Table of Contents

Preface 1
1.1 1.2 1.3

Introduction
Electrical system HV AND MV equipment
1.2.1 1.3.1 1.3.2 1.3.3 Voltage Classification High voltage equipment Medium voltage equipment Common HV and MV equipment

1
1 2
3

Use of HV and MV equipment

4
4 4 5

1.4 1.5 1.6 1.7

Need for testing Purpose of testing Categories of tests Variations to test voltages and results
1.7.1 1.7.2 1.7.3 Altitudes above sea level Temperature conditions Tolerances

5 6 6 7
7 8 8

2
2.1 2.2

Insulation testing
Need for insulation Principles of insulation testing
2.2.1 2.2.2 2.2.3 Capacitive current (Ic) Dielectric absorption current (Ida) Resistive (leakage) current (Ir)

9
9 10
11 11 11

2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13

Purpose of insulation testing Testing the insulation of equipment Insulation resistance test voltages Types of testers Construction of a tester Connecting a tester Test procedure Precautions to be taken when measuring insulation Polarization index Step voltage test Readings and interpretation

13 14 15 16 16 16 18 21 22 23 24

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2.14

Dryness of insulation using absorption ratio

25

3
3.1

High potential tests

Purpose of hi-pot testing
3.1.1 3.1.2 3.1.3 3.1.4 AC high potential testing (also called an over-potential test) Power factor testing AC hertz test Resonant test

29
29
29 29 29 30

3.2 3.3 3.4 3.5

AC and DC hi-pot tests Test equipment construction and connections Safety precautions to be taken Test voltages as per applicable standards

30 31 32 33

4
4.1 4.2 4.3 4.4 4.5 4.6 4.7

Oil testing
Transformer oil dielectric properties and uses The need for testing transformer oil Dielectric test Improvement of oil by filtration Oil filtration units Test of acidity Other tests
4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.7.6 4.7.7 4.7.8 4.7.9 Interfacial tension test (IFT) Color Relative density Dielectric dissipation factor Water content Flash point Viscosity Pour point Specific resistance Features and importance Basic gas analysis inferences DGA study methods DGA case studies

35
35 36 37 38 40 43 43
43 44 45 45 45 45 46 46 46

4.8

Dissolved gas analysis

4.8.1 4.8.2 4.8.3 4.8.4

46
46 47 48 50

4.9

Precautions to be taken when sampling oil

54

5
5.1 5.2 5.3

Testing of transformers
General Routine tests Guarantees and tolerances

65
65 66 67

Table of Contents iii

5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17

Visual inspection Winding resistance measurements Turns ratio measurement Polarity and vector group check Impedance voltage and load losses No load losses and current measurement Insulation resistance tests Dielectric tests RIV Corona measurements Partial discharge measurements Impulse tests Tests on OLTC Type tests Special tests
5.17.1 5.17.2 5.17.3 Measurement of zero sequence impedance Short circuit test Other special tests Main insulation (C1) test connections Test procedure Test results and inference Hot collar test Test connections Test procedure Test results Other tests on bushings

67 68 68 69 71 72 72 73 74 75 75 76 77 77
77 78 78

5.18

Tests on bushings
5.18.1 5.18.2 5.18.3 5.18.4 5.18.5 5.18.6 5.18.7 5.18.8

78
79 79 79 79 80 80 80 80

6
6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8

CT testing
Instrument transformers Current transformer types Burden and accuracy classes Other technical parameters Polarity Magnetization curve Metering and protection CT requirements Major tests on a CT
6.8.1 6.8. 2 6.8. 3 Type tests Routine tests Special tests Short time current Ith withstand test Temperature rise test

81
81 82 85 87 89 89 90 92
92 92 93

6.9

Test procedures
6.9.1 6.9.2

93
93 93

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6.9.3 6.9.4 6.9.5 6.9.6 6.9.7 6.9.8 6.9.9 6.9.10 6.9.11 6.9.12 6.9.13 6.9.14 6.9.15

Impulse tests RIV test Partial discharge test PF voltage tests Inter-turn over-voltage test Chopped impulse test on primary winding Capacitance and dielectric dissipation factor Transmitted over voltages measurement Ratio verification test Accuracy class verification Polarity test Test for CT magnetizing curve Short circuit test

93 95 96 96 96 96 97 97 98 98 98 98 100

6.10

Safety precautions

100

7
7.1 7.2 7.3 7.4

VT testing
Types of voltage transformers Basic technical terms Connection of voltage transformers Tests on voltage transformers
7.4.1 7.4.2 7.4.3 Type tests Routine tests Special tests Temperature rise test Short-circuit withstand capability test Impulse test on primary winding Lightning impulse test Switching impulse test Wet test for outdoor type transformers RIV test Power frequency withstand test Partial discharge test Chopped impulse test on primary winding Capacitance and dielectric dissipation factor Transmitted over voltages measurement Ratio and accuracy class verification test

101
101 103 105 107
107 107 107

7.5

Test procedures
7.5.1 7.5.2 7.5.3 7.5.4 7.5.5 7.5.6 7.5.7 7.5.8 7.5.9 7.5.10 7.5.11 7.5.12 7.5.13

107
107 109 109 109 111 111 111 112 112 113 113 113 114

8
8.1 8.2 8.3

Ducter testing
Need for the instrument Description of instrument Working principle
8.3.1 Kelvin bridge

117
117 117 118
118

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8.3.2 8.3.3

Wheatstone bridge Four wire instrument

119 120

8.4 8.5 8.6 8.7

Milli-ohmmeter vs micro-ohmmeter Breaker contact resistance measurement Transformer resistance measurement Precautions during measurements

122 123 123 125

9
9.1 9.2

Tests on other major equipment

Other major equipment HV/MV switchgear and breakers
9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 Routine tests Type tests Lightning impulse voltage tests Power-frequency voltage tests Testing for internal faults

127
127 127
127 128 128 128 130

9.3 9.4

MV motors MV capacitors
9.4.1 9.4.2 9.4.3 Routine tests Type tests Test procedures Type tests Routine tests Procedures

133 134
134 134 134

9.5

Disconnectors
9.5.1 9.5.2 9.5.3

135
135 136 136

10
10.1 10.2

Field tests
Need for field tests General safety procedures
10.2.1 10.2. 2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7 Basic precautions Test area safety practices Control and measurement circuits Grounding and shorting Spacing High-power testing General Visual and mechanical inspection Electrical tests Acceptance criteria Visual and mechanical inspection Electrical tests

137
137 138
138 139 139 139 140 140 140

10.3

Transformers
10.3.1 10.3.2 10.3.3

141
141 141 142

10.4

Switchgear
10.4.1 10.4.2

142
142 143

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10.4.3

Acceptance criteria Visual and mechanical checks Electrical checks Test values Visual and mechanical inspection Electrical tests Acceptance criteria Visual and mechanical inspection Electrical tests Acceptance criteria Visual and mechanical inspection Electrical tests Acceptance criteria Visual and mechanical inspection Electrical tests Acceptance criteria

143

10.5

High voltage disconnectors

10.5.1 10.5.2 10.5.3

143
143 143 143

10.6

MV cables
10.6.1 10.6.2 10.6.3

143
143 144 144

10.7

MV bus ducts
10.7.1 10.7.2 10.7.3

144
144 145 145

10.8

Instrument transformers
10.8.1 10.8.2 10.8.3

145
145 145 145

10.9

Rotating machinery
10.9.1 10.9.2 10.9.3

146
146 146 146

10.10

Surge arresters
10.10.1 Visual and mechanical inspection 10.10.2 Electrical tests 10.10.3 Acceptance criteria

146
146 146 146

10.11

Outdoor bus structures

10.11.1 Visual and mechanical inspection 10.11.2 Electrical tests 10.11.3 Acceptance criteria

147
147 147 147

10.12

Engine generators
10.12.1 Visual and mechanical inspection 10.12.2 Electrical tests 10.12.3 Acceptance criteria

147
147 147 147

10.13

Maintenance tests
10.13.1 Multiplication factors 10.13.2 Recommended schedule

147
148 148

Appendices

151