PRE COMMISSIONING TESTS AT SUB STATION

DAVINDER SINGH, BHEL

TESTING
TYPE TESTS ROUTINE TEST ACCEPTANCE TESTS SAMPLE TESTS SITE TESTS

PRE COMMISSIONING TEST AT S/S

WHY PRE COMMISSIONING TESTS ARE NECESSARY AT SITE ?

315 MVA ,400/220KV/33KV, AUTO TRANSFORMER

OFAF- 315 MVA RATING, ONAF-252 MVA RATING ONAN-180 MVA RATING OLTC +10% TO -10% IN STEP IN 16 STEPS ON 400KV SIDE/

IMPACT RECORDER ANALYSIS

TO BE DETACHED AFTER THE TRANSFORMER IS PLACED ON PLINTH AT SITE CHECK NITROGEN PRESSURE INSIDE THE TRANSFORMER AFTER RECEIPT AT SITE

PRE COMMISSIONING TEST AT S/S

INDIVIDUAL EQUIPMENT TESTING AS PER SUPPLIERS RECOMMENDATIONS , CUSTOMER REQUIREMENT FIELD QUALITY PLANS FOR COMMISSIONING ARE AVAILABLE OF LEADING UTILITIES. RELAY TESTING WIRING CHECK SYSTEM TESTING

PRE COMMISSIONING TEST AT S/S

GENERAL GUIDELINES
NOTE DOWN THE AMBIENT CONDITIONS AT THE TIME OF TESTS CLEAN THE EQUIPMENT INSULATORS ETC. TAKE DUPLICATE MEASUREMENTS-TO AVOID RETEST AT LATER DATE. THE READINGS ARE BENCH MARK FOR FUTURE COMPARISON

PRE COMMISSIONING TEST AT S/S

GENERAL GUIDELINES FOLLOW THE INSTRUCTIONS GIVEN IN THE OPERATION AND MAINTENANCE MANUAL OF THE EQUIPMENT SUPPLIER. CHECK THE CUSTOMER PRECOMMISSIONING FORMATS AND PROCEDURES IF ANY. TEST BEFORE THE CUSTOMER REPRESENTATIVE AND NOTE THE READINGS IN A REGISTER. FILL THE COMMISSIONING FORMATS AND GET SIGNATURE OF SUPPLIER REP., ERECTION REP. AND CUSTOMER ENGINEER.

TRANSFORMER COMMISSIONING TESTS

INSULATION RESISTANCE MEASUREMENT VECTOR GROUP & POLARITY SHORT CKT IMPEDANCE MAGNETIC BALANCE TEST FLOATING NEUTRAL VOLTAGE MAGNETIZING CURRENT TEST VOLTAGE RATIO TEST OIL, DG TESTING AFTER OIL FILTRATION IR MEASUREMENT OF BUSHING CT

TRANSFORMER COMMISSIONING TESTS

CONTINUITY TEST OF BUSHING CT POLARITY TEST OF BUSHING CT CURRENT RATIO TEST MAGNETIC CURVE PERFORMANCE CONTACT RESISTANCE MEASUREMENT CAP & TAN DELTA OF BUSHING CAP & TAN DELTA OF WINDING PROTECTION AND ALARM TEST FRA

IR MEASUREMENT
IR MEASUREMENT OF TRANSFORMER WITH 500V MEGGER CONTROL WIRING-1000M OHM TAP CHANGER
MOTOR-1000 M OHM CONTROL WIRING-1000M OHM

COOLING SYSTEM
MOTOR FAN- 10.4 G OHM MOTOR PUMP-8.6 G OHM CONTROL WIRING- 1000 M OHM

ACCEPTANCE CRITERIA + GREATER THEN 1 M OHM

IR MEASUREMENT IR MEASUREMENT WITH 5000V MEGGER

MAIN WDG G OHM, 39 DEG C 15 S HV+IV TO LV 14.7 60 S 19.1 600 S 44.2 FACTORY TEST 33 DEG C 15 S 2.95 60 S 5.43 600 S 12.7

HV+IV TO LV

13.7

18.3

43.9

2.06

5.5

14.6

HV+IV TO E
LV TO E 15.4 19.9 45.7 4.41 8.55 22.7

VECTOR GROUP VECTOR GROUP Yn 0 d 11

1R1+3R1 3B1 N 2B1 2R1 2Y1 3Y1

1B1

1Y1

APPLY 415 V 3 PHASE TO HV TERMINALS

VECTOR GROUP
TERMINALS SITE RESULTS AT 415V FACTORY RESULTS AT 409V

1R1-1Y1
1Y1-1B1 1B1-1R1 3Y1-1B1 3Y1-1Y1 3R1-N 3Y1-N 1R1-N 2R1-N 2Y1-N 2B1-N

418V
414V 417V 411V 384V 239V 220V 239V 131V 131V 130V 236V 410V 384V

2R1-N=2Y1-N=2B1-N SHALL BE EQUAL 3R1-N GREATER THEN 3Y1-N & 3Y1-1B1 GREATER THEN 3Y1-1Y1, SO VECTOR GROUP Yn0d11 IS CONFIRMED

POLARITY TEST

POLARITY TEST IS DONE BY TRANSFORMER RATIO METER OF M/S ELTEL, TYPE TRM200 OR EQUIVALENT

WINDING RESISTANCE
TO BE MEASURED ON ALL TAPS DIRECT DIGITAL READING METERS MEASUREMENT AT 10A OR 25A NORMAL INDUCTIVE SUPPRESSED TAP VOLTAGE SITE RESULTS FACTORY
30 DEG C 1R1-2R1 1Y1-2Y1 1B1-2B1 2R1-N 2Y1-N 2B1-N 0.2231 0.2246 0.2231 0.2879 0.2886 0.2876 RESULTS 34 DEG C 0.2131 0.2153 0.2131 0.2854 0.2856 0.2857

MAGNETIC BALANCE TEST

APPLY 1-PHASE 230V ON ONE PHASE OF HV WDG & NEUTRAL & MEASURE ACROSS OTHER HV WDG
APPLY V 1R1N,240V 1Y1-N ,241 V 1B1-N, 242V SITE MEASURE APPLY V 236.8V FACTORY MEASUREMENT 221.5V 24V

1Y1N=227.6 1R1-N 135.9V 22.6V

1B1N=28V 106.9V

236V

128.0V

108.0V

1Y1-N 221.1V

236V

22.0V

220V

FLOATING NEUTRAL VOLTAGE

DISCONNECT THE NEUTRAL FROM GROUND APPLY 3-PH 415 V ON HV SIDE AND MEASURE ON IV SIDE ON NORMAL TAP POSITION
HV WDG VOLTAGE APPLIED IV WDG VOLTAGE REMARKS MEASURED

1R-N

238.5V

2R-N

130.4V

1Y-N

239.5V

2Y-N

131.4V

NO FACTORY TESTING OF THIS TEST

1B-N

240.2V

2B-N

131.1

N-EARTH

0.778

SHORT CIRCUIT CURRENT TEST

APPLY 3-PH, 415 V ON HV WDG & SHORT LV WDG
VOLTAGE APPLIED 390V 390V 390V 390V 390V LV WDG SHORT COMBINATION 3 PH SHORT 3 PH SHORT & GROUNDED 2 PH SHORT 2 PH SHORT & GROUNDED 1 PH GROUNDED IR IY IB

0.622 0.613 0.312 0.308 0.001

0.632 0.623 0.312 0.308 0.001

0.632 0.623 0.640 0.612 0.001

HV RATIO TEST
APPLY 3 PH ,4 WIRE,415V ON HV TERMINALS AND KEEP IV OPEN. IT SHALL BE MEASURED ON ALL TAPS. TO MEASURE BETWEEN HV/IV; HV/LV;IV/LV
VOLTAGE APPLIED IR-N 1Y-N 1B-N VOLTAGE MEASURED 2R-N 2Y-N 2B-N RATIO SITE/FACTORY SPECI FIED

231.5
IR-N 232.4

232.3
1Y-N 235.1

234
1B-N 234.4

128.9
3R-3Y 33.0

129.7
3Y-3B 33.1

130.2
3B-3R 33.1

1.796/ 1.797

1.804/ 1.796

1.797/ 1.795

1.796

7.042/ 7.011

7.103/ 7.005

7.082/ 7.011

6.998

OIL TESTING
SAMPLE TO BE TESTED AND SHALL CONFIRM TO IS 1866 BEFORE CHARGING
OIL BDV SAMPLE MIN. KV IS-1866 IS-1866 IS-1866 MAIN TANK 60 50 40 80KV MOISTU TAN RE DELTA PPM 15 20 25 9 90 DEG C 0.05 0.05 0.05 0.025 RESISTI VITY OHMCM 1X10 ^12 1X10 ^12 1X10 ^12 92.7 INTERF. REMAR TENSION KS DEG N/M 0.03 0.03 0.03 145KV ABOVE 145KV 72.5 KV 72.5KV BELOW TESTED 22.04.07

DISSOLVED GAS ANALYSIS

TO BE CHECKED JUST BEFORE CHARGING, JUST AFTER CHARGING, 24 HRS AFTER CHARGING, 7 DAYS AFTER CHARGING, 15 DAYS AFTER CHARGING. PARAMETERS IN % OF TOTAL GAS IN PPM H2- 0.71,CH4-0.63,CO,CO2,C2H4,C2H6,C2H2,O2,N2 OTHER GASES NIL

SECONDARY WINDING RESISTANCE

ALL CORES AND TAPPING CT WINDING RESISTANCE TO BE CHECKED
CORE BETWEEN TERMINAL R -PH Y-PH B-PH

CORE 1

1S1-1S2

2.29 OHM

2.24 OHM

2.17 OHM

CORE 2

2S1-2S2

1.51 OHM

1.57 OHM

1.48 OHM

IR MEASUREMENT BUSHING CT IR MEASUREMENT WITH 500V MEGGER FOR HV, IV & LV & BETWEEN CORES OF BUSHINGS
BETWEEN HV G OHM, 39 DEG C R PH EARTH- CORE-1 12.7 Y PH 15.8 B PH 12.15

EARTH- CORE-2

16.8

17.3

14.8

EARTH- CORE-3

HV+IV TO E

15.4

19.9

45.7

POLARITY TEST ON BUSHING CT

WITH 1.5 V DC CELL CONNECT + AT P1 AND AT P2
CORE BETWEEN R-PH Y-PH B-PH

CORE 1

1S1( + )-1S2( - )

OK

OK

OK

CORE 2

2S1( + )-2S2( - )

OK

OK

OK

CURRENT RATIO TEST

USE PRIMARY INJECTION KIT
CORE PRIMER CURRE Y% NT SEC CURRE NT 0.794 RATED RATIO ACTUAL % RATIO ERROR

CORE-1

80

800A

1000/1

993/1

0.7

CORE-2

80

480

0.805

600/1

594/1

0.6

MAG CURVE OF BUSHING CT

NOT TO BE DONE FOR METERING CORES, KNEE POINT VOLTAGE 1000V
APPLY VOL. ACTUAL VALUE
250V

1S1-1S2 R PH mA
10.2

1S1-1S2 Y PH mA
11.4

1S1-1S2 B PH mA
11.2

0.25X KVP

0.50X KVP

500V

17.4

13.6

16.0

0.75X KVP

750V

32.5

21.3

26.1

CAPACITANCE AND TAN DELTA BUSHING

HEALTHINESS OF INSULATION. MEASURED FOR HV, IV & LV BUSHINGS
VOLTAG E CAPACITENCE AT SITE PICO FARAD CAPACITENCE AT WORKS PICO FARAD

R
10KV ON HV 465

Y
467

B
464

R
465

Y
465

B
463

10KV ON IV
10KV ON LV

310
184

319
185

315
184

309
187

317
187

314
187

CAPACITANCE AND TAN DELTA BUSHING

HEALTHINESS OF INSULATION. MEASURED FOR HV, IV & LV BUSHINGS
VOLTAG E TAN DELTA AT SITE TAN DELTA AT WORKS

R 10KV ON HV 0.0040

Y 0.0039

B 0.0039

R 0.0033

Y 0.0036

B 0.0032

10KV ON IV
10KV ON LV

0.0021
0.0035

0.0023
0.0034

0.0021
0.0035

0.0018
0.0033

0.0019
0.0025

0.0020
0.0027

CAPACITANCE AND TAN DELTA TRANSFORMER

HEALTHINESS OF INSULATION. MEASURED FOR HV, IV & LV TRANSFORMER
VOLTAGE 10KV CAPACITANCE IN PICO FARAD SITE HV+IV/LV HV+IV/LV+G 6.801 14.81 FACTORY TAN DELTA

SITE 0.005218 0.004252

FACTORY

SHORT CIRCUIT IMPEDANCE TEST

IT IS MEASURED BETWEEN HV/IV;IV/LV;HV/LV
TAP NO. IV OF R&N SHORTED, LV OPEN- R PH V I IV OF Y&N SHORTED, LV OPEN Y PH V I IV OF B&N SHORTED, LV OPEN- B PH V I

243

4.12

238

4.02

240

4.08

PROTECTION & ALARM

TO CHECK THE FOLLOWING PRESSURE RELIEF VALVE -7PSI, MAIN TANK BUCHHOLZ RELAY-ALARM & TRIP OLTC BUCHHOLZ RELAY-ALARM & TRIP OTI -ALARM AT 85 C, TRIP 100 C WTI -ALARM AT 95 C, TRIP 105 C COOLER FAN START 75 C OIL PUMP START 85 C

FREQUENCY RESPONSE ANALYSIS

THIS DONE ON ALL WINDINGS HV, IV & LV AT DIFFERENT FREQUENCIES 10 TO 2000 HZ,100 TO 20000 HZ, AND 1000 TO 200000 HZ AND PLOTTED BETWEEN FREQUENCY AND DB

400KV CIRCUIT BREAKER

RATING OF 400KV SF6 CB TYPE 3AT2 CB , BHEL HYD BRAKING CAPACITY 40 KA RATED NORMAL CURRENT- 2000A

OPERATING MECH- HYDRAULIC AND PNEUMATIC

SITE TESTS ON CB
CHECK PRESSURE OF N2 210 BAR IN R,Y,B PH PUMP RUNNING TIME 4.5 MIN FOR R, Y, B PH TO ATTAIN 345 BAR PUMP START AT 325 BAR AUTO RECLOSE LOCKOUT AT 300 BAR GENERAL LOCKOUT AT 253 BAR SF6 DENSITY MONITOR- ALARM 7.1 BAR, BLOCK 6.1 BAR, NORMAL 8.4 BAR CHECKED SF6 LEAKAGE IN 24 HRS- NIL CHECKED THE ANTI PUMPING CONTACTOR

SITE TESTS ON CB
CHECK TRIPPING CIRCUIT OK CHECK CLOSING THROUGH CC-1 OK CHECK CLOSING THROUGH CC-2 OK ANTI PUMPING FEATURE- OK POLE DISCREPANCY FEATURE- OK BREAKER POSITION INDICATION- OK CHECK FOR ANNUNCIATION IN CONTROL ROOM

SITE TESTS ON CB
OIL PRESSURE DROP DURING OPERATION
R PH Y PH B PH

PRESSURE BEFORE OPERATION

325

325

325

PRESSURE AFTER OPERATION

PUMP RUNNING TIME

315

315

315

10 SEC

10 SEC

10 SEC

SITE TESTS ON CB
OPERATION TIME
R PH Y PH B P74H

BREAK I TRIP

27.2

29.3

29.7

BREAK 2 TRIP
CLOSE-I

27.3

29.1

29.7

78.6

74.2

74.9

CLOSE-2

78.6

74.7

76.9

SITE TESTS ON CB
COIL RESISTANCE MEASUREMENT IN OHM
R PH Y PH B PH

CLOSING COIL-I CLOSING COIL-II TRIPPING COIL-I

79.66

80.37

79.48

96.42

79.95

78.18

164.5

176.2

168.0

SITE TESTS ON CB
IR TESTING OF CONTROL CIRCUIT 500V MEGGAR IN M OHM
R PH Y PH B PH

CLOSING COIL-I CLOSING COIL-II TRIPPING COIL-I

34600

32200

23800

25200

16700

20400

15500

21800

20800

SITE TESTS ON CB
IR TESTING OF CB WITH 5000V MEGGAR IN M OHM
R PH WITH EARTH
INTERRUPTE 214000 R1 INTERRUPTE 505000 R2

Y PH WITH EARTH
234000

B PH WITH EARTH

115000

133000

115000

CAP & TAN DELTA

INTERUPTER-1 INTERUPTER-2

CAPACIT SITE ANCE FACTOR Y TAN DELTA SITE

496.5

507.9

509.1

518.4

503.7

509.8

511

510.1

512.3

514.0

509.3

511.1

0.03484

0.0033

0.00245

0.00791

0.00935

0.00686

FACTOR Y

0.00133

0.00232

0.0011

0.00103

0.00072

0.00170

CONTACT RESISTANCE TEST

DCRM KIT IS USED ,IT MEASURES COIL CURRENT, ARCING CONTACT AND MAIN CONTACT RESISTANCE , SPEED OF TRAVEL
R Y B

ACROSS EACH POLE

92.6

71.5

84.1

ACROSS INTERRUPTER 1 ACROSS INTERRUPTER 2 VALUES ARE IN MICRO OHM

55.4

59.1

59.4

68.5

55.3

85.6

SITE TEST FOR ISOLATOR

400KV , 2000A, ISOLATOR WITH MOTOR OPERATING MECHANISM. TEST THE IR VALUE OF MOTOR WINDINGS TO EARTH WITH 500V MEGGER VALUES R PH- 2180, Y PH-2500, B-PH 730 MEGA OHM. TEST THE IR VALUE OF ISOLATOR MALE SIDE CONTACT TO EARTH WITH 5000V MEGGER VALUES R PH- 125000, Y PH-505000, B-PH 310000 MEGA OHM. OPERATE THE ISOLATOR AND MEASURE THE MOTOR CURRENT- 0.83,0.87,0.93 AMPS. O/L SETTING AT 1.4

SITE TEST FOR ISOLATOR

MEASUREMENT OF OPERATING TIME9.28,8.73,8.61 SEC FOR OPENING AND 9.06,8.83,8.17 FOR CLOSING 9.06,8.83,8.17 SEC.IT SHALL BE LESS THEN 12 SEC. CONTACT RESISTANCE MEASUREMENT IN MICRO OHM-7.22, 12.43,27.2 OPERATION ON UNDER VOLTAGE. PICK UP 98%, DROP VOLTAGE 52% OF CLOSING , OPENING AND INTERLOCK COIL. CHECK THE NO AND NC CONTACT OPERATION

SITE TEST FOR CT

RATING OF 400KV CT 2000A, 40KA FOR 1 SEC,5 CORES CORE 1 & 2 RATIO 2000-1000/1A, PS CLASS, KVP1000V, FOR BUS BAR PROTECTION CORE 3 -2000/1000/500/1 A,20 VA, 0.2 CORE 4 & 5 RATIO 2000-1000-500/1A, PS CLASS, KVP 2000V, FOR DISTANCE PROTECTION

SITE TEST FOR CT

IR TEST PERMITTED VALUES 400KV -400M OHM, 220KV 200M OHM CHECK PRIMARY WITH CORE-1,2,3,4,5& EARTH AND SEC CORE1,2,3,4,,5 WITH EARTH
R -PH P-CORE-1 P- EARTH SEC CORE 1EARTH 20000 M OHM 20000 M OHM 500 M OHM Y-PH 15000M OHM 15000M OHM 500M OHM B-PH 40000 MOHM 20000 MOHM 5000 MOHM

SITE TEST FOR CT

POLARITY TEST WITH 1.5 V CELL- OK SECONDARY WINDING RESISTANCE IN OHM
R -PH Y-PH B-PH

CORE5- 5S1-5S2

2.4

2.3

2.3

CORE5- 5S1-5S3

4.6

4.5

4.7

CORE5- 5S1-1S4

9.7

9.8

9.7

CAPACITANCE AND TAN DELTA CT

HEALTHINESS OF INSULATION.
VOLTAG E CAPACITENCE AT SITE PICO FARAD R 10KV 722.2 Y 727.6 B 734.8 CAPACITENCE AT WORKS PICO FARAD R 734.0 Y 740.0 B 746.0

TAN DELTA
10KV 0.00185 0.00187 0.00185 0.0019 0.0019 0.0020

CURRENT RATIO TEST

THROUGH PRIMARY INJECTION KIT MEASURE AT 20,40 AND 80% CURRENT FOR ALL CORES AND TAPINGS.
R CORE 1 1S11S2 AT 20 % CORE 1 1S11S2 AT 40 % 198 406 Y 200 406 B 201 406 ERROR

CORE 1 1S11S2 AT 80 %

799

801

807

SITE TEST FOR CT

MAGNETIZING CURRENT IN mA TEST-TO BE MEASURED AT 25,50,75,100,110 %
R -PH Y-PH B-PH

CORE5- 5S1-5S2 AT 25%, 250V CORE5- 5S1-5S2 AT 50%, 500V CORE5- 5S1-5S2 AT 75%, 750V

6.6

7.4

9.5

9.8

10.6

14.1

13.8

14.6

20.2

SITE TEST FOR CVT

220KV CVT RATING :220KV,RATIO 220 KV/110 V BY ROOT 3,3 SECONDARY WINDING, SEC-1,2 , BURDEN 50VA, CLASS 3P

SEC-3 , BURDEN 50VA, 0.2

CAPACITANCE AND TAN DELTA CVT

HEALTHINESS OF INSULATION.
VOLTAG E CAPACITENCE AT SITE PICO FARAD R 10KV 4395 Y 4427 B 4382 CAPACITENCE AT WORKS PICO FARAD R Y B

NOT AVAILABLE

TAN DELTA
10KV 0.00311 0.00321 0.00294 NOT AVAILABLE

SITE TEST FOR CVT

IR TEST PERMITTED VALUES 400KV -400M OHM, 220KV 200M OHM CHECK PRIMARY WITH SECONDARY CORE-1,2,3& EARTH
R -PH P- S CORE-1 P-S CORE-2 P-S CORE-3 5000 M OHM 10000 M OHM 10000 M OHM Y-PH 5000M OHM 5000M OHM 5000M OHM B-PH 5000 MOHM 10000 MOHM 10000 MOHM

VOLTAGE RATIO TEST APPLY 230 V ON PRIMARY AND MEASURE THE VOLTAGE IN SECONDARY

SURGE ARRESTOR
IR TEST WITH 5KV MEGGER :MEASURE IR VALUES OF EACH STACK TEST LEAKAGE CURRENT METER. TEST COUNTER READING AND ITS WORKING BY INJECTING 500V. TOTAL LEAKAGE CURRENT = CAP CURRENT + RESISTIVE CURRENT. RESISTIVE CURRENT MEASURE WITH THIRD HARMONIC. IF THIS CURRENT EXCEED 500MA, THE SA TO BE REPLACED.

RELAY TESTING
INTERNAL PANEL WIRING CHECK EXTERNAL CABLES WIRING ,CONTINUITY TEST INDIVIDUAL RELAY TESTING AS PER RELAY SETTINGS, PRIMARY CURRENT INJECTION TESTING COMPLETE SCHEME TESTING

TOTAL SUB STATION

CHECK THE IR VALUES BEFORE CHARGING CHECK THE EARTHING GRID RESISTANCE AS PER DESIGN. FIRE FIGHTING EQUIPMENT TO BE CHECKED AND TESTED. EMULSIFIER SYSTEM IS IN WORKING CONDITION GRAVEL SPREADING, DANGER PLATES, FENCING ,GATE ETC SHALL

TOTAL SUB STATION

BATTERY AND BATTERY CHARGERS ARE COMMISSIONED AND WORKING. AUXILIARY AC SYSTEM CONSISTING OF AUX. TRANSFORMER, HORN GAP FUSE, ACDB, LIGHTING SYSTEM ARE WORKING AIR CONDITIONING SYSTEM OF CONTROL ROOM/PLCC ROOM WORKING

TOTAL SUB STATION

DG SET IS IN WORKING CONDITION LAYOUT DRAWINGS, EARTHING DRAWINGS, ROUTINE TEST REPORTS OF ALL EQUIPMENTS, SITE TEST REPORTS, EARTHING MEASUREMENT REPORTS ARE SUBMITTED TO ELECTRICAL INSPECTOR

TOTAL SUB STATION

CHARGES FOR ELECTRICAL INSPECTOR AGENCY TO BE PAID ELECTRICAL INSPECTORS GIVES COMMENTS /CHARGING PERMISSION SUB STATION CHARGED

THANK YOU