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Commissioning Procedures

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Commissioning Procedure Of Power Transformer

In Transformer testing it can be classified into power and distribution transformers. It Rating plate
show nominal voltage, current of primary and secondary voltage at various of the tap changer,
connection symbols ( vector group), % impedance weight of oil etc.

Before starting transformer testing some of per-commissioning checks a physical inspection of


transformer is to be carried out along with the general arrangement drawing.The parts mentioned on
the drawing are to be checked for physical mounting.

Check the following points before start the Transformer testing:-

1.
1. Oil leakage from bushing, valves, air release plugs, etc.
2. Direction of mounting of Buchholz relay, as per arrow on the relay; the arrow should point
towards the conservator.
3. Oil level in condenser bushing.
4. Oil level of main tank and OLTC (On load Tap Changer) tank should be up to the filling
mark on MOG ( Minimum oil level guage)
5. Earthed at two points.(Very important before start the transformer testing)
6. Stoppers provided for locking of wheels.
7. Test taps on HV(High voltage) condenser bushing are fixed.
8. Valves on each radiator, both top and bottom should be open.
9. Valves on either side Buchholz relay should be open.
10. Arcing horns for bushing, if provided to be set as per manufacture’s instructions. If LAs are
provided for the transformer, it is advisable to set the arcing horn distance a bit higher.
11. Tightness of conductor / cables on transformer, HV side, LV side and neutral to be checked.
12. Check resistance and IR (Insulation resistance) values of NGR (Neutral Ground Resistor), if
provided.
13. Ensure that oil is filled in OTI (Oil Temperature Indicator) and WTI (Winding temperature
Indicator) pockets.
14. Check that colour of silica gel in breathers of main conservator and OLTC (On load Tap
Changer) conservator is blue.
15. Oil in breather cups to be filled upto level indicated.
16. Diaphragm of explosion vent, if provided to be checked.
In Transformer Testing following electrical checks are to be carried out and results recorded in the
test reports.

Prior to ratio check OLTC (On load Tap Changer) if provide is to be made functional OLTC can be
of two types,

 OLTC in-built in the main tank


 OLTC separate chamber type
1.
1. For in-built OLTC ( diverter switch) ensure that the lamp on the drive mechanism(DM) is
same as the one in the display on the main tank. Then connection the main operating rod
between the OLTC DM and diverter switch. Conduct mechanical operations on the OLTC
taking it through all the taps. Ensure that the final end position ( upper and lower limit )
switches operate.
2. During the raise / lower operation note that direction of operating mechanism. Switch off the
3 PH AC supply and check operation of raise / lower contractor as per commands from DM.
3. With OLTC at some intermediate tap, switch on the 3 phase supply and give either raise /
lower command to the OLTC. Check whether the mechanism is moving in the right direction
for the command given. If the direction is reverse, switch off the AC and DC supply, verify
that the phase sequence of the supply is correct, if not correct reverse the phase sequence at
the motor terminal box.
4. Observe the operation of LOTC and check blocking of operation at the end positions.
5. Verify that insertion of manual operating handle cuts off electrical operation.
6. Test the Automatic Voltage Regulating Relay (AVRR), if provided perform automatic
operation from the AVRR.
Transformer Testing:-

1-Ratio test:-
Apply 3 ph , 415V to high voltage winding of the transformer and ,Ensure the induced voltage on the
low voltage terminals at all taps. Ensure variation in secondary volts as the taps are changed and
compare the results with manufactures test report or ratio mentioned on transformer nameplate.If delta
tertiary stabilizing winding is provided (usually provided for Y Y transformers), open the delta
shorting link and measure the voltage across the two terminals during ratio test-it should be
negligible. Refer above figure

2-Vector group test:

Make a test set up as per figure . Ensure that neutrals of HV / LV are isolated from earth.Measure the
voltage as per test format EFS / Transformer.
3.No load / Magnetizing current test:-
Remove the shorting between primary & secondary and measure the currents in all the phases while
maintaining the supply at primary. This test is done at nominal tap and at the minimum and maximum
taps.
Expected currents – Ir / Iy / Ib – 1:0.0:1 for star transformer
-Ir / Iy / Ib 1: 1:1.3 – for delta transformer
The currents should be in the order of mA. Refer the above figure.

4-Short circuit Current test:


With the transformer at nominal tap, apply 3ph 415 V to the primary and adequate shorting on the
secondary side ( depending on % impedance ) ensure bushing CT (Current Transformer )secondaries
and WTI CT secondaries are through

a. Measure currents in primary and secondary


b. Check the current in CT secondary bushing CT,WTI CT, LDC CT
Repeat point (a) at maximum & minimum taps.
5-Core balance test:-
Apply 415V between phase-phase( for delta transformer) and phase-neutral ( for star transformer) on
secondary side. Ensure that adequate safety precautions are taken on the primary side, as high voltage
will be induced. Measure the current and voltage for the following phases –
For Delta Transformer Vry, Vyb, Vbr
For star transformer -Vry, Vyb, Vbr, Vrn, Vyn, Vbn.

6-Insulation Test:-
Upto 6.6KV a insulation tester of 2.5 KV may be used and beyond 6.6 KV, 5 KV voltage level may
be used.

Polarisation index is record by IR value at 10/1 min ratio.

DIELECTRIC
POLARISATION INDEX 10/1
ABSORPTION 60 / 30 SEC INTERPRETATION
MIN RATIO
RATIO

—– Less than 1 Unsatisfactory


DIELECTRIC
POLARISATION INDEX 10/1
ABSORPTION 60 / 30 SEC INTERPRETATION
MIN RATIO
RATIO

1 to 1.25 1 to 2 Dubious

1.4 to 1.6 2 to 4 Good

More than 1.6 4 Very good

Note: IR values of delta tertiary stabilizing winding should also be taken with earth and with HV and
LV winding.

7-Transformer Oil Testing :-


Prior to charging of transformer confirm the healthiness of the oil by testing the dielectric strength of
oil. The oil is to be tested at 2.5 mm gap. 6 nos reading have to be taken and a average of these
reading is the the break down voltage of the oil.

EQUIPMEN TEST
CHARACTERISTI FREQUENC PERMISSIBL REMEDIAL
T METHO
CS Y OF TEST E LIMITS ACTION
VOLTAGE D

> 170 KV Immediately > 50 KV


Reconditionin
Break Down voltage 70 – 170 KV IEC 156 prior > 40 KV
g
< 70 KV charging > 30 KV

8-Special Test:-

Winding resistance should be carried out with 24 V battery. Rheostat with 10 A rating, along & digital
multimeter, two pole switch Circuit as per figure connect the battery to one winding of the
transformer and adjust the current to 2A. Measure the voltage at bushings. Winding resistance
calculated should be compared with factory test results. Do not disconnect the wires without reducing
the current avoid voltage spikes.
Winding resistance test should be done after all the other tests have been completed.

ote :-In transformer testing, if more than one run of cable per phase is used on the transformer LV
side, it should be confirmed that there is no cross-over of phases between any run. Such a crossover
would result in a dead short circuit on the LV side of the transformer. This can be verified during no-
load magnetizing current test-the magnetizing current on the transformer HV side should be in the
order of mA, with the all the LV side cables connected. Alternatively, thus can be confirmed during
the transformer differential stability test.

Note :-In transformer testing, if more than one run of cable per phase is used on the transformer LV
side, it should be confirmed that there is no cross-over of phases between any run. Such a crossover
would result in a dead short circuit on the LV side of the transformer. This can be verified during no-
load magnetizing current test-the magnetizing current on the transformer HV side should be in the
order of mA, with the all the LV side cables connected. Alternatively, thus can be confirmed during
the transformer differential stability test.

Prior to energizing ensure the following in transformer testing:-

1. Cleaning of the transformer, especially the bushing. Ensure that all protections are operative.
Buchholz relay maybe tested by using the test screw, or by pumping in air with a bicycle
pump, or by draining oil from the relay after closing both side valves.
2. Air release from the transformer is to be done from air release plugs on the main tank,
radiators, HV & LV bushing, Buchholz relay and OLTC prior to charging of transformer. Do
not release air from the condenser bushing as they are hermetically sealed.
3. Check operation of OTI / WTI, ensure oil in the temperature probe pots.
4. All inter connecting valves are open position.
5. Check IR value between each winding an earth, and between windings. Neutral earthing is to
be disconnected for this purpose.
6. Check that HV and LV neutral earthing has been re-connected after megger test.
7. Earthing and delta shorting of tertiary stabilizing winding ( if provided), to be checked.
8. Proper setting of OTI & WTI to be done.
1. Perform trip test from all the transformer protections, including Buchholz relay, PRD, Oil surge
relay, OTI and WTI.
2. All protection relays to be properly set.
3. Reset the maximum reading pointer (MRP) of OTI & WTI.
4. Ammeter selector switches should be selected to read some phase current.
5. All MCBs, fuses and switches in Marshalling boxes, Craps, isolator cubicles and breaker cubicles
should be in circuit.
6. If transformer is provided with an OLTC, energise it at Tap#1; if the transformer is provided with
an off-circuit tap changer, energise it at the nominal tap.
Testing of Fan control Cubicle:-
Fan control cubicle houses the control and hardware for running of cooling fans with the fans running
the transformer can be loaded to the specified rating on the nameplate (ONAF).

The fans are started with the operation of WTI contact. Preferably S1 should be allocated to run the
fans. Normally two banks of 4 fans are provided on the radiators.In each bank one fan is spare and
three fans will run continuously until that contact from WTI drops out. Prior to starting of fans
following thing have to be checked:-

1. Measure IR value of the fan motors.Power Transformer Te


2. Check for free rotation of fan blades (rotor), ensure that they do not foul with the radiators.
3. Ensure proper earthing of motors, fixing of fan on the frames
4. Check for proper setting of overload relays.
After the fans have been started the direction of airflow should be checked. The flow of air should be
on towards the radiator fins.

Check operation of the fan circuit in auto and manual mode and also confirm the change over of
standby fan in case of fan failure.

After Energizing the Transformer :-


1. If OLTC is provided, run the tap changer from Tap #1 upto nominal tap.
2. Check the phase sequence and magnitude of the transformer secondary voltage at the incoming
line PTs.
3. If the transformer is an extension to an exiting system, do the phasing out w.r.t the exiting PTs.
4. Check for any abnormal sound or vibration in the transformer.
5. Keep the transformer energized on no-load for 24 hours; take reading of OTI, WTI and current.

Pre commissioning check/Instruction of Protection Relays

Refer to Siemens protection relays:-

1. Check the relay model number (type number) is as per specifications. Note the serial no of the
relay of the relay.
2. Inspect the relay for signs of physical damage.
3. Check that any series resistors, where applicable, have been installed e.g. for CTMM relays a
series resistor is required in the power circuit, depending on the supply voltage.
4. Test the relay as per the procedure for the given relay.
Protection relays can be divided in to current operated ( eg- CDG series, & SJ600, bus differential,
transformer differential etc), Voltage operated (VAGM, VD, 7RW 600), relays requiring voltage &
current inputs (CDV, 7SJ531, 7SA etc).

Testing instruction for CDG relays.


1. Test to be done in accordance with commissioning instruction for above relays for non-directional
& directional inverse time over current and earth fault relay with MRI 220C.
2. Reading obtained during testing should be recorded in commissioning test.
3. For permissible variations in current please refer of commission manual.
4. The above mentioned commissioning instructions & commissioning test report should be referred
to by commissioning engineers where these relays are to be tested & commissioned.
5. Where necessary depending on customer’s equipment & manual consent on Test/Formats etc.
suitable test procedure may be adopted after documenting the consent.
6. Manufactures test recommendations shall be final in case of any disagreement / ambiguity.

Step by step Commissioning guidelines of HV/ HT Cable


1. Check continuity of the HT cable to confirm R, Y and B phase at both ends as per marking. This
is especially important when there is more than one run of cable phase; any cross-over will result
in a dead short circuit.
2. The Cable screen is to be earthed at one end only.
3. Cable gland plate should be of non- magnetic type e.g. aluminum.
4. Perform HV / HT test on the cable.Apply only Dc voltage, as cables have relatively higher
capacitance. Check IR values before and after HV test. The HV and megger tests are conducted
between each phase and earth, with the other two phases earthed.
5. In case the cable lug is of aluminum and the busbar is of copper, bimetal washers are to be put
between the plug and the bus bar, with the Al on the Al side and CU on the Cu side.
6. Ensure tightness of the cable termination at both ends.

Testing and commissioning of indoor Vacuum circuit breaker

Physical Inspection and Mechanical checks:-


1. Check the circuit breaker, vacuum bottle and insulators for cracks or other signs of physical
damage.
2. Check the tightness of connections, including flexible connection between vacuum bottle and
busbar.
3. Switch off control power to the breaker of disconnect the control plug. Discharge the closing and
tripping springs- this done by first tripping the breaker (if it is closed), then closing the breaker,
then tripping it again. Open the cover of the mechanism box. Check for damage, check tightness
of push-on lugs at closing and tripping solenoids-if not tight, use a nose plier ti tighten the
same,close the cover.
4. Manually charge the closing spring,using the spring charging handle. Manually close the circuit
breaker then manually trip it. Charge the spring again to confirm that it is OK after closing and
tripping was done.
5. DO a vacuum check on the vacuum bottle. This is done by de-coupling the moving contact of the
bottle from the insulated coupling rod and physically checking the pressure with which the
moving contact pushes against the fixed contact. This is just a qualitative test,done at site to
ensure that the vacuum is OK.
6. Check for erosion of the contacts of the vacuum bottle.
Breaker IR Values :-

With the Circuit breaker in closed condition, check IR values of each phase to earth and between
phases. With the breaker in ope condition , check IR values across each vacuum bottle.
Special Tests:-

1. Contact resistance : With the circuit breaker


in closed position, use a micro-ohmme ductor tester to measure the contract resistance cross each
pole of the breaker.

2. Breaker Timing Test :

Note:-DC supply to breaker closing coil for closing timing


Dc supply to breaker tripping coil for tripping timing

Measure the closing time and the tripping time of the circuit breaker.To the time interval between
the operation of the close / trip command contact and the instant when the main contacts of the
breaker close / open. This can be measured connecting a close / trip command spare contact to the
“start” input of an electronic timer and the breaker main contacts “Stop” input of the timer.

What is short circuit current?


When two or more conductors are different phases come in contact with each other in a line,
transformer or any other power element, then the part of the impedance is shunted out of the circuit
due to which a large current flow in the un-faulted phases, such current is called the short circuit
current.

It reduces the effect of impedance in the circuit while the current in the circuit rises.

 The flow of large current will overheat the equipment.


 The flow of short circuit current in the current carrying parts produces a force of electrodynamics
interaction which may destroy or damage the equipment.
Fault MVA = (Base MVA / % Z ) × 100

MVA = KVA / 1000

Where,

Base MVA= Transformer Rating

%Z = Impedance + 10 % tolerance of z

Isc =Fault MVA / (√3 × Base KVA )

Where,

I SC = Value of fault current or short circuit current in KA

Base KVA= Transformer is secondary output voltage (like 6.6kv/440 v)

Single lie Diagram


So let’s take Quick Observation

Calculate Fault current at each stage of following Electrical System SLD having details of.

 Transformer Rating is 2.5 MVA.


 Transformer Impedance is 7.25 %.
Solution:

Use the above formula to convert MVA to KVA

2500/1000= 2.5 MVA

As per above formula

Fault MVA =2.5 / (7.25 % + 10% tolerance) × 100

= 2.5 / (7.25 +0.725) × 100

=31.32 MVA

Now calculate Short circuit current


Isc = 31.32 / (√3 × 0.44) = 41.09 KA

Short circuit current is 41.09 KA.

The cross sectional area of high voltage cable where calculated shall not be less the value determined
by following formula:-

S = (I SC *√t ) / K

Where,

S= Nominal cross sectional area of the conductor in mm2

I SC = Value of fault current or short circuit current in KA

T=Fault clearing time in seconds (1 second or 3 second)

K= Factor taking account of the resistivity, temperature co-efficient, heat capacity of the conductor
material, initial and final temperature. Value of K (as per BS 7671) shall be taken as 0.094 for XLPE
insulated Aluminium cables, 0.143 for XLPE insulated Copper cables
and 0.076 for PVC Insulated Aluminium cables.

Note:–

1. Wherever the application of the formula results in a non standard size a conductor to the next
higher standard cross section area shall be used.
2. Short circuit duration for cables must be commensurate with the tripping time of the protective
deceives associated with feeder.

Let’s go through a example:

Data Available/ Require :-

Suppose Short circuit current (ISC )= 50 KA

Tripping time for system is 1 second.

Solution:

XLPE insulated Aluminium cables

As per above formula:-

S= (50× √1)/0.094 = 531.91 = 532 sqmm

So select in near size of cable like 3 core 630 sqmm .

XLPE insulation Copper cables

As per above formula

S= (50× √1)/0.143 = 349.65 = 350

So select in near size of cable like 3 core 400 sqmm .


So Finally we found two different size of high voltage cable and Cable will select as per system
require. Copper cost is higher than aluminium.

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