oil
soaked cotton waste / wooden dust, etc. Incinerate as
per local regulations.
Contact manufacturer for further action & before
recommissioning.
In case of fire / explosion of product, immediately
de-energize the HV circuit, if not already tripped.
Extinguish the fire. Take actions as per local
regulations. Contact manufacturer for further action.

7.3 Material safety data sheet (MSDS)

Indentification of the substance / preparation & the
company :
Product :
Electrol uninhibited transformer oil conforming to IEC
60296 - 2003
Class I and IS335 - 1993
Product Grade :
Transformer oil type IEC : 60296 - 2003 Class I
Raj Petro Specialities Pvt. Ltd.
146/2/3 Karad Village, Madhuban Dam Raod,
Silvassa 396 230
UT OF D & NH
Composition : Refined mineral oil
Typical Properties :
o
Physical State @ 25 C: Liquid
O
Kin Viscocity @ 40 C : 9.34 CST
Appearance : Bright & Clear Oil
Density @ 20OC : 0.820 Kg/L
Solubility in water : Negligible
Storage, Handling and Protective Measures :
Stability / Reactivity
Stable.
Hazardous Nature :
Hazardous Nature not required.
Storage Container Materials :
New steel drums made out of CRCA sheet confirming to IS
1783 specification or in bulk, in EP coated steel drums or in
SS tanks.
Storage Condition :
Store in cool, clean, dry place with adequate ventilation.
Avoid heat naked flames and strong oxidizing agents.
Individual Protective Measure :
Skin : Use oil resistant gloves that overalls to
minimize skin contact and contamination of
personal clothing.
Eye : Wear safety glasses
Respiratory : Avoid inhalation of mist.
When handling drums of this product safety boots or shoes
should be worn.
Ventilation :
General or local exhaust ventilation should be provided if
oil
mists are generated in any event threshold limit value of
5mg/m3 for oil mist should not be exceeded.
Toxity :
Non Toxic in normal conditions.
Irritation :
Non irritating.
Electrol : A transformer oil is manufactured from Mineral
Oils of types shown to be Non-carcinogenic in lifetime
animal skin painting studies.
Electrol : A transformer oil is expected to be of a low order
of acute schematic toxity. In normal use it is not expected
to be associated with irritation of either skin or eyes and it
is not expected to be a skin sensitizer. No long term toxic
effects are to be expected.

First Aid Measures :

Skin contact : Remove oil soaking clothing. Wash
affected parts of the body thoroughly with soap and water,
kerosene, gasoline or organic solvents must not be used.
Oil soaked clothing, including footwear, must be
thoroughly cleaned before being worn again.
Eye contact : Hold eyelids open and flush eye with water.
Inhalation In the event of dizziness or nausea, remove
casualty to fresh air. If symptoms persist obtain medical
attention. If breathing stops give assisted respiration by
mouth to mouth or mouth to nose method.
Ingestion : Oil products must not be siphoned by mouth.
Ingestion is an unlikely even however if it does occur DO
NOT INDUCE VOMITING. No emergency measures are
needed but if adverse health effects follow, refer for
medical
attention.
Fire and Explosion :
Flash point, PMCC : 156OC
Auto-ignition temperature :
Expected to be greater than 320OC (ASTM method)
Flammability Limits : Petroleum vapours are flammable
(explosive) in proportions between approximately 1
percent and 10 percent of vapour in air by volume at
ambient tempreature and pressures. The vapour pressure
of this product is expected to be too low ambient
temperatures for the lower explosive limit to be reached.
Extinguishing Media :
Recommended : Foam, carbon dioxide (Co2), dry
chemical and extinguishers. Sand or earth may be used to
another small fires.
To be avoided : Water jets should not be used since
product
will float and spread out on top of water and may re ignite.
Action in case of spillage :
Absorb a small spillage with sand or earth. Sweep up and
contain absorbent and then remove it to an appropriate
facility for disposal in compliance with local regulations.
Large spillages should be prevented from spreading by the
use of sand or earth. If possible transfer the spilled oil to a
salvage tank, otherwise treat as for a small spillage.
Disposal of used product and container (where
applicable)
Used oils may contain harmful impurities, which present
risks to health that are not present when handling the new
oil. It is not possible to be more specific since the presence
and absence of harmful impurities is use dependent
therefore ALL use oil should be allowed to contaminate soil
or water and should be disposed of in accordance with
prevailing regulations, preferably to a recognized collector
or contractor. The competence of the collector or contractor
to satisfactorily deal with waste oil should be established
beforehand.
This information is based on our knowledge as of and is
intended to describe the product for the purposes of health
and safety requirements only. It should be not therefore be
construed as guaranteeing any specific property of the
product.

S.O. No. of the Product..

Sr. No. of the Product.

IN CASE OF TRANSIT DAMAGES MARK THE LOCATION OF DAMAGE / OIL LEAKAGE ON THIS DRAWING
AND SEND IT TO CGL (ADDRESS IS GIVEN OVERLEAF)

Crompton Greaves Ltd.,

Switchgear Division (S1)
A-3, MIDC, Ambad, Nasik - 422 010. India.
Tel. : +91 253 2301271, 73
Fax : +91 253 2381247
Email : swgr.contact@cgglobal.com
Registered Office
CG House, 6th Floor, Dr. Annie Besant Road, Worli, Mumbai- 400 030.
Visit us at : www.cgglobal.com