A.

K Goel,
Chief Manager(HRD)
arunkgoel@powergrdindia.com
Ph-9599192366
8/22/2018 1
8/22/2018 2
 Pre-commissioning checks/ tests are the activities
carried out to ascertain the correctness,
completeness of installation and healthiness of the
equipment before its charging.

 Commissioning Team-

 Responsibilities of Commissioning team: The

responsibilities of the commissioning team are to
go through statutory clearances and standing
instructions before initial charging of new
equipment,.

8/22/2018 3
 Witness Pre-Commissioning tests after erection of
individual equipment as per requirement of guidelines
issued by Corporate Asset Management or in line with
manufacturer's recommendation and test charging.
 Investigate failure of equipment during test charging,
declare commencement of trial operation and evaluate
guaranteed test results and recommend acceptance as
may be provided in the contract.
 List out deviations/ exception/ incomplete work, for
acceptance/ rejection. Proper documentation also to be
ensured by the Commissioning team based upon the
observations for the above for future reference

8/22/2018 4
 Checks after the receipt of transformer/reactor at site
 Insulating oil
 Internal inspection
 Tightness test with vacuum
 Oil filling and circulation
 Testing
 Preliminary checks before charging
 Checks of auxiliaries and protection
 Charging
 Post commissioning checks

8/22/2018 5
 All personals should be apprised of safety procedures
 Personnel protective equipment
 Warning signs
 Safety barriers
 Fully equipped and functional fire fighting system

8/22/2018 6
 Nitrogen pressure or dry air pressure of the main tank
 Dew point of the nitrogen or dry air inside tank
 Core insulation test
 Impact recorder ( to be sent to manufacturer or if
software available can be analysed at site)
NOTE:- THE ABOVE MENTIONED CHECKS ARE
TO BE CARRIED OUT ON THE TRAILER ITSELF
BEFORE UNLOADING OF MAIN TANK

8/22/2018 7
 Unpacking without damaging
 Any damaged or missing component to be intimated to the
manufacturer
 Materials repacked and stored if commissioning not
immediate
 Fragile instruments indoor storage eg:- oil level gauge,
temperature indicators etc.
 Packing cases to be placed on suitable supports to allow
free flow of air no water logging, easy for inspection and
handling/transportation,
 Proper drainage, no component gets submerged

8/22/2018 8
 Main tank filled with nitrogen or dry air
 Daily check of pressure
 If drop in pressure found, dew point to be taken
 If drop in dew point, fresh nitrogen or dry air has to be
filled
 Leak has to be detected and tightened

8/22/2018 9
 Filled with processed oil ( BDV > 70KV, moisture
content < 5ppm)
 BDV AND water CONTENT TESTED EVERY
THREE MONTHS
 If value beyond limits, oil filtration done

8/22/2018 10
 Oil in 209L drums or oil tanks
 Proper record of drums to be maintained
 To be checked for free moisture and appearance
 Oil sample to be sent to nearest lab for testing BDV >
50kv, moisture content < 40ppm, resistivity >
150x1012 ohm-cm, tan delta < 0.01 @90 0c
 Oil tanker- 02 samples
 209L oil drums- given table

8/22/2018 11
8/22/2018 12
 Oil drums vertical with lid upwards for 24 hours
 Clean the area around lid
 Use glass or brass tube to sample the oil
 Discard first two samples
 Suitable receptacle preferably glass bottles cleaned
with same oil then final sample taken

8/22/2018 13
 PRECAUTIONS

 WHAT IS TO BE
DONE

8/22/2018 14
 Along with manufacturer’s representative
 Dry and sunny weather
 Dry air should be used if main tank filled with nitrogen
 Avoid any foreign materials
 Loose materials should be removed from pockets
 Protective clothing and shoes
 Tools securely fastened
 An inventory of all materials taken inside tank to be
maintained and checked before closing of inspection
cover

8/22/2018 15
8/22/2018 16
8/22/2018 17
8/22/2018 18
 Removal of any shipping blocking or temporary
support.
 Examination for indication of core shifting.
 Tests for unintentional core or core clamp grounds.
 Visual inspection of windings, leads, and connections
including clamping, bracing,
 Blocking, spacer alignment, phase barriers, oil boxes,
and coil wraps.
 Checks for dirt, metal particles, moisture, or other
foreign material.

8/22/2018 19
8/22/2018 20
 Minimize exposure of active parts (core+coil)
 Presence of dry air ( dry air generators or dry air
cylinders )
 Transformer sealed off after working hours
 If tank has nitrogen then first vacuum then dry air
pushing. For safe breathing.
 A slight overpressure at night to check any leakage
(<30 mbar)

8/22/2018 21
 Check leakage if any leak detecting instruments or soap
solution or plastic bags tied around valves
 Get transformer under oil as soon as possible
 All fittings and auxiliaries with oil sealing to the tank
should be fitted first. Oil filling becomes easy.

8/22/2018 22
 Oil is drained out below the inspection covers
 Other exposure activities are as below:
1) bushing erections
2) jumper connections of bushings
3) fixing bushing turrets
4) core insulation checking (in case the checking point not
accessible outside)
5) buchholz relay pipe work fixing on cover
6) gas release pipes/equalizer pipe fixing
7) entering inside the tank for connections/inspection etc

DEPENDING UPON THE DURATION OF EXPOSURE OIL

PROCESSING (DRYING) AND OIL FILLING IS DONE

8/22/2018 23
 Before oil filling, leakage test is a must.
 Evacuate transformer from top of tank till pressure < 50mbar.
 Vacuum stopped.
 After 1 hour take pressure reading p1
 After 30 minutes reading p2
 (P2 – P1) x V < 3.6 ; V= VOLUME OF TANK (see rating
plate)
 Take 2 to 3 readings, if ok , then leak test successful, and
further vacuum till 1torr done and maintained as per given
table.
 If not , then leak attended
 OLTC chamber to be vacuumed simultaneously and vacuum
released simultaneously

8/22/2018 24
 After passing leakage test, vacuum maintained in tank
for the duration as mentioned below

8/22/2018 25
 Transfer oil from drums to tanks for filtration
 Filtration done
 Oil parameter testing :
 1. Break down voltage (bdv) : 70kv (min.)
 2. Moisture content : 5 ppm (max.)
 3. Tan-delta at 90 °c : less than 0.01
 4. Interfacial tension : more than 0.035 n/m
 Nitrogen filled transformer to be oil filled under
vacuum

8/22/2018 26
 Oil filled from bottom valve
 Oil fill speed in main tank < 5klph
 Continue oil filling until the level reaches approximately
200 mm above the ambient oil level indicated on the
magnetic oil level gauge in the expansion vessel. Then,
release the vacuum with dry air of dew point -40 0c or
better.
 Oil filled in OLTC at atmospheric pressure
 Oil filled in cooler banks without vacuum at atmospheric
pressure
 Care must be taken not to pressurise the cooler bank

8/22/2018 27
 Upon completion, open the top cooler isolating valve in
order to equalize the pressure in the cooler with the
transformer tank
 Before filling oil into the conservator, the air cell/
bellow to be inflated to 0.5 psig i.E.0.035kg/cm2 max.
By applying pressure (N2/compressed dry air) so that it
can take
 Breather pipe attachment
 Filling rate maximum 2klph
 Oil filled from main tank

8/22/2018 28
 Oil extracted from bottom valve in main tank and
poured in from top valve
 Oil heated in filter machine till 60 0c. Above 70 0c oil
oxidises
 Circulation done for at least 2 times of tank volume.
 (At freezing ambient temperature the circulation time is
increased, circulate 3 times the volume at temperature
down to minus 20 ° c, increase to 4 times below that
temperature)

8/22/2018 29
 Break down voltage (BDV) : 70 KV (min.)
 Moisture content : 5 ppm (max.)
 Tan-delta at 90 °c : 0.01 (max.)
 Total gas content : < 1%
 Resistivity at 90 °c : 6 x 10 ohm-cm (min.)
 Interfacial tension : 0.035 n/m (min.)
 *Oxidation stability (test method as per iec 61125 ,method c, test
duration: 500 hour for inhibited oil)
A) acidity : 0.3 (mg koh /g) (max.)
B) sludge : 0.05 % (max.)
C) tan delta at 90 °c : 0.05 (max.)
 * Separate oil sample shall be taken and test results shall be
submitted within 45 days after commissioning for approval of
POWERGRID.

8/22/2018 30
WET TRANSFORMER/REACTOR MEANS THE
SOLID INSULATION HAS ABSORBED
MOISTURE

 If transformer/reactor received without positive

pressure
 If dry air not used during erection activities
 Overexposure of active part of transformer/ reactor
during erection (overexposure when exposure > 12 hrs)

8/22/2018 31
 Carefully watched and recorded
 Fire fighting ready as we deal with heat and inflammable
oil
 All openings of main tank for conservator, cooler banks,
OLTC etc shall be isolated and blanked
 Fill tank with N2 till positive pressure of 0.15 kg/cm2
 Keep for 24 hours
 During this nitrogen circulation, heaters installed around
tank till 70-80 0c achieved by the core & winding indicated
in OTI.
 Check dew point.

8/22/2018 32
 If dew point ok then oil filling done else
 Vacuum done till pressure of 1-5 tor for 48 hrs with less
than 40ml/hour condensate
 If more than 40 ml/hour comes then up to 96 hours
 After this again nitrogen circulation for 24 hours with
heating done, then dew point checked
 If achieved then ok, IF NOT THEN NITROGEN
CYCLE WITH HEATING INCREASED FOR 48
HOURS

8/22/2018 33
8/22/2018 34
 Core insulation test
 Earth pit resistance measurement
 Insulation resistance (IR) measurement
 Capacitance and tan delta measurement of bushings
 Capacitance and tan delta measurement of windings
 Turns ratio (voltage ratio)measurement
 Vector group and polarity
 Magnetic balance test
 Floating neutral point measurement

8/22/2018 35
 Measurement of short circuit impedance
 Exciting/magnetising current measurement
 Operational checks on OLTC
 Tests/check on bushing current transformers (BCTs)
 Operational check on protection system
 Stability of differential, REF of transformer/reactor
 Frequency response analysis measurement (FRA)
 Winding resistance measurement
 Dissolved gas analysis (DGA)

8/22/2018 36
 Done when the transformer/reactor is still on trailer,
also done when integrity of core insulation is affected,
in charged transformers when DGA indicates ethane,
ethylene and methane
 Disconnect the three terminals from each other ( core
clamp, core lamination and ground)
 Test the insulation between core clamp to ground and
core lamination to ground at 1kv ( should be >
10Mohm at 60 seconds )
 Connect the three terminals once again (normal
condition)

8/22/2018 37
 An earth tester kit is used
 Pit earthing connection removed from main grid
 Measurement by three point method
 Working of earth tester……
 Two spikes at a distance of 25m and 50m are placed in one
line
 There is a dc generator
 Dc current converted to ac current using rectifier and fed to
spike to prevent electrolytic effect due to dc current
 Earth resistance is displayed which should be less than
1ohm, if not the treatment with salt and charcoal is to be
done

8/22/2018 38
 Tests insulation between winding and tank and between
windings (rest of the windings being earthed)
 Neutral should be disconnected from earth
 A 5KV Insulation Tester is used

8/22/2018 39
8/22/2018 40
 Two measuring factors, dielectric absorption coefficient
or index (DAI) & polarization index (PI)
 DAI=RATIO OF IR at 60 secs to IR at 15 secs, it
should be > 1.3 at 30 0C
 PI= RATIO OF IR at 600s to IR at 60s, it should be as
follows:-

8/22/2018 41
 Measurement of loss in insulation of bushings
 Dissipation factor or loss factor (tan delta)= ratio of
resistive current to capacitive current
 Kit used= 10KV or 12 KV fully automated capacitance and
tan delta measurement kit
 C1 measurement in UST mode at 2KV and 10 KV (UST=
ungrounded sampling test mode)
 C2 in GSTg at 1KV (grounded sampling test with guard
mode )
 Limit is 0.5%
 WHAT IS C1 & C2 ?.....

8/22/2018 42
 The combination for C & tan ä measurement of
winding is same as that of measurement of IR value.

8/22/2018 43
 Winding combination for auto transformer.

8/22/2018 44
8/22/2018 45
 Kit used= Automatic Transformer Turns Ratio Meter

8/22/2018 46
 Purpose:- Paralleling of transformers

8/22/2018 47
 Purpose:- Paralleling of transformers

8/22/2018 48
 Purpose:- Detect damage to winding during
transportation

8/22/2018 49
8/22/2018 50
 Purpose:- Detect fault in winding

8/22/2018 51
 Purpose:- detect winding movement that usually
occurs due to heavy fault current or mechanical
damage during transportation or installation since
dispatch from the factory.

8/22/2018 52
 Purpose:- It is performed to locate defects in the magnetic core
structure, shifting of windings, failure in turn to turn insulation or
problem in tap changers
 Change in reluctance of magnetic circuit thus affecting the current required
to establish flux in the core.
 Done before all DC tests ( DC may cause saturation of winding)
 Single phase voltage upto 10KV applied on one winding while the rest of
the winding are open

8/22/2018 53
 Purpose:- To assess the mechanical integrity of the
transformer which may get disturbed due to
transportation shocks.
 Done after erection and oil filling. Results compared with
factory value
 The FRA signatures should be analyzed in conjunction with
Impact Recorder readings

8/22/2018 54
8/22/2018 55
 Purpose:- It is carried out to calculate the I2R losses and to calculate
winding temperature at the end of a temperature rise test. It is also
done at site to ensure healthiness of a transformer that is to check loose
connections, broken strands of conductor, high contact resistance in
tap changers, high voltage leads and bushings etc.
 The winding resistance shall be preferably done when the difference in the
top and bottom temperature of the winding (temperature of oil in steady-
state condition) is equal to or less than 5 °C.
 The winding resistance should preferably be carried out last after
completion of all other LV tests, as after this test core gets saturated
and tests like magnetizing current, magnetic balance etc. carried out
after winding test may be affected and indicate a misleading results,
if the core is not de-magnetized before carrying out these tests.

8/22/2018 56
 Measurement done using Automatic Kit
 At all taps in forward and reverse direction, resistance
measured between HV to IV winding
 At normal tap between IV-N winding
 In LV winding between phases
 All the readings taken converted to reading at 75 0C with
formula

8/22/2018 57
 Purpose:- Tap changer functioning properly
 Manual operation of drive. Tap position in drive and TC should be same.
 Motor drive push button test. Should get switched off automatically after
one switching operation
 Changeover from 9b to 10 and vice versa requires high torque. Tap changer
end position to be checked to see there is no slipping over causing failure
 Continuity of winding at all taps to be checked. At no point should the
voltage should indicate zero
 With the transformer energised at rated voltage and frequency but on no
load, one complete cycle of operation to be taken

8/22/2018 58
 Continuity of all cores using multi meter
 Polarity using a 9V battery .
 Secondary winding resistance tests of individual cores
of Bushing CTs using a multi-meter
 Insulation Resistance Measurement of winding to earth
and between winding to winding for all HV, IV and LV
turrets
 Current Ratio test:- Apply 20%, 40% and 80% of rated
current on the primary and measure the secondary
current. (Permissible limit: Protection core-±3% and
Metering core- ±0.5%)

8/22/2018 59
 Magnetising Curve Performance:- (Not done for metering
core)
 Purpose:- To check that the current transformer is
working in the linear region of its magnetising curve.
 Various values of Knee point voltage (0.25, 0.5,0.75, 1, 1.10)
applied to primary and then secondary current measured to
see the linear relationship of Voltage and current. It should
not saturate even at 1.1 Knee Point voltage

8/22/2018 60
8/22/2018 61
 Breather silica gel is blue in Main Tank, OLTC
 MOG level ok
 Marshalling Box and other kiosks OK
 Valves OK
 Checks on Cooling System such as (1) Checks on cooling fans-rotation,
speed & Control (Manual /temp /load) setting checks (2) Checks on
Cooling pumps- rotation, vibration/noise, oil flow direction
 OTI&WTI check, calibration, cooler control, alarm, trip settings
 Check on gas actuated relays such as PRD, Buchholz relay, Oil Surge
Relay
 Contact Resistance Measurement of Terminal connectors
 Checks on Transformer/ Reactor protection (differential, REF, Over-current
& stability tests etc.)

8/22/2018 62
 Purpose:- To detect faults within the
Transformer/Reactor

8/22/2018 63
 Two ways to conduct: (1) through Primary test Tap (M point)
if available (2) using actual earthing if M point not available
 Through Primary Test Tap
 Measure the spill current in REF relay which should be nearly zero.
 Switch off Current Injection.
 Reverse the polarity of R phase Bushing CT and again start Current
Injection.
 Appreciable spill current will appear in REF relay.
 Repeat the same procedure for Y and B phases and note down the
results.
 This test has to be performed from both HV side & LV side w.r.t.
Neutral.
Testing of Reactor will be done similarly

8/22/2018 64
 Primary test tap not available
 Apply 440V three phase voltage at three phase bushing of H.V.
side with
 the help of three phase variac.
 Earth the R phase of the LV side (through isolator earth switch or
discharge rod).
 Measure the spill voltage (in mV)/ spill current (in mA) at REF
relay which should be nearly zero.
 Reverse the polarity of R phase Bushing CT and again switch on
440V supply.
 Appreciable spill voltage/ current will appear in REF relay.
 Repeat the same procedure for Y and B phases and note down the
results in formats.
.
Testing of Reactor will be done similarly

8/22/2018 65
 Release air at the high points, like oil communicating bushings, buchholz
petcock, tank cover and the cooling devices including headers, radiators,
pumps, expansion joints etc. of the transformer. Air release should be resorted
from low points to high points.
 Check tightness
 Check that the valves are in the correct position
 Silica gel in breather is blue and oil cup is fill with oil
 CC, CL properly grounded
 Check oil level in main tank and OLTC conservators, bushings
 Connection of terminal connectors
 Bushing CT terminal properly shorted and earthed
 Neutral bushing earthed
 Tan delta test taps earthed

8/22/2018 66
 Tap position should be same at control cubicle and the tap head
 Step by step operation- local and remote electrical operation as well as manual
operation and parallel operation, if any
 Electric and mechanical limit switches and protective relays
 Oil parameter results should conform to the limits mentioned
 Check OTI and WTI settings
 Ensure oil in thermometer pockets as well as OTI and WTI pockets
 Installation of buchholz relay, Oil surge relay, PRD
 Check Insulation resistance of auxiliary circuit at 2KV
 Check the earthing of main tank and cooler banks at two different places
 Measure the supply of the auxiliary circuits
 Check the direction of installation of oil pumps
 Check the direction of rotation of the pumps and fans
 Check the working of the oil flow indicators
 Check the setting of the thermal overload relays, heating and lighting of cubicles
 Check the protection of the Transformer/reactor

8/22/2018 67
 Thermo-vision Scanning:- To be done after 24 hours of charging to detect
any hot spots and then after a week.
 Oil sample to be sent after 24 hours of charging for DGA testing
 Online Moisture measurement
 Vibration measurement of reactors :-Movement of the core-coil assembly
and shielding structure caused by the time –varying magnetic forces
results in vibration of the tank and ancillary equipment. These
vibrations have detrimental effects such as excessive stress on the core-
coil assembly

8/22/2018 68
8/22/2018 69
 Just before charging, an oil sample has to be taken for DGA, BDV, and
moisture measurement
 The equipment charged from incoming side whether 400 or 220 KV on no
load
 Initial Magnetising current is very high depending upon the moment of cycle
 Transformer should be kept on no load for 12 hours
 During this time, vibrations, abnormal cracking noise, etc. are to be observed
 After that it may be checked for gas collection.
 After successful charging, performance of transformer / rector should be
checked under loading; OTI/WTI readings should be monitored for 24 hours
and ensured that they are as per loading.
 DGA samples may be sent as per Standard practice (after 24 hrs of energizing,
one week, 15 days, one month and three months after charging, thereafter as
per normal frequency of 6 months ).

8/22/2018 70