APFC O&M Manual

Safety at assembly and testing of panels at
Customer Site ABB India Limited

PGHV-Capacitors & Filters
Power Products Division
SAFETY NOTE:
1. Ensure the safety shoes, glasses, gloves and ear plugs. For electrical tests, shoes used should not
have any metal protection layer.
2. Ensure that any personal protective equipments were worn correctly and same is in good condition.
3. Ensure the tools and its settings are inspected and ensure the upgradation date.
4. Any equipment not meeting its manufacturers set criteria must not be used and is to be reported to the
maintenance department immediately.
5. Extension cords should have earthing and the running cable should be free of damages to avoid
electrical accidents.
6. Ensure Air supply pipes are appropriately lifted off the floor where possible to eliminate the possibility of
damages and accidents.
7. Ensure floor area is clear and clean during and after work process.
8. Set-up isolation barriers and chains around the equipment/panels to be tested.
9. Hang DANGER labels over the chains on all four sides of dedicated testing area.
10. Ensure the time to time calibration of all the instruments and its maintenance to avoid
failure/accidents.
11. If any equipment, practice or environment is considered to be unsafe, see your Supervisor
without delay.
ENVIRONMENTAL NOTE
1. Environmental aspects are controlled by storing and using materials as per the relevant guidelines and
using engineering controls and/or personal protection equipment where appropriate.
2. Fluid leaks or spills must be cleaned up immediately the accident or incident occurs. Care must be
taken to ensure all items used in containing or cleaning of accident or incident are disposed of in the
correct manner, as stated in the relevant guidelines.
3. All incidence should be reported to the supervisors.
4. Significant leaks or spills need to be monitored.
Safety at Assembly & Testing.

Date : 29.12.2015 Issued By: Dinesha G
Enclosed Capacitor (Filter) bank ABB India Limited
COMMISSIONING CHECKLIST PPHV-Capacitors
Power Products Division
Customer name/site: Date:
Items Observation
1.0 General
1.1 Check phase-phase and phase-earth clearances.
1.2 Check for damage.
1.3 Check all connections as per GA & SLD and check for for tightness.
1.4 Insulation Resistance on busbars (>100M) with 5000V/2500V Megger *
1.5 Micro-Ohmmeter test of all connections (if required to check the interconnections)
1.6 Power frequency HV test (10kV AC phase-earth) **
(* IR should be done before & After HV test)
(** HV should be done at 70% of 10kV, if already 100% voltage is applied during routine
test)
2.0 Incoming Power Cables And Busbars

2.1 Check mounting, positioning, of all insulators and busbars and check for damage.
2.2 Check all interconnection bars joining modules are fitted.
2.3 Check all busbars and current carrying connections for tightness.
2.4 Check phasing correct.
2.5 Check cable and busbar support system is satisfactory.
2.6 Incoming cable terminated correctly and supports fitted.
2.7 Cable sheath earthed.
2.8 Earth cable fitted.
3.0 Cubicle
3.1 Capacitor bank name plate is fitted.
3.2 Clean equipment, wiping insulating parts clean with non-fraying cloth, remove any
grease or adhesive dirt.
3.3 Check for appropriate joining of modules.
3.4 Check doors and panels to ensure straight, square and function.
3.5 Paint finish no chips or scratches. (Touch-up paint supplied).
3.6 Correct and level positioning of cubicle(s). Anchor bolts fitted.
3.7 Check for name plate details & rating & Type.
4.0 Capacitors (if fitted)

4.1 Check mounting of the capacitors and for damaged bushings.
4.3 Check all capacitor connections (busbar and cable) for tightness.
4.4 Check phasing.
4.6 Check the capacitance in each phase.
4.7 Check for capacitor bracket earthing (paint beneath the bracket should be removed)
5.0 Reactors (if fitted)

5.1 Check mounting of reactors. Check for damage.
5.2 Check incoming and outgoing connections for tightness.
5.3 Check phasing.
PPHV – CAPACIOTRS 1
4.2 Remove reactor packing timbers (if fitted for transportation).
6.0 Fuses (if fitted)

6.1 Check fuses are fitted correctly. Check for damage.
6.3 Check phasing.
7.0 Current Transformers (if fitted)

7.1 Check mounting of current transformers. Check for damage.
7.2 Check connections for tightness.
7.3 Visual inspection of primary and secondary circuits, terminal blocks and earthing.
7.4 Check shorting links correctly fitted (marshalling box).
8.0 Voltage Transformers (if fitted)

8.1 Check mounting of voltage transformers. Check for damage.
8.2 Check connections for tightness.
8.3 Visual inspection of primary & secondary circuits, terminal blocks, fuses and earthing.
8.5 Check phasing
9.0 Earthswitch (if fitted)

9.1 Check mounting of earthswitch. Check for damage.
9.3 Check phasing.
9.4 Check earthswitch operation and state of auxiliary contacts (if fitted)
10.0 Isolator (if fitted)

10.1 Check mounting of isolator. Check for damage.
10.3 Check phasing.
10.4 Check isolator operation and state of auxiliary contacts (if fitted)
11.0 Circuit Breaker (if fitted)

11.1 Check mounting of breaker. Check for damage.
11.3 Check phasing.
11.4 Check breaker operation and state of auxiliary contacts (if fitted)
11.6 Insulation resistance test (Ph-En) & (Ph-Ph).
11.7 Check for continuity.
12.0 Earthing
12.1 Earth cable fitted.
12.2 Continuity of earth conductor.
12.3 Check the Earth resistance
12.4 Check for equipment earthing (only capacitor as reactors are with resin cast insulator)
13.0 Surge arrestors (if fitted)
13.1 Check mounting of SA. Check for damage.
13.2 Check for earth connections & tightness.
13.3 Surge Counter connection (if any)
13.0 Protections
13.1 Check for Over current protection settings (Irss =110Amps)
13.2 Check for Earth fault settings.
13.3 Check for time settings.
13.4 Check for Over voltage settings (110%)
13.5 Check for Under voltage settings (90%).
14.0 Measurements
14.1 Check for AC Aux. voltage
14.2 Check for DC Aux. voltage.
14.3 Check for Ammeter & voltmeter & Mvar meter connections.
Procedure to Energize the Capacitor bank-
1) Check and confirm earth switches are in OFF positions (if any).
2) Close main ( bus ) isolator (if Any).
3) In control panel of circuit breaker, local/ remote switch should be in remote
position.
4) Ensure that closing spring of circuit breaker is in charged condition.
5) Check in control relay panel three phase bus supply voltage availability & under
voltage relay is reset or not.
6) Check that the master trip relay in control and Relay panel is in reset position.
7) Check for pre close trip circuit healthiness in both the Trip circuit supervision Relay
for RED LED glowing, which indicates healthiness of trip circuits.
8) Check whether there is sufficient load on the bus & make sure that the indication of
“BREAKER READY FOR CLOSING”.
9) After satisfying above conditions Close the circuit breaker.
10) After closing the breaker check for POST CLOSE Trip circuit supervision (if provided).
If the RED LED is not glowing TRIP the Circuit breaker Manually.
NOTE- NEVER CLOSE CIRCUIT BREAKER FROM CIRCUIT BREAKER PANEL (i.e. FROM
LOCAL), EXCEPT FOR MAINTENANCE JOB.
SAFETY:
FOR UNITS DESIGNED TO IS 13925 - ISOLATE & EARTH SUPPLY. WAIT TEN
MINUTES. APPLY HAND EARTHS TO ALL CAPACITOR TERMINALS.
FOR UNITS DESIGNED TO IEC60871 - ISOLATE & EARTH SUPPLY. WAIT

TEN MINUTES. APPLY HAND EARTHS TO ALL CAPACITOR TERMINALS.
HV capacitors
These instructions apply to type CHD capacitors, supplied as standard with your APFC
System. The capacitors are impregnated with FARADOL 810.
Safety Regulations
When working with capacitor banks the following safety instructions in particular must be
observed.
 Do not touch a capacitor bank until it has been completely discharged, short-circuited
and grounded. Also short-circuit the capacitor units individually. If there is an internal
fault, such as a damaged discharge resistor, there may still be a voltage even though
the capacitor bank has been discharged.
The capacitors have internal discharge resistors which, depending on the standard
used reduces the voltage of the unit as defined in the following table:
Table 1 – Capacitor Discharge Rates
Standard Discharge Rate

IS 13925 Down to 50V within 10 minutes
IEC60871 Down to 75V within 10 minutes
 Avoid skin contact with the impregnation fluid in the event of leakage, and avoid
breathing in fumes or gases from the impregnation fluid. In the event of skin contact,
wash with soap and water. If fluid gets in your eyes, rinse with lukewarm water.
Installation – Mechanical
Tightening torque Capacitor Units (all models)

The tightening torque for the capacitor bushings is to be 25 Nm.
Table 2 Busbar Connections
Nut/Bolt Size Torque Nm

M6 8
M8 20
M10 40
M12 70
Table 3 Structural Connections
Nut/Bolt Size Torque Nm

M6 10
M8 25
M10 50
M12 85
M16 190
Connection of Earth Bar

The earth bar located at the base near the front of the APFC System is connected
between modules using the hardware provided. The APFC System shall be connected to
a suitable earth grid.
Connect the earth

bars between the
modules.
Figure : Earth Bar
Installation - Electrical
Field Power Wiring
When selecting the appropriate cable size due consideration should be given to possible
future extension of the equipment. Cables and isolating switchgear should be rated at 1.5
times the nominal capacitor current of the total capacitor bank and should always be
coordinated with the current rating of the systems protection level. Furthermore, there are
important installation requirements specified in local supply authority rules. In determining
the appropriate size of installation cabling the following are some of the parameters that
should be considered:
 maximum output power of the PFC unit;
 current carrying capacity of the system busbars;
 fault rating of the system;
 physical location of the installation relative to main switchboard.
The nominal current rating of the PFC System can be calculated:

Q
Inom  Where Q = PFC System Var’s
3V
V = System Voltage
Ensure correct phasing of cables from the main switchboard to the incoming connections
of the PFC System.
STANDING (in General) INSTRUCTIONS
1) Whenever the breaker trips due to any fault the concerned relay will drop its flag
and simultaneous alarm and annunciator indication will come. The personnel in
charge of the installation shall silence the alarm and record all the control panel
indications as well as the time of tripping and corresponding load conditions.
Further action may be taken in consultation with a competent authority.
2) In the case of tripping due to unbalance relay the bank should be recharged only
after rectifying the cause of unbalance. If a capacitor unit has failed it is replaced
with another one of equal value. In no case the bank is to be operated
unbalanced. Any re arrangement of capacitor units to obtain new value of
capacitance involves extensive redesign calculations in ABB office not covered by
this contract.
3) If the voltage relay provided is instantaneous, alarm and annunciator indication

may appear during switching on or even during operation due to transient over /
under voltages. Voltage relays are provided with time delay relay that ensures
that the circuit breaker will trip during persistent abnormal voltage condition,
depending upon the setting of the timer. The capacitor bank can be re-energised
after the abnormal condition has disappeared and ensuring that no other
protection has operated simultaneously.
4) If the earth fault / over current relay has operated look for possible short circuits or
grounding or check whether LA has operated. The bank may be charged after
rectifying the fault and meggering.
5) If an automatic power factor control relay is provided it should be put into service
only when sufficient load is there. Otherwise this will cause unnecessary hunting
of the bank, which will reduce the life of the breaker.
6) If DC failure occurs the personnel in charge of the system should manually trip the
breaker immediately as all the protection will be out of service.
7) If the re-close blocking timer is not working, the bank should not be put in auto
mode. Operating staff should consciously ensure that every re-closing should be
done after 5 minutes of discharge time only.
8) Oil temperature alarm / tripping if provided shall operate in case of overheating of

the reactor either due to internal fault in the reactor. Problem may be identified, if
necessary re-calibration of the gauge may be done & the capacitor may be re-
energised if no internal fault has been identified.
9) Do not operate the capacitor bank under light load.
10) Never operate any equipment above its rated values
11) A separate fence may protect the entire capacitor bank installation and no
unauthorised persons must be allowed to touch the installations.
12) Unlike some other equipment the capacitor retains its charge for definite time.
Therefore, before handling the units the entire bank is to be isolated by first
tripping the breaker and then by opening the isolator. Wait for 5 minutes before
touching a capacitor unit, always discharge, short and then ground it.
13) During servicing and maintenance of any equipment the nature and design of the
system is to be preserved. Any modification whatsoever must be done only in
consultation with a competent authority.
14) In case of any difficulty in operation or maintenance kindly contact the supplier for
assistance.
15) Competent authority may make changes in the operating instructions based on
their special studies without violating principles of safe operations within rated
capacities.
16) Users of the capacitor banks expecting power relief in tariff should bear in mind
that most of the tri-vectors increment the MVAh even when capacitive MVArh are
being drawn just as in case of inductive MVAr drawal. Capacitive MVArh may not
nullify the previous inductively incremented MVAh. This means operating
capacitor banks during net leading power factor conditions shall also attract poor
power factor penalty not withstanding the fact that the power factor shall be
leading during this period. This is because the power factor calculations are made
by utilities based on integrated monthly figures of MWh / MVAh. This aspect calls
upon judicious advice to be evolved by the competent authority of the consumer
after closely studying their own load profile, being made available to the operating
staff as regards switching off and on the banks. This is necessary to make best
commercial use of the banks.
PPHV – Capacitors
OPERATING INSTRUCTIONS FOR APFC PANEL
A) To Switch ‘ON’ the APFC panel:

1) Check that Earth-switch is in OPEN position.
2) Check that Isolator is in CLOSED position.
3) Switch ON the Upstream Circuit Breaker.
4) In Manual Mode: Switch ON/OFF the outgoing stages as per kVAr requirement
in the system using Push buttons.
5) In Auto Mode: APFC relay will sense the kVAr requirement and automatically
give commands to switch ON/OFF the outgoing stages.
B) To Switch ‘OFF’ the APFC panel:

1) In Manual Mode: Switch OFF all the outgoing stages using Push buttons.
2) In Auto Mode: Select OFF mode in Auto-Off-Manual Selector switch. This will
switch OFF all the outgoing stages.
3) Switch OFF the Upstream Circuit Breaker.
4) Isolator shall now be in OPEN position.
5) Earth switch shall be put in CLOSED position.
*Now panel will be ready for any shut-down/maintenance activities.
C) Electrical Interlock between APFC panel and Upstream CB:

Off-load isolator can be opened only after Upstream CB Tripping.
For this, Castle lock (1NO+1NC) is used.
1HYC416004_A
ABB
INSTRUCTION MANUAL
FOR
INSTALLATION, OPERATION AND
MAINTENANCE
OF
H.V. SHUNT & SERIES CAPACITORS
ABB INDIA LIMITED

Power Products – HV Capacitors
Plot nos. 4A, 5&6, II Phase, Peenya Industrial Area
Bangalore – 560 058
Phone : +91 80 2294 9327
This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be
used for any unauthorized purpose. ABB India Limited, Peenya, Bangalore – 560058, Karnataka, INDIA
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ABB
Table of contents
1) Introduction
2) Safety regulation
a. Explosion
b. Leakage
c. Safety equipment
3) Handling
a. Documents
b. Transport / unloading
i) Lifting device
ii) Unpacking
iii) Storage
4) Installation
a. Documents
b. Tightening torque
c. Support insulators
d. Module
e. Connection insulators and busbars
f. Capacitor unit
g. Connection cables
h. Connection of capacitor bank
i. Capacitor bank
5) Commissioning
a. Inspection prior to energization
i) Visual inspection
ii) Capacitance measurement
b. Inspection after energization
i) Voltage measurement
ii) Current measurement
iii) Unbalance current
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c. Checking operation data
i) Voltage
ii) Capacitor current
iii) Ambient temperature
iv) Unbalance voltage
v) Unbalance current
d. Special precaution
e. Maintenance
i) During operation
iii) Clearing
iv) Cracks
v) Leakage
vi) Painting damages
vii) Replacement of faulty capacitor units
f. Disposal of Faradol impregnated capacitors
g. Corrective action after relay operation

i) Unbalance protection
ii) Overload protection
iii) Relay protection setting
iv) Trouble shooting
6) Annexure I (Do’s and Don’t’s)
7) Annexure II (List of documents)
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1. INTRODUCTION
This instruction applies only to FARADOL (Jarylec) impregnated (PCB-free) high

voltage capacitors manufactured as per IEC 60871-1 / IEEE 18 – 2002 / IEC
60143 –1.
This instruction is a guide for persons working with capacitors but does not
replace official regulations or any insurance company requirements relating to
the installation and operation of capacitors.
The capacitor banks are built up of single phase or 3 phase capacitor units to
form a composite capacitor bank of required rating and is supplied along with
the accessories like banking materials, structures, interconnection materials,
etc.. The capacitors of ABB are made of 100% polypropylene film impregnated
with non-PCB, non-toxic dielectric (FARADOL) and are provided with internal or
external fuses or are Fuseless and discharge resistors.
Each capacitor unit is made up of a number of elements in series parallel

combination. Capacitor units are of two types : 1-phase and 3-phase.
Capacitor fuse, if provided, can be internal or external. In case of External fuse
type HRC fuse or expulsion type fuse and being used.
In case of internal fuse capacitor unit, if a particular element has failed the
respective fuse will blow and disconnect the element. However, this will not
affect the operation of the capacitor unit but will result in a slight reduction in the
capacitance value. In Case of Externally Fused Bank or Fuseless Bank, there
will be a slight change in the Capacitance value upon element failure.
2. SAFETY REGULATIONS
When working with capacitor banks, the following safety regulations must be
observed.
Until bank is short circuited and grounded it shall be considered as energised

After capacitor bank has been disconnected, same voltage always remains in
each capacitor unit. Grounding may only be conducted once discharge period
has passed. The discharge period is counted from when circuit breaker is open.
Before work is begun with capacitor unit It is important that entire capacitor bank
has been grounded. The recommendation is to wait at least 10 minutes. There
after unit must be short circuited.
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Do not touch a capacitor bank until it has been completely discharged,
short circuited and grounded. Short circuit the capacitor units individually.
In some special cases, primarily for test lab applications, the capacitor units do
not have discharge resistors. In these cases, special care must be taken. The
discharge circuit must include suitable resistance and the discharge tool must
have extra insulation to withstand full voltage.
a. Explosion
In extreme cases, a capacitor unit can fail with case rupture as a result. In
such cases, there can also be risk for oil leakage and perhaps even fi re.
b. Leakage
Upon capacitor unit leakage, avoid skin contact with the impregnation fluid.
In the event of skin contact, wash with soap and water. If fluid is splashed
into the eyes, rinse with lukewarm water and seek medical care. For
detailed information about the impregnation fluid, see the material safety
data sheet for the Faradol 810. For measures to be taken in the event of
leakage, see Section 5 (e) (v).
c. Safety equipment
While handling goods during unloading and installation it is important to

consider local laws and regulation regarding personal safety
3. HANDLING
The following instructions explain how the equipment is safely handled.
a. Documents
The following documents are required in relation to arrival, unloading and

unpacking:
· This manual
· Packing lists
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b. Transport/Unloading
i) Lifting devices
The capacitors must never be lifted by the bushings.
The nuts on the bushing studs shall be tightened with a torque of 20-
25 Nm approximately.
The equipment can be heavy and bulky. Due to this, it is important to

ensure that you have suitable lifting devices available upon arrival for
unloading and handling.
All transports to and from the substation must be conducted with the
material properly enclosed in its packaging.
Upon arrival of the equipment, it is important to carefully check for

transport damage and that the delivery is complete. Be especially
careful when unpacking insulators.
If there is damage/shortage, it is important to document this with
photos and that the freight forwarder is contacted as soon as
possible. Immediately send the photos, along with the part number
of the damaged material, to the ABB India Ltd to minimize the risk
for unnecessary delay of replacement material.
It is recommended that all material is verified and checked with the

packing lists before starting the installments alternatively the storage.
Kindly also refer Clause 5 (e) (v) for action in case of leakage.
NOTE THAT A CAPACITOR UNIT MUST NEVER BE LIFTED OR

HANDLED BY THE BUSHING AND DO NOT ROLL THE UNIT FOR
MOVING FROM PLACE TO PLACE. OTHERWISE, SOLDER
SEALING WOULD GIVE RISE TO LEAKAGE, WHICH IS
UNDESIRABLE.
Take care not to damage the paint of the units during installation.
Protect the sides of the units from scratches when they are pushed
into the rack. Touch up any paint damage that may occur.
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ii) Unpacking
Be careful during unpacking to make sure that the goods is not

damaged! The content in the boxes shall be verified against the
packing lists during unpacking, unless this has already been
made upon arrival of the goods.
iii) Storage
With storage means up to six (6) months for capacitors delivered

mounted into racks. Capacitors delivered as loose units shall be
unpacked at arrival unless assembled directly. The capacitors
shall be stored on an even and well-drained surface that is
adapted for the load of the goods. The storage shall be placed in
a well-ventilated space or under a roof. High humidity in
combination with high temperature is unsuitable even for shorter
storage, why the time frame of six (6) months for capacitor
modules in hostile environments should be shorter. Do not
storage the goods in a wet box.
4. INSTALLATION
a. Documents
The following documents are required in relation to installation/assembly:

· This manual
· Assembly drawing
· Bill of Material
· Packing lists
b. Tightening torque
Nuts on the bushings with clamps for copper cables are torqued to 15–
20 Nm.
Stainless steel nuts/bots on busbar connections (with lubricant):

Nuts / bolts, size Tightening torque, Nm
M6 8
M8 20
M 10 35
M 12 65
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Other, galvanized, nuts/bolts (without lubricant):
Nuts / bolts, size Tightening torque, Nm

M6 10
M8 25
M 10 50
M 12 85
M 16 205
M 20 430
c. Support Insulators
If applicable, the support insulators

with threaded holes shall be
positioned on steel beams of
sufficient dimension, such as
Ibeams. Insulators with through-
holes can instead be placed on the
foundation and secured with
expansion bolts or bolts cast into the
concrete. It is important that these
are aligned because the insulators
must be on a well-balanced surface.
Once this has been fulfilled, the
insulators are positioned. Do not
fully tighten them; adjustments will
probably be necessary at a later
stage. Use spacing washers/shims
where necessary to relieve stress on the isolators.
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The next step is to place the module at
its correct position according to the
assembly drawing. It is important to
place the rack on the insulators with
care since they can otherwise be
damaged. If there is more than one
rack per phase or if the three phases
are placed above one another, the first
rack must be tightened before
continuing with the next phase or rack.
If the insulators are heavy, they should
be lifted with a lifting device and
secured with bolts. If the insulators are
light, it can be easier to lift the module
and bolt the insulators in place from
beneath before the entire module with
the insulators is lifted into place.
d. Module
The capacitor bank is delivered with all capacitor

units mounted in the rack. Each rack has
a predefined position in the bank with an
individual number that matches the
suppliers' assembly drawings.
As many components as possible are

fitted to each rack prior to delivery. All
additional materials, such as bolts,
insulators, busbars and sleeves that are
needed during assembly at the site, are
packed in separate boxes Follow the
assembly drawing so that each module
is fitted at the correct position in the
capacitor bank, in other words, correct phase, correct level and correct
orientation.
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When lifting the modules, use the lifting slings (see picture above) or lift
it in the rack.
If paint damage occurs during assembly then see section-VI (e) (vi)
Bushing on capacitor units may not be subjected to external pressure or
impact. Capacitors should not be lifted by bushings
d. Connection Insulators and busbars
Once all racks are in place and

properly tightened begin fitting
connection insulators and bus bars
Bus bars are fitted as per assembly
drawings and GA drawings Necessary
cutting of bus bars and drilling holes
should be done at site.
e. Capacitor Unit
For tightening the nuts of the capacitor unit terminal, first fix both the parts of
terminal connector on the bushing stud, pass the interconnection wire through
the groove provided, place the plain washer, spring washer and then put a nut
on the top as shown in page no --.Then tighten the nut carefully without
exerting excessive force with the help of a Spanner.
The torque during tightening should be approximately 20-25 Nm and should

not exceed 40 Nm.
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f. Connection cables
Conductor should be cut at

right length and connected
between bushing of units
using connector. The
schematic drawing and GA
drawing should be referred
for inter connection of
units.
Kindly note rack shorting
must be done as per GA
drawing to achieve
defined potential to rack.
Rack shorting
g. Connection of capacitor banks
Before a capacitor bank can be energized or grounded, it must be

discharged to maximum 10% residual voltage, which corresponds to the
time which is specified for re-connection on the capacitor bank rating
plate. The discharge is made by the internal discharge resistors, and is
necessary to avoid harmful overvoltage.
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The recommendation is that the switching equipment has an interlocking
system to prevent reconnection of the capacitor bank before it’s
discharged to less than 10% residual voltage.
i) Capacitor Bank
The capacitor banks either come as separate capacitor units, racks and
connecting parts or as complete modules and the units mounted in
racks. With a view of voltage distribution and balance, the units in a
capacitor bank must be installed in a given order.
IF THE UNITS ARE DELIVERED ASSEMBLED IN RACKS, THEY

WOULD ALREADY HAVE BEEN BALANCED. THE RACKS ARE
MARKED AND MUST BE POSITIONED IN ACCORDANCE WITH THE
INSTRUCTIONS ON THE INSTALLATION DRAWING.
The tolerance group of each unit is marked on the unit rating plate on
the right hand side. In case the unit has to be replaced, please ensure
that the new unit being replaced has the same tolerance or a tolerance
group near to the unit being replaced. This is to ensure a proper
balanced bank. For filter banks used for installation like HVDC, the new
unit being replaced should have a tolerance not more than one step
away from the unit being replaced.
Carefully observe the instructions in the test report on the installation

drawing so that the units are correctly positioned in the rack and the rack
is correctly positioned in the bank.
5. COMMISSIONING
The following documents are required in relation to Commissioning.

· This manual
· Assembly drawing
· Bill of Material
· Positioning charts/bank balancing charts
· Routine test report
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a. Inspection prior to energization
i) Visual inspection
Check that modules are fitted at the correct positions according to the
assembly drawing.
Check that all internal connections are properly made, follow the current
path from the incoming terminal through the complete capacitor bank.
Check that all rating plates are in place.
Check that all inter connection cables seems to be of the correct

dimension and that parallel conductors are used where this is specified.
Check the earthing connections and potential connections for the

complete capacitor bank.
Check that the capacitor bank is properly secured towards the

foundations.
Check all surface treatments (painting, galvanizing, porcelain etc.).
Check all air clearances within the capacitor bank. The following table
gives some minimum air clearance distances as per IEC 60071-2, 1996.
System voltage Insulation level Air clearance distance (mm),

(kV) BIL/SIWL (kV) phase-phase and phase-
ground
3.6 40 60
7.2 60 90
12 75 120
17.5 95 160
24 125 220
36 170 320
52 250 480
72.5 325 630
123 450 900
123 550 1100
145 550 1100
145 650 1300
170 650 1300
170 750 1500
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All capacitor units delivered from the factory has passed routine testing
as per applicable standard. Due to this, it’s not necessary to measure the
capacitance of all units in the capacitor bank prior to energization.
However, we still recommend to perform a capacitance measurement to
be performed on all units in the bank, because it gives the benefit of
having a reference value of the capacitance from a measurement with
own measuring equipment for future maintenance, and also the benefit
of maintenance staff having a chance to get familiar with the equipment.
For the capacitance measurement we recommend to use an ABB
Portable Capacitance meter CB2000 which allows to perform the
measurement without removing the interconnections between the
capacitor units.
A capacitor unit with capacitance that has changed more than

approximately 10% compared with the value in the routine test report,
should be replaced. An exact value can be obtained from the supplier,
since it’s depending on the actual design of the capacitor unit.
Checking of insulators:- Insulators can be checked by measuring

insulation resistance using Megger.
Tightening torque
Check all tightening torques for the nut on the top of the bushing, as well
as all other electrical connections. The correct torques can be found in
Section 4 (b).
b. Inspection after energization
i) Voltage measurements
It’s recommended to perform a voltage measurement before and after

the capacitor bank is energized. The purpose of the measurement is to
check the change of the voltage level in the network before and after the
capacitor bank is connected.
ii) Current measurement
The purpose with the current measurement is to confirm that the current
do not exceed the design values for the equipment.
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iii) Unbalance current
The purpose with the measurement of the unbalance current is to verify

that the capacitor bank has been properly balanced.
c. Checking Operating Data
The following measurements shall be made to ensure the Healthiness of

capacitors.
i) Voltage
Voltage before and after switching on the capacitor bank. The capacitor
must not be subjected to a continuous voltage exceeding 110% of the
nominal voltage for a period exceeding 12 hours in a period of 24 hours.
ii) Capacitor Current
The capacitor must not be subjected to a continuous current exceeding

130% of the rated current.
iii) Ambient Temperature
The capacitor bank must not be continuously subjected to an ambient

temperature exceeding the stated temperature class.
iv) Unbalance Voltage
When residual voltage transformers are used for unbalance protection,

the open delta voltage shall be minimum.
v) Unbalance Current
In case neutral current transformers are used, the unbalance current

shall be minimum at the time of commissioning.
If the individual capacitors are at different temperatures, for example

because of solar radiation, the unbalance current / voltage immediately
after switching on the bank may differ from the value after a few hours in
service. The unbalance current / voltage should therefore, be measured
when the capacitors have reached their normal operating temperature.
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d. Special Precautions
When the system is feeding non – linear loads such as thyristor

convertors, arc furnaces etc., that generate harmonics, it
is recommended that application check be carried out before connecting

the capacitors to such a system.
The voltage and current margins stated above are intended to allow
operation during temporary peaks. These margins should not be used
under normal service conditions.
Voltages and currents should, therefore be measured under all the load
situations that occur, in order to ensure that the capacitor bank is not
overloaded.
Pay special attention to periods of light load. A capacitor bank always

causes a small increase in voltage. At light loads this can result in
problems. Since the voltage may already be high even with out the
capacitor bank. Avoid operation of capacitors with leading power factor .
When the load is low there is also a risk of resonance between

capacitors and transformers and this may give rise to considerable over
voltages.
e. MAINTENANCE
In order to assure long life time and trouble free operation, periodical
inspection of the capacitors banks are suggested as listed below:
Visual examination of the bank for fouling, deterioration of painting or

leaking of capacitor units. Insulators and bushings shall be cleaned
periodically .On peeling off of the paint or when localised
corrosion/rusting takes place, repainting should be undertaken after
proper cleaning of the surfaces. However it is recommended to repaint
the units periodically depending upon the site conditions.
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i) During operation
Checking the Unbalanced voltage/current : Regularly check the

unbalance current and note the measured values. In the event of faults,
the unbalance current changes by degrees. Small continuous deviations
can be explained by temperature variations.
Settings and operation of the protective relays shall be checked.
All external connections shall be checked for tightness.
For the capacitor banks with units having internal fuses, the unbalance
current value of upto 50% of the tripping value of the protection system
is acceptable. Failure of single element does not affect the service ability
of the capacitor bank or significantly reduce its service life.
If the unbalance current value exceeds 50% of the tripping value, the
capacitance of all the units in the bank shall be checked and those
whose values deviate by more than 10% from the original value must be
replaced.
Capacitance measurement is only performed at fault indication or when

the unbalance protection has tripped the bank. However, we recommend
regular measurements of all units in the bank to check condition of each
unit.
Initially the inspection should be done at shorter intervals (4 to 6

months). After experience, the gap between inspections may be
gradually increased.
Furthermore, use a torque wrench to ensure that bushing tops and

electrical connections are tightened to the correct torque. Also check that
fuse holders are torqued for capacitor units with external fuses
Page : 17/41
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iii) Cleaning
Conduct an ocular inspection for among other things, soiling, paint

damage or leaking capacitor units. Insulators and bushings are wiped
clean as necessary. An extremely dirty capacitor bank can be rinsed with
water. In the event of heavy soiling, cleaning should be regularly
conducted.
iv) Cracks
Ensure no insulators are damaged. For insulators replacement you need

to take away modules above insulators For regarding mounting after
swap refer instruction above for installation
v) Leakage
If a capacitor is damaged and there is leakage, it must be replaced.

Leakage of less than 1 dl, however, can be sealed by soldering or with
polyurethane putty, depending on the location of the leak. A small
amount/drops of impregnation fluid can enter the top of the bushing and
discolor the porcelain. This occurs in such case very soon after delivery
and stops as soon as the seal in the bushing is sufficiently moistened by
the impregnation fluid and cooled. Wipe off the discoloration and check
that it does not reoccur. Spilled impregnation fluid can be absorbed with
sawdust or similar material. A rag soaked with a cleaning agent, such as
petroleum spirits, can be used for cleaning. Safety directives for
impregnation fluid and a material safety data sheet can be sent upon
request. Please contact the supplier.
vi) Painting damages
Minor paint damages can be made good at site by cleaning the

damaged area and touching up the paint.
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vii) Replacement of faulty capacitor unit
Upon replacement of a faulty capacitor unit, it should be aimed to

achieve as small deviation in capacitance as possible. Preferably the
replacement unit should have the same or adjacent sign, compared to
the faulty unit. The sign can be noticed on the capacitor unit rating plate,
the routine test report or the positioning chart. If no such replacement
unit with similar sign is available, the supplier can assist in performing a
new balancing and unbalance calculation. In this case, there’s a risk that
a few more capacitor units has to be moved within the capacitor bank, to
obtain an acceptable balancing of the capacitor bank.
When ordering a replacement unit, it’s important to notify the factory of

exactly which unit(-s) to be replaced, which means the order- and unit
number that can be found in the unit rating plate. It is recommended to
take a photo of the rating plate and send it to the supplier.
f. Disposal of FARADOL Impregnated capacitors
Impregnated capacitor elements are disposed of according to the

country’s environmental directives. During work in which one can come
in contact with wet capacitor elements, the use of protective gloves
(rubber) and safety goggles or a visor to guard against splashing into the
eyes is recommended. The capacitor unit's connections must be short-
circuited while working. The container is punctured and the free
impregnation fluid is collected before the container is fully opened.
Remove the capacitor element package from the container and short
circuit the capacitor unit before removing all soldering and copper
busbars. Both the fluid and capacitor unit can be burned in an
incinerator. Remaining after incineration are primarily aluminum and a
smaller amount of copper.
The recommended way of disposal of FARADOL impregnated capacitors

is to burn them. Before doing this, open the capacitor and pour the free
fluid (3-6litres) into a container.
Both the fluid and the remaining contents can be burned in an

incinerator in the same way as mineral oil based fluids AFTER
OBSERVING SAFETY REGULATIONS GIVEN UNDER CLAUSE 2.
After incineration, only solids (6-8 kg) and small particles of copper
remain. Apart from the above residue, only water and carbon dioxide
are given off on burning with normal supply of oxygen.
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g. Corrective Action After Relay Operation
i) Unbalanced protection
When the capacitor bank has been disconnected by the unbalance

protection, the capacitance of all the units shall be checked and the
faulty units shall be replaced with units having capacitances as close as
possible to that of the faulty unit. The unbalance voltage/current shall be
checked after recharging the bank.
ii) Overload protection
In case of tripping by overload protection due to temporary

overvoltages/overcurrent, the bank may be put into service when the
disturbance has been eliminated.
NOTE : AFTER TRIPPING, THE BANK SHALL BE RE-ENERGISED

ONLY AFTER 5 MINUTES / 10 MINUTES (AS GIVEN IN THE BANK
RATING PLATE) SO THAT RESIDUAL VOLTAGE ACROSS
TERMINALS IS LESS THAN 10% OF THE RATED VOLTAGE.
iii) Relay Protection Settings
If the control and relay panel is supplied by ABB, refer the recommended
Relay Settings given in the Operation and Instruction manual. If the
control and relay panel is not in the scope of ABB, then the settings of
the relays shall be provided in such a way that:
Overloads specified in IEC 60871-1 are taken care of. The following
major relays are generally required for capacitor protection :
· overcurrent and earth fault
· under voltage
· over voltage
· unbalance relay
The voltages are to be chosen based on specific application and custom

requirement.
In addition, under voltage relay shall be provided by the customer to

facilitate tripping of the capacitor bank, when the voltage dips below 80%
of the nominal system voltage.
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iv) Trouble shooting

Symptom Fuse type Possible Corrective action
cause
Unbalance signal Internally Element fault Check the bank
alarm fused / no and the next
fuse shutdown
Unbalance signal Externally Element fault Schedule
and/or external fused External shutdown within
fuse has blown flash-over near future see
section 5 (e) (vii)
Unbalance signal Internally Element fault See section 5 (e)
has tripped circuit fused / no External
breaker fuse flash-over
Unbalance signal Externally Element fault See section 5 (e)
has tripped circuit fused External
breaker flash-over
For further Instructions refer Annexure 1 (Do’s and Don’ts).
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ANNEXURE – 1
Do’s and Don’ts for capacitor bank guide for commissioning engineer.
Introduction
This document gives information to commissioning engineer to follow certain important

guidelines.
Capacitor bank is not a standard product like CT/CVT/Circuit breaker. It is customized

product and is assembled in site. The capacitors with racks, loose aluminium flats,
supporting angles, insulators are transported to site. It should be assembled as per GA
drawing
Kindly note all big failures/flashovers/sparkings in capacitor banks are due to

improper connections/improper clearances/improper protection settings
To make successful commissioning of capacitor bank following should be taken care

· Connections
· Clearances
· Protection settings
The commissioning engineer should carry following documents before assembly of

capacitor bank
· General Arrangement drawing ( latest copy)
· Foundation plan
· Schematic diagram
· Rack and Aluminium flat,support angle insulator drawings.
· Unbalance calculation sheet
· Relay protection settings for other protection such as
overvoltage/undervoltage/overcurrent/short circuit protection settings.
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Following should be carefully taken care
Connections
Connections should be checked as per GA drawing and Schematic drawing.

Sr Don’t or Dos Impact
no.
1 Hot spot
Do not put GI washer between terminal

connector and Aluminium flat
Wrong
2 No hot spot.
DO Terminal connector should have butt

contact with Aluminium flat
Current flows from conductor to clamp to
Aluminium flat
Right
Page : 23/41
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no.
3 Hot spot
Do not put Insulating tape between

conductor and connector
Wrong
4 No hot spot.
DO Bare conductor should be used

between top and bottom terminal
connector
Right
Page : 24/41
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no.
5 Reduction in clearance.
This can result bushing to
bushing flashover causing
severe damage to unit
and bank.
Do not extend the conductor length

beyond top cap metallic part or bushing.
The conductor should not projected
beyond top cap metallic part
Wrong
6 No flashover risk during

overvoltage or normal
voltage.
DO Conductor should be extended till

bushing top cap metallic part. If it is more
than top cap metallic part then it should
be trimmed.
Right
Page : 25/41
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no.
Loose connection Hot
spot
Do not Continue if the bolt is wrongly

supplied and terminal connector and
threads are mismatching. Ask factory to
supply correct bolt
Wrong
8 No loose connection no
hot spot
DO Terminal connector should easily be

connected to bolt without any thread
mismatch.
Factory should sent this assembled i.e.
“bolt and terminal connector assembled to
avoid this error
Right
Page : 26/41
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no.
9 Lack of rack shorting will
result floating potential
at rack and cause
abnormally high
overvoltage beyond the
design limit on capacitor
bushing and inter rack
insulator. This can result
failure of inter rack
insulator bushings and
severe damage to total
capacitor bank.
Do not Forget Rack shorting
Wrong
10 Rack shorting will
uniformly distribute the
voltage on inter rack
insulator and capacitor
bushing since rack has
fixed potential. This will
not allow the overvoltage
on unit and insulator
beyond the designed
limit
DO Rack shorting as per GA drawing
Page : 27/41
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no.
11 It can generate hotspot
due improper connection
between copper
conductor and terminal
connector
Do not keep tie wire inside connector.

Wrong
12 This will avoid any hot

spot
Keep tie wire for copper conductor outside

terminal connector
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no
.
13
Melting of conductor within 8 hours in

Do not keep tie wire between service resulting plant shut down
connector and conductor
14 Do not keep Loose connection

especially busbar jumpers
Melting of jumper within15 secs of

charging due to huge sparking
resulting in shutdown
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Kindly ensure tightness with skilled manpower under supervision of experienced
knowledgeable engineer
Clearances
Capacitor bank is made up of various component such as capacitor unit, busbar
support insulator, capacitor racks, inter rack insulators, bank support insulators,
aluminum flats, flexible conductor and GI support angles for supporting insulators.
Hence it is important to refer GA drawing and Schematic drawing bank detailed drawing
such as flat drawing angle drawing before assembling the capacitor bank. The erection
commissioning engineer should be trained to understand capacitor bank and
clearances. He should take advice of capacitor technical department while erection
and commissioning. Any mistake in assembly or connection can result violent failure of
capacitor unit and bank. The capacitor bank should be charged after technical
clearance of PPHV Capacitor technical department. Following clearances should be
checked
Page : 30/41
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Sr Dos Remark and
no. description
1 Capacitor unit
DO – Measure clearance between Current container is at different
carrying Aluminium flat and capacitor potential i.e. rack
Container. potential while
Aluminium flat is at
different potential.
Hence it is necessary
to check clearance
between Aluminium flat
busbar and container.
This clearance should

be as per GA drawing
and IEC standard
insulation coordination
2 Insulator supporting
DO Measure clearance between insulator angle is at rack
supporting angle and bushing metallic cap potential i.e. unit
container potential
while bushing terminal
cap is at unit voltage
potential. It is
necessary to check the
clearance between
insulator support angle
and bushing metallic
cap
This clearance should

be as per GA drawing
and IEC standard
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Sr Dos Remark and description
no.
3 DO – Measure clearance between Phase to phase clearance
phase to phase. especially capacitor bank when
RYB phases are vertically
installed are very important.
Phase to phase clearance
should be measured as follows.
Between R phase- Y phase
Between Y phase – B phase
This clearance should be as per

GA drawing and IEC standard
4 Phase to neutral clearance

DO Measure clearance between phase especially capacitor bank when
to neutral RYB phases are vertically
installed are very important.
Phase to neutral clearance
should be measured.
Since bank is vertical the
clearance between R phase
neutral and Y phase and Y
phase and Y phase neutral
should also be measured as
follows.
R phase – R neutral
Y phase – R neutral
Y phase – Y neutral
B phase- Y neutral
B phase- B neutral

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no.
5 Unit bushing are connected to
DO – Measure clearance between incomer phase conductor by
flexible conductor for connection to flexible copper conductor. It is
unit to incomer phase and container necessary to check the
which is at rack potential clearance between the flexible e
copper conductor to container
which is at rack potential

6 Each rack will have fixed

DO Measure clearance between rack to potential based on rack
rack nearest metallic parts. shorting. The clearance
between racks is designed
based on the potential
difference between two racks.
The insulator is also specified to
based on potential difference
between racks.
It is necessary to measure
minimum clearance between
two racks.
No other metallic part is allowed
in between two racks.

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no.
7 In case of C filter where
DO – Measure clearance between Resister resistor is mounted on
and capacitor incomer and Unit to resister top of capacitor. Resister
interconnection and rack body capacitor incomer
and rack are at different
potential. Flexible
interconnection between
resister and capacitor
should have sufficient
clearances.
This clearance should be

as per GA drawing and
IEC standard insulation
coordination
8 Phase to earth clearance
DO Measure clearance between Phase to should be measured.
earth In 11kV capacitor bank
rack is connected to
earth potential
This clearance should be

as per GA drawing and
IEC standard insulation
coordination
Page : 34/41
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no.
9 This can cause
flashover between two
bushing which may
lead to unit as well as
bank failure
Rack shorting wire should not be close to

other bushing which will reduce clearance
Wrong
10 This will avoid any
flashover between
bushings
Rack shorting conductor should be keep

away from other bushing close to container
since container rack have same potential
11 This will strengthen

insulation and avoid
flashover between
insulator support angle
and conductor/bushing
For corner units especially near bus support

insulator bird caps and insulation sleeved
conductor should be provided to avoid bird
fault
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Protection
Following protections are required for capacitor bank
· Overcurrent protection—Overload protection

· Earth fault protection
· Overvoltage protection
· Under voltage or No voltage protection
· Unbalance current or voltage protection
· On time delay- Once capacitor is switched off it should not be switched on till
capacitor is discharged fully. The capacitor feeder should be switched on only
after time delay. This time delay depends on discharge time of capacitor
specified by IEC/IS or customer specific.
Commissioning engineer should take unbalance calculation document to decide

unbalance alarm and trip settings.
Based on type of relay the unbalance current/ overvoltage/overcurrent/earth fault

current setting are transferred to relay settings.
Overcurrent protection 1.2* bank current (calculated based on Installed bank voltage
and installed MVAR) K=0.1 IDMT
Earth fault – based on system and Current transformer rating.
Overvoltage- alarm-1.1* Rated system voltage at bus time – IDMT k=0.2
Trip 1.15 Rated system voltage at bus time- definite time =1 sec
Under voltage – Trip -0.8* Rated system voltage at bus. Time- 2 sec
Unbalance current- As per unbalance calculation sheet given by designer. Time
setting for trip is 100mS
During commissioning, unbalance current setting should be kept more sensitive
based on actual unbalance current. It is advisable to keep unbalance current to
1.5 to 2 times actual unbalance current for initial stabilisation period. This will help
to trip the capacitor bank very fast and avoid cascading effect.
It is advisable to keep some commissioning spares to avoid delay in
commissioning if one or two units failed during test charging.
Unbalance current – as per unbalance current calculation time IDTMT K=0.1
On time delay- capacitor breaker should be switched on only after discharge of
capacitor bank. This time delay is normally 600 sec or 300 sec depending on discharge
time specified for capacitor bank.
For SVC, HVDC projects, protection setting will be given separately by System
Engineer.
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Pre commissioning checks
Visual checks- Oil leakage from Bushing or bracket.

Checking of clearances and connection protection as above.
Condition of bushing. Any damage to bushing
Megger- Insulation resistance of all insulators i.e. bus support insulator and inter rack
insulator.
Capacitance measurement of all units
Natural unbalance current. This can be done at low voltage measurement (230V). The
unbalance current is measured at 230V in mA and linearly extrapolated to rated voltage
of capacitor bank. The natural unbalance current should not be more than 20% of
tripping current mentioned in unbalance calculation document.
Tightening torque for bolts at bushing top should be 15 to 20 Nm
Low voltage measurement to check unbalance current
For big bank like SVC filter bank where no of units are more. The low voltage
measurement is advisable at site to check natural unbalance current.
This measurement is done at 400V (phase to phase voltage). This is possible at site
since 3 phase 400V is available at site.
Requirement- 3 phase supply which is available in control box in switchyard, accurate

milli ammeter, 400V 10 A cables for interconnection, multimeter to measure current
voltage.
Procedure- connect the 3 cables R/Y/B to incomer of bank. This measurement can be
done with reactor or without reactor.
Connect one cable between 2 neutrals by disconnecting NCT.
Switch on the supply voltage 3 phase 400V

Conduct unbalance current in mA by clamp on milli ammeter.(if milli ammeter is not
clamp on type then connect milli ammeter in series with cable which is connecting
between neutrals.
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Note down voltage/current and unbalance current in milli ammeter
Sr Bank Voltage (V) Line current Unbalance current in mA

No details R Y B (A)
The unbalance current should be extrapolated to bank rated voltage as below
Unbalance current in NCT primary at rated voltage = [Rated Voltage (v)/400V]*

unbalance current measured at 400V
Check this unbalance current is at least 50% less than trip current of unbalance
calculation of capacitor bank
If this unbalance current is more than 50% of trip current then kindly balance the bank
by swapping units based on individual unit capacitance phase capacitance group
capacitance. When unbalance current is less than 50% of trip current and all
clearances are ok and all units capacitance values are ok and insulation resistance of
all insulators are ok then bank can be charged and monitor the actual unbalance
current.
Monitor unbalance current for 12 hours (hourly unbalance current should be recorded)
If there is no abnormality the bank can be continue in service
For single phase banks- FSC/HVDC/ railway application—low voltage measurement is

done as above with single phase source voltage 230V.
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Low voltage measurement at site
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General information about insulation level and clearances
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Page : 41/41
*************************************
INSTALLATION OPERATION AND
MAINTENANCE INSTRUCTIONS
FOR DRY TYPE TRANSFORMERS
AND REACTORS.
***************************************
INSTALLATION,OPERATION AND MAINTENANCE INSTRUCTIONS
FOR DRY TYPE TRANSFORMERS/REACTORS.
1. INSPECTION ON ARRIVAL: It is recommended that immediately on arrival,

the transformer/reactor should be unpacked,examined for any sign of damage in
transit,particular attention being paid to the following:
a) Tank sides dented.

b) Protruding fittings damaged.
c) Bushing cracked or broken.
d) Bolts loose due to vibration in transit.
2. STORAGE: It is essential that the transformer/reactor should be kept with

silicagel packets inside to reduce the extent of possible condensation of moisture for
indoor service then it should be stored in indoor environment.
3. HANDLING: Transformers/reactors should always be lifted by the lugs or

shackles provided for the purpose and simultaneous use should be made of all lugs or
shackles in order to avoid any unbalance in lifting. Jacks should never be placed under
valve or cooling mesh,where jacking lugs are not provided.
4. LOCATION: A transformers/reactor of indoor type should be installed in a clean

dry room,which should be well ventilated sufficient clearance around the transformer/
reactor should be provided to permit proper ventilation. The air inlets and outlets
shall be of adequate size and so placed as to ensure proper air circulation for efficient
cooling of the transformer/reactor. It is necessary to provide sufficient headroom for
lifting the core and windings. It is often advisable to incorporate a lifting beam,
capable of supporting the maximum weight involved.
5. FOUNDATION: Since the transformer operates without moving parts, generally

a simple foundation is satisfactory. For reactors, extra precautions are required in
respect of proper anchoring at bottom, as its vibration level is high. A level concrete
plinth of correct size should be provided. Where rollers are fitted, suitable rails or
tracks should be provided and when the transformer is in final position, the rollers
should be locked to prevent accidental movement of the transformer/reactor. Flat
paving stones may also be used for platforms provided they are laid on a firm
foundation and withstand the weight of the transformer/reactor.
6. CABLING: Cable trenches inside sub-station and switch station shall be filled with
stand,pebbles or completely covered with non-inflammable slabs.
7. DRYING TRANSFORMERS/REACTORS: If as a result of tests carried out
presence of moisture is indicated or the insulation resistance readings are not
satisfactory it is necessary to dry the transformer/reactor.
The transformers/reactors should never be left unattended during the drying periods.
It should be carefully watched through the drying process and all observations shall be
recorded. If the drying is improperly performed, great damage, may result to the
transformer/reactor insulation through overheating.
8. DRYING WITH CORE COILS IN OIL BY THE SHORT CIRCUIT

METHOD: The winding should be heated by short circulating one of the windings
(in case of transformer) and applying a suitable voltage on the other. The success of
this method depends upon correct loading to maintain the temperature of winding and
insulation within safe limits.
The handhole covers should be removed or raised slightly to allow moisture to escape.
All openings should be protected from weather. Drying should be continuous without
a break maintaining the temperature of the transformer at a specific value of say 80C
and a log sheet of the record should be maintained.
Drying should be continued until constant or increasing dielectric strength is shown by

the tests & insulation resistance of windings are satisfactory.
RECOMMENDED SCHEDULE FOR PREVENTIVE MAINTANANCE.
Frequency of Equipment/Item Details of maintenance work.

maintanance.
QUARTERLY a) Connections i) Tighten connections,replace refill

Worn out thimbles/lugs.
ii) Examine insulating beads/sleeves

on connectors & replace where
necessary.
HALF YEARLY b) Bushing & arcing i) Clean off all dust,paint and other
(Before and after the horns. deposits.
rainy season) ii) Examine & replace the cracked
broken or chipped bushings.
iii) Examine & replace the damaged
gaskets.
iv) Adjust the arcing horns for
alignments and proper gaps
between rods.
YEARLY c) Barbed wires Recondition or replace barbed wire as
danger plate etc. necessary,paint & reprint the danger
plate,if defaced.
d) General condition. Clean off all dirt etc from the body of
the transformer/reactor & tighten all
bolts nuts etc.
Dry type transformers & reactors are

provided with cooling ducts in the
winding. If the atmosphere is dusty then
dust is likely to clog the ducts. Hence
depending on the extent of dust
formation
the windings shall be preferably vacuum
cleaned at definate intervals. During
cleaning the transformer/reactor shall
be out of circuit.
e) Load balancing. i) Check load on three phases with the

help of clip-on ammeter under max,
load condition & adjust as far as
possible balance loading on all three
phases.
f) Earth testing. i) Tighten the earth connections.
ii) Examine & replace broken earth

leads conductors with proper sizes.
iii) Measure the earth resistance during the

driest part of the year of (A) neutral of
transformer (B) transformer body &
other metal parts (c) lighting arresters.
It shall be more than 2 ohms.
iv) In case of higher values,recondition the

earths by driving the rods deeper into
ground or by addition of water through
pipe.

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Safety at assembly and testing of panels at

Customer Site ABB India Limited

8. Set-up isolation barriers and chains around the equipment/panels to be tested.

3. All incidence should be reported to the supervisors.

4. Significant leaks or spills need to be monitored.

Safety at Assembly & Testing.

Customer name/site: Date:

2.0 Incoming Power Cables And Busbars

4.0 Capacitors (if fitted)

5.0 Reactors (if fitted)

6.0 Fuses (if fitted)

7.0 Current Transformers (if fitted)

8.0 Voltage Transformers (if fitted)

9.0 Earthswitch (if fitted)

10.0 Isolator (if fitted)

11.0 Circuit Breaker (if fitted)

Procedure to Energize the Capacitor bank-

FOR UNITS DESIGNED TO IEC60871 - ISOLATE & EARTH SUPPLY. WAIT

Table 1 – Capacitor Discharge Rates

Standard Discharge Rate

Tightening torque Capacitor Units (all models)

Table 2 Busbar Connections

Nut/Bolt Size Torque Nm

Nut/Bolt Size Torque Nm

Connection of Earth Bar

Connect the earth

Figure : Earth Bar

The nominal current rating of the PFC System can be calculated:

3) If the voltage relay provided is instantaneous, alarm and annunciator indication

8) Oil temperature alarm / tripping if provided shall operate in case of overheating of

9) Do not operate the capacitor bank under light load.

10) Never operate any equipment above its rated values

OPERATING INSTRUCTIONS FOR APFC PANEL

A) To Switch ‘ON’ the APFC panel:

B) To Switch ‘OFF’ the APFC panel:

C) Electrical Interlock between APFC panel and Upstream CB:

ABB INDIA LIMITED

a. Inspection prior to energization

b. Inspection after energization

f. Disposal of Faradol impregnated capacitors

g. Corrective action after relay operation

6) Annexure I (Do’s and Don’t’s)

7) Annexure II (List of documents)

This instruction applies only to FARADOL (Jarylec) impregnated (PCB-free) high

Each capacitor unit is made up of a number of elements in series parallel

Until bank is short circuited and grounded it shall be considered as energised

While handling goods during unloading and installation it is important to

The following instructions explain how the equipment is safely handled.

The following documents are required in relation to arrival, unloading and

The capacitors must never be lifted by the bushings.

The equipment can be heavy and bulky. Due to this, it is important to

Upon arrival of the equipment, it is important to carefully check for

It is recommended that all material is verified and checked with the

NOTE THAT A CAPACITOR UNIT MUST NEVER BE LIFTED OR

Be careful during unpacking to make sure that the goods is not

With storage means up to six (6) months for capacitors delivered

The following documents are required in relation to installation/assembly:

Stainless steel nuts/bots on busbar connections (with lubricant):

Nuts / bolts, size Tightening torque, Nm

If applicable, the support insulators

The capacitor bank is delivered with all capacitor

As many components as possible are

d. Connection Insulators and busbars

Once all racks are in place and

APFC O&M Manual

APFC O&M Manual