July - September 2015 Volume 32 No.

3
Pg. No.
1. ERDAs Laboratories for Evaluation of 1.0 ERDAs Laboratories for Evaluation of Insulating Materials

Contents
: A Capability Profile ... 01
Insulating Materials: A Capability
2.0 Major Business Contract and Empanelments Received ... 05
Profile 3.0 Letters of Appreciation ... 06
ERDA has state-of-the-art laboratories for 4.0 Customer Meetings ... 06
certification evaluation of liquid and solid 5.0 Research & Development ... 07
insulating materials used by the electrical 6.0 Important Visitors and Industrial Visits ... 09
engineering industry. The liquid dielectrics 7.0 Invited Lectures at ERDA ... 10
laboratory undertakes evaluation of mineral and 8.0 Training Programs Conducted / Planned ... 10
synthetic oils used in electrical products such as 9.0 Health & Happiness Program by Art of Living ... 10
transformers. Evaluation of new as well as in- 10.0 Technical Articles ... 11
service oils is undertaken. Facilities are also 11.0 Inspiring Leader: Dr. M. Visvesvaraya ... 12
available for evaluation of lubricating oils. The solid
dielectrics laboratory is engaged in evaluation of
solid insulating materials such as papers,
pressboards, laminates, rubbers, etc. Both
laboratories have been providing services to utilities
and industries for over four decades.
1.1 Liquid Dielectrics Laboratory
1.1.1 Introduction
ERDAs NABL accredited Liquid Dielectrics
Laboratory has state-of-the-art equipment for
evaluation of transformer, capacitor, & lubricating
oils. The laboratory is also equipped to undertake Gas Chromatograph (GC)
evaluation of natural and synthetic ester based oils
as per various national and international standards.
Sophisticated diagnostics and evaluation equipment
available with this laboratory include automated gas
chromatographs with headspace system, HPLC for
Furan analysis, flash point apparatus, interfacial
tensiometer, rotating bomb oxidation stability setup
(RBOs), resistivity and tan delta bridge, etc. The
laboratory is also equipped with specialized
analytical test facilities such as FTIR spectrometer
for PNA analysis and detection of presence of
oxidation inhibitors along with a sophisticated gas
chromatograph for identification of PCBs in oil. Tensio Meter
The laboratory has nearly thirty ongoing rate related to liquid dielectric insulation systems. Major
contracts of oil evaluation with generation, R&D projects successfully executed include
transmission and distribution companies as well as development of an online evolved hydrogen gas
various process sector industries such as cement, sensor for rapid fault detection in transformers.
petrochemicals, etc. The laboratory evaluates more This pioneering and innovative invention has won
than 10,000 oil samples every year. This translates many national & international awards and has been
into condition assessment of more than 8,000 power successfully technology - transferred to a major
transformers every year. transformer manufacturer in the USA.
The laboratory provides consultancy in liquid To facilitate decentralized and quick access to its
dielectrics and also undertakes R&D projects customers in different regions of the country, the
 02

laboratory has established NABL accredited Sonepat and ERDA(South) Rajahmundry]

facilities for oil evaluation at Rabale, Navi Mumbai
(ERDA-West), Rajahmundry (ERDA-South), &
Sonepat (ERDA-North). The laboratory is also
equipped with a mobile van for undertaking
transformer oil evaluation at site. The laboratory
provides regular services for collection of
transformer oil samples from in-service
transformers at customers site.
With it highly qualified, skilled and experienced
manpower along with its state-of-the art
infrastructure with outreach centers spread all over View of Mobile Van
the nation, combined with the massive scale of its
operations, the laboratory has emerged over the
years as the number one laboratory of choice of the
Indian utilities and industries.

Resistivity & Tan Delta Testing in Mobile Van

High Performance Liquid Chromatograph

1.1.2 Certification Evaluation & Testing Capability
1.1.2.1 Evaluation of Used Mineral Oil Filled in
Transformer [as per IS & IEC]
1.1.2.2 Evaluation of New Transformer Oil Moisture Content Determination & Dissolved Gas Analysis
[as per IS & IEC] in Progress in Mobile Van
1.1.2.3 Specialized Evaluation Services: The mobile test laboratory and the site laboratories
Dissolved GasAnalysis [IS:10593-2006] are equipped with facilities for following NABL
accredited transformer oil tests:
PNA Analysis [IS: 13155-1991)
Electric Strength (BDV)
Furan Analysis [IEC:61198-1993]
Water Content
Oxidative Inhibitor Content [IS:13631]
Resistivity
Moisture Content Determination in Paper
Insulation Tan Delta
Degree of Polymerization of Paper used in Oil Dissolved GasAnalysis
Filled Transformers Flash Point
1.1.2.4 Services Provided Through Mobile Test Acidity
Laboratory for Oil Evaluation at Customer Sludge
Doorstep and through Site Laboratories Inter Facial Tension
[ERDA (West) Navi Mumbai, ERDA (North)
 03

In-service, oil testing capability Plastics

Density (only available at site laboratories) B-Stage Epoxy Glass Cloths
FuranAnalysis Molding Materials
(only available at ERDA(West) laboratory) Varnishes
1.1.3 Major Research & Development Projects Resins
Successfully Executed Combined Flexible Insulation Sheets
Development of Demonstration Model of Fiber-Glass Reinforced Laminates
Transformer Oil Reconditioning Plant for Rural
Areas Rubberized Cork Sheets
Residual Life Assessment of Power Transformer PGAM Tape / Semica Therm Tapes
by Laboratory Simulation Rubber / Fiberglass Sleeves
Development of Online Evolved Hydrogen Gas Poly Propylene Films
Sensor for Transformer Fault Detection FiremanAxe, Multi Edge RescueAxe
Development of Prototype Thermosyphon for SMCs/DMCs
Power Transformer
Cable Truncking
Field Trial of Thermosyphon in Power
Piercing Connectors
Transformers in GEB Grid
Dead-end Clamps
Development of Natural Ester based
Transformer Oil Rubbers
Evaluation of Synthetic Ester Oils Insulating Sleeves
Failure Investigations of Oil Filled Equipment Cable Filling Compound/Cable Outer Sheath for
Oxidative Induction Time (OIT)
1.2 Solid Dielectrics Laboratory
Security Seals
1.2.1 Introduction:
1.2.3 Some Major Evaluation Tests Undertaken at
The solid dielectrics & polymers laboratory has an
Solid Dielectrics Laboratory:
array of sophisticated facilities & instrumentation
for certification testing & characterization of a large UV Exposure
class of dielectric & polymeric materials in various ClimaticAgeing
forms and shapes, as per national and international Tensile Strength
standards. These state-of-the-art facilities include
instrumentation for characterization/identification Flexural Strength
of rubbers & plastics, determination of glass Heat Deflection
transition (Tg) and melting point (Tm) of polymers Impact Strength
as well as measurement of degree of polymerization.
Volume Resistivity
1.2.2 Products / Materials Evaluated:
Surface Resistivity
A subset of the solid dielectric & polymeric
materials routinely evaluated as per National / Dielectric Strength
International standards include: Dissipation Factor and Dielectric Constant
Papers Conductivity and pH of Aq. Extract for Kraft
Press Phan Papers Paper / Press board
Press Boards and Pre Compressed Boards Air Permeability
Laminates Degree of Polymerization
Cable Jointing Compounds ThermalAnalysis by TGA/DSC
Adhesive Tapes 1.2.4 Specialized Evaluation Tests:
Non-Ignitable Boards To facilitate the Indian industry in meeting ROHs
regulations while exporting electro technical
 04

items to the European Union, the solid dielectrics

& polymers group at ERDA has set up a
laboratory for certification testing for ROHs
compliance as per the framework of IEC 62321.
The compliance testing against this standard can
be conducted at two levels at ERDA. At level-I,
an Innov-X Systems make X-Ray Fluorescence
Spectrometer (XFS), is used for rapid screening
for Pb, Hg, Cd, Cr, & Br (300 ppm cap). For
more precise quantification of the five hazardous
elemental species, capability exists for the next
level-II tests using a state-of-the-art Perkin Optical Emission Spectrometer
Elmer make Atomic Absorption Spectroscopy
(AAS)
ERDA also has capability for facilitating precise
quantification of hexavalent Chromium ions
(Cr+6) as well as Poly-Brominated Biphenyls
(PBBs) and Poly-Brominated Diphenyl Ethers
(PBDEs), as per the requirements and guidelines
of IEC 62321
Specialized test services such as ESDD/NSDD
based measurements for pollution levels on
insulators
UV - Accelerated Ageing - Weathering Test Chamber
Optical emission spectroscopy based chemical
analysis of MS, SS, & Cu (IS 228/IS 440).
1.2.5 Major EquipmentAvailable with the Laboratory

Fourier Transform Infrared Spectrometer

X-Ray Fluorescence Spectrometer (XRF)

Atomic Absorption Spectrometer (AAS) High Performance Liquid Chromatograph


Universal Testing machine (UTM)
2.0 M a j o r B u s i n e s s C o n t r a c t s a n d
Empanelments Received
2.1 Empanelment with NTPC
ERDA has been empanelled as an agency for
carrying out energy audit and performance
assessment by NTPC for 3 years. This empanelment
will enable ERDA to grow rapidly in the area of
performance efficiency assessment of thermal
generating stations.
2.2 Power Quality Measurement as per CEA
Guidelines:
ERDA received offer from Powerica Ltd for
carrying out power quality measurement at the point
of common coupling (PCC) where, 20 MW wind
generating station of Powerica Ltd is
interconnecting with 66 kV grid of GETCO. The
work involved measurement of mandatory
parameters (as per CEA guidelines) such as voltage
and current harmonic content, DC injection and
flicker for wind power plants. The measurements
were carried out for a continuous period of 24 hours.
The recorded data included frequency, current,
voltage, active power, reactive power, apparent
power, power factor, current TDD, voltage THD,
short term flicker, long term flicker and DC current
injected from wind generating station to grid.
Fig. 1. Temperature Contour
05
Comparative Tracking Index (CTI) Tester
The captured data, voltage and current waveforms
were analyzed up to 25th order harmonics using Fast
Fourier Transform (FFT) algorithm and current total
demand distortion (TDD) and voltage total
harmonic distortion (THD) were calculated. Using
the FFT algorithm, DC component in current was
extracted from harmonic data and compared with
limits as per CEA guidelines. Calculated voltage
THD and current TDD were compared with limits
given in CBIP publication no. 251-1996 and IEEE
519:2014 respectively. Flicker limits were
compared with limits mentioned in IEC 61000-3-7
The measurements were carried out in presence of
officers from Powerica Ltd and GETCO. Detailed
report with detailed conclusions and
recommendations was submitted to Powerica.
2.3 Residual LifeAssessment of Turbine Rotor
As part of a residual life assessment contract from
GSECL, ERDA undertook detailed numerical
simulation of a 210 MW BHEL KWU design turbine
rotor with the objective of predicting its remnant life
with respect to the degradation mechanisms of creep
and low cycle fatigue. This work was undertaken by
conducting coupled structural and thermal analysis
in steady state and transient solution modes. Typical
results obtained are shown in Figs.1 and 2, below:

Fig. 2. Equivalent Stress Contour
3.0 Letters of Appreciations
The edited extracts of a letter of appreciation
received from an esteemed customer is presented
below:
4.3
3.1 ..We wish to thank you for the courtesy
extended to our engineer and got the test conducted
on top priority in spite of your busy schedule. This
gesture will go a long way in the professional
relation of ERDA and us. Our special thanks to the
engineers of Short Circuit, Impulse and High
Voltage Laboratory. We really appreciate the prompt
service provided by ERDAStaff..
4.0 Customer Meetings
4.1 Delhi Metro Rail Corporation (DMRC)
Presentation on ERDA Capabilities was
organized at DMRC, Metro Bhawan, New Delhi
on 26th August 2015. Key speakers from ERDA
were Mr. Nilesh Pandya on Cables, Mrs. Sangeeta
Godkhindi on Insulator Testing and a General
Presentation by Shri Rajat Varshney. A Total of 17
Officials of DMRC including Director Mr. A.K.
Garg & Two Executive Directors Mr. A.K. Singh &
Mr.A.K. Sharma attended the presentation.
4.2 Gujarat State Electricity Corporation Limited
(GSECL)
A one day program on Performance Efficiency
Testing & Condition Monitoring of Thermal Power
A View of the Customer Meet Program at GSECL, Wanakbori
06
Plants was organized on 10th August 2015 for
GSECL officers at Wanakbori Thermal Power Plant.
A total of 61 engineers from their various power
stations attended the program.
Interactive Session at TANGEDCO, Chennai
ERDA organized an Interactive Session at
TANGEDCO Headquarters on 20th August to
present its credentials and capabilities to the
officials of TNEB Ltd., as a part of its marketing
plan.
The program began with a show of various videos
followed by general presentation. Thereafter,
technical presentations pertaining to testing of
transformers, CT/PTs, energy meters, EMI / EMC,
T&D hardware, reliability studies, cables as well as
condition monitoring of electrical products were
made by senior officers of ERDA.
In all, 38 engineers from the Generation,
Transmission and the Distribution sectors of TNEB
attended the meeting. They found the session very
useful and informative.
The participants inquired specifically about
harmonics measurement, specifications for the
mobile van apart from active participation during
the presentations. Dr. P. A. Krishnamoorthy, Dy.
Director and Shri K. V. Annadhurai coordinated the
event.
A View of the Interactive Session at TANGEDCO, Chennai
 07

5.0 Research & Development

5.1 Papers Published / Presented / Invited Talks Delivered
Sr. Title Authors Name of the Journal / Conference
1. Energy Efficiency Improvement of B. Vasiyani and Electrical India, Vol. 55; No.7; July 2015;
Motorized Fluid Handling Machinery: G.S. Grewal p.66-70
Case Studies
2 Design and Development of Pilot Asheesh Dhaneria, Conference on Solar Power Development
Microgrid System & Test and Satish Chetwani, (Including Roof Top Solar Systems) and
Certification Gautam Brahmbhatt Issues for its Grid Connectivity, organized
jointly by CBIP and CIGRE India on 30-31
July 2015 at New Delhi
3 Importance of Testing and Gautam Brahmbhatt, Conference on 'Make in India: Bright
Conformance in LED Manufacturing Nitin Patel, Prospects of LED Manufacturing'
Vinod Gupta organized by PHD Chamber, Delhi
on 14th August 2015
4 Energy Efficient Motors & Pumps R.P.Singh, Seminar on 'Standardized Pumps For
Satish Chetwani, Energy Conservation organized by BIS
Gautam Brahmbhatt, Ahmedabad on 03rd September 2015
Vinod Gupta
5 Cables Flammability Evaluation Nilesh Pandya IEEMA Journal, Vol.7, Issue No.1,
September 2015, p. 58-62
6 Solar Cables for Photovoltaic Systems Nilesh Pandya, Electrical India, Vol.55, No.9, September
Sheetal Panchal, 2015; p. 52-54
Jay Purohit
7 Industrial Pumping Systems: G.S. Grewal Invited talk delivered at Essar Learning
Fundamentals and Energy Centre, Essar Steel Ltd., Hazira, 18th
Conservations September 2015 as a part of Engineers Day
Celebrations
5.2 Completed R&D Project: Development of 2.2kW are normative, but IE4 class is intended to be only
IE4 Motor informative, since sufficient market and
Electric motors used for industrial applications technological information is not available to allow
consume 60-65% of the generated electrical energy IE4 standardization.
worldwide. Electric motor systems are, by far, the In order to help electrical motor manufacturers to
most important type of load in industry, accounting develop indigenous technologies for IE4 class
for approximately 70% of industrial electricity. In motor, ERDA has taken up an internal R&D project
the tertiary sector (non-residential buildings), to develop an IE4 class motor.
although not so relevant, electric motor systems use ERDA has developed an IE4 class efficiency, 2.2kW
about one third of the consumed electricity. In order common 3 squirrel cage machine, which is easy to
to promote a competitive motor market manufacture and does not use costly permanent
transformation, a new international standard, the
IEC 60034-30 has been approved. This standard
globally harmonizes motor energy-efficiency
classes in general-purpose, line-fed, three-phase,
squirrel-cage, induction motors (IMs). In this
standard, four efficiency classes are proposed,
namely Standard Efficiency (IE1), High-Efficiency
(IE2), Premium Efficiency (IE3) and Super- Electromagnetic CFD Analysis
Premium Efficiency (IE4). IE1, IE2 and IE3 classes Analysis of Motor for Fan Design

Developed 2.2kW IE4 Class Motor
magnets. This development was possible through
design optimization carried out using CFD and FEA
based electromagnetic analysis for stator, rotor,
winding and the fan.
The developed motor was tested at ERDA and found
to have efficiency of 90.73%, with a power factor of
0.748 and a temperature rise of 29C. The same
motor can also be classified under dual rating of
2.2kW IE4 and 3.7 kW IE3 in the same frame as per
the test results achieved.
5.3 Failure Investigation of Power Plant Tubing
5.3.1 The Evidence:
A case of failure of a water-wall boiler tube of a coal-
based thermal power plant was received for failure
analysis study. The failed tube had a rupture parallel
to the longitudinal axis of tube with a shape of a
fish-mouth caused due to internal hoop-stress
assisted fracture. The rupture lips showed extreme
Fig. 1: Ruptured water-wall tube in as-received condition shows opening-up of tube due to rupture (1),
and erosion of tube surface at & near crack-tips (2) & (3)
08
thinning. The external surface of tube wall at-and-
near rupture indicated erosion caused due to fluid
impingement. The tube wall also showed reduction
in thickness from external side (outer surface) at and
near rupture, on the fire-side of tube (Fig.1). The
chemical composition analysis of the tube material
confirmed that it was a plain carbon steel of grade
SA 210 Gr. A1 as per design specification.
Metallographic examination indicated that the tube-
material was in normalized (heat-treatment)
condition, as per requirement. No degradation with
respect to high-temperature or creep degradation
was observed, (Fig. 2). Hardness measured on the
cut samples at various locations was 148 HV, which
is as per requirement (HV165 HV max) of the
standard.
5.3.2 The Conclusions
The evidence of wall thinning along with the
erosion-corrosion type topography of the tube
surface at & near rupture suggested the failure
mechanism to be erosion corrosion driven wall
thickness reduction, eventually leading to unstable
crack propagation. As the tube is located in the
vicinity of the soot-blower, impacting steam flow
conditions due to malfunctioning of soot blower led
to rapid erosion corrosion with eventual failure
under excessive hoop stress. As a remedial measure,
it was suggested to ensure adequate alarming and
inter locking circuitry in the soot blower system to
enable undertaking of timely corrective action.
Fig.2: Micrograph shows ferrite (bright) and pearlite (dark)
phases indicating normalized (heat-treatment) condition.
No degradation with respect to creep was observed

6.0 Important Visitors and Industrial Visits
6.1 A team, comprising of Shri S. Sumanth, Director
(Transmission), Shri M. S. Prabhakar, Suptg.
Engineer (T&P) and in charge Chief Engineer 6.3
(T&P), Shri Renuprasad, Executive Asst to Director
(Transmission) and Shri Ananthashayana Iyengar,
Executive Engineer from Karnataka Power
Transmission Co. Ltd., (KPTCL), Bengaluru visited
ERDAon 31st July 2015.
6.4
6.2 A team of Senior Executives from BESCOM,
Bengaluru visited ERDAon 4th & 5thAugust 2015.
The team comprised of Mrs. G. Sheela, General
Manager (QS&S), Mr. H. Narayana Naik, Chief
6.5 Industrial Visits
Final year Electrical Engineering students from seven engineering colleges [total number of 420 students] have
made industrial visits to ERDA. In July September, 2015.
A view of Engineering Students at our Campus during Industrial Visit
09
Engineer (T&P), Retired from KPTCL, Mr. B. R.
Somashekar, Dy. General Manager and Shri T.
Raghu,Asst. General Manager
Bangladesh Rural Electrification Board (BREB)
officials, Mr. Md. Yeakub Ali Patwary, Jt. Secretary
and Mr. Md. Mostafa Kamal, Project Director
visited ERDAon 4th September 2015.
Seven Senior Officers from Reliance Industries
Limited., Mumbai and Vadodara, Dr. Ajit Sapre, Dr.
Rakshvir Jasra, Dr. Sanjeev Katpi, Dr. Pradip
Munshi, Mr. Ninad Ingle, Mr. Jayesh Vora, and Mr.
Gordhan Goyal visited ERDA on 4th September
2015.
 10

7.0 Invited Lectures at ERDA

Mr. Amelendu Mohanty, Technical Advisor, TBEA delivered a lecture on Power Transformers on 23rd July 2015
at Chemburkar Learning Centre. Fifty nine ERDA staff members participated in the lecture. This highly
informative and interactive lecture was widely appreciated by the participants.

A view of Mr. Amelendu Mohanty, Technical Advisor, TBEA Delivering his Lecture

8.0 Training Programs Conducted / Planned

8.1 A two day training on Design Aspects & Performance Evaluation of Motors & Pumps was conducted on 6-7
August 2015. Alarge number of participants from utilities and industries participated in the program
8.2 A special program on Evaluation of Cables & Accessories, was conducted for RITES Ltd., Mumbai on 25-26
September 2015 at our premises.
8.3 Training Course Planned
1. High Voltage Evaluation Techniques 8-9 October
2. Foundation Course of Smart Grid [Jointly with India Smart Grid Forum (ISGF)] 15-17 October
3. EMI/EMC Evaluation Techniques for Electronic Equipment & Machinery 16-17 October
4. Uncertainty Measurement in Electrical Discipline 27-28 November
5. Condition Monitoring of Motors, Generators, Pumps & Turbines 3-4 November
6. Industrial Energy Management Techniques 16-17 December
9.0 Health and Awareness Workshop by NGO - Art of Living
ERDA organized a Health and Happiness workshop from 7th - 11th September 2015. A total of 25 ERDA
employees participated in the workshop. This workshop is specially designed for corporates by Art of Living,
the biggest NGO in the world, and has proved to be the best solution for Stress Management. The workshop
includes various yoga exercises such as Sudarshan Kriya, Asanaas, Meditation etc. The workshop was
conducted by well-known yoga trainer Dr. M. Makkar. The workshop has been deeply appreciated by all
participants and many employees have requested for a second batch.

A view of the Asanaas being Performed during the Workshop Workshop Participants with Yoga Trainer, Dr. M Makkar
 11

10.0 Technical Articles: Dissolved Gas completely removed from the oil by degassing &
Analysis for New Transformers gases formed during drying and impregnating the
transformer in the factory. Furthermore, duration of
10.1 Introduction
test is short and only small amount of gas is
The trouble free performance of a transformer generated.
during its service life is of paramount importance in
10.3.1Stage I: Analysis
power stations to ensure uninterrupted and
economic power supply of transformers which Therefore, for the interpretation of DGA results
operate under complex environmental conditions before & after heat run tests, a guideline has been
and variable thermal and electrical stresses during suggested by CIGRE working group. Table-1
service. As a result of normal ageing process, indicates the maximum values of gases which can
insulating oil breaks down and produces gases like be dissolved in the oil of new transformer before
hydrocarbons, hydrogen and carbon oxides which heat run test. The interpretation method after heat
dissolve in oil. The rate of generation and presence run test is based on the rate of increase of particular
of some combustible gases in large quantities gases and fixed permissible limits. It is also
definitely indicate some internal fault in incipient suggested to ensure that the detection sensitivity of
stage and if not monitored regularly, even at an equipment should be consistent with the actual
advanced stage. Therefore, it is advisable to detect concentration levels to be measured with the
the faults in its early stage, so that the development changes which yield significant information. The
of major faults with consequent damage to a smallest detectable quantity (Sd) of the individual
transformer can be avoided. gases is also given in Table-1.
Analysis of dissolved gases has been a proven Table-1
technique in use for the last 2-3 decades for Gas Concentration of Minimum Detectable Value
monitoring the health of a transformer in service by Sd and Maximum Permissible Value of Gases
sensing incipient fault well in advance before, even (X)1in Oil
the Buchholz relay operates. Moreover, the latest Sl. No. Gas Sd (X)1
trend is also to conduct DGA as a special test on new (ppm) (v/v) (ppm) (v/v)
transformers at manufacturers end, before and after 1 CO2 10.0 200.0
the heat run test.
2 CO 5.0 80.0
10.2 New Transformers
3 H2 2.0 15.0
DGA may be carried out on oil immediately after
filling the transformer, prior to starting the heat run 4 CH4 0.1 2.5
test, followed by the next DGA, approximately 2 & 5 C2H6 0.1 2.0
24 hours after the termination of heat run test at the 6 C2H4 0.1 2.0
manufacturers works. However, during the test, 7 C2H2 0.1 1.0
additional oil samples may be taken at intervals of To decide the permissible changes of individual
about 4 hours each, if required. gases during heat run test, the maximum analytical
At site, the analysis may be carried out on new oil spread (Sa) should be evaluated as follows, for any
after filling in the transformer and before charging. gas (say X);
This forms the initial bench mark for the Sa(X) = 0.1 (X)1+ 2 Sd (X)
transformer for trend monitoring in service. The
analysis may be repeated after three months of Where, X1 = Original quantity of gas X
service to ensure that no abnormality is indicated Sd = Smallest detectable quantity
during the initial period of operation of new If the difference in concentration of any gas before
transformer after commissioning. and after heat run test is less than Sa of the gas,
10.3 Before &After Heat Run Tests transformer is healthy and no further interpretation
The existing methods of interpreting DGA results is required. Otherwise, resource has to be taken to
are not applicable for new transformer, oil as before Stage-IIAnalysis.
the test, there may initially be small amount of gases 10.3.2 Stage II: Analysis
dissolved in the oil, the source of which may be If all the criteria in range1 given in Table II are
gases formed during the refining processes and not fulfilled by DGA result it can be concluded that the
 12

transformer has no thermal fault. However, if one or Table - 2

more criteria exceed the range 1 limits and all the No. Criteria Range 1 Range 2
1. (C2H2)2 (C2H2)1
criteria lie below the range 2 limits, there is a <Sa(C2H2) <Sa(C2H2)
2. 1/t{[(H2)2(H2)1]+[(CH4)2(CH4)1]
possibility of a fault caused by load current and/or + <2 ppm (v/v)/hr <5 ppm(v/v)/hr
leakage flux. In such cases, oil during service shall [(C2H4)2 (C2H4)1] +[(C2H6)2
(C2H6)1]}
be closely monitored by DGA.
3. 1/t [(CO)2 (CO)1] <5 ppm (v/v)/ hr < 25 ppm(v/v)/hr
If one or more of the limits of range 2 are exceeded, 4. 1/t [(CO2)2 (CO2)1] < 20 ppm (v/v)/hr < 100 ppm(v/v)/hr

more oil samples taken during heat run test shall be 5. (C2H4)2 (C2H4)1
(C2H6)2 (C2H6)1 < 1 ppm (v/v)/hr < 3 ppm (v/v)/hr
analyzed to obtain more information for which, an
Here t is duration of heat run test in hours, (X)2 and (X)1 are concentrations of
arrangement between purchaser and manufacturer gas X, after and before the test.
is required. 5th criteria may only be used if increase in gas concentration of C2H4 &C2H6
before and after heat run test are > 10 Sa
11.0 Inspiring Leader: Dr. M. Visvesvaraya
Dr. M. Visvesvaraya was born on the 15th of September 1861. All through his student days he worked hard
and in a systematic way. He was an early riser and started his work quite early. When he was twenty, he
joined the Science College in Poona to study Engineering. Three years later, by sheer determination and
hard work he ranked first in the L.C.E. and the EC.E. Examinations. He started his career as Assistant
Engineer at Nasik for Government of Bombay. From Bombay, Visvesvaraya went to Hyderabad as Chief
Engineer. Here he achieved something that was simply impossible at that time. The river Moosa divided
the city of Hyderabad into two. When rains lashed, the river was in floods and the waters of the river poured
into many houses, and men and cattle were carried away. Visvesvaraya planned dams to tame the Moosa
and also suggested that parks should be laid out on the banks of the river.
His resourcefulness earned him the position of a Chief Engineer in Mysore State. Visvesvaraya continued
to be the Chief Engineer of Mysore for three years. In 1912 when he was 51, the Maharaja of Mysore chose Visvesvaraya as his Dewan.
Visvesvaraya realized that industry was the backbone of a country. So he developed the existing industries. He also got experts from
other countries to help by teaching their skills. Thus many new industries came up during his chief minister ship. He started the
Sandal Oil Factory, the Soap Factory, the Metals Factory, the Chrome Tanning Factory and Bhadravati Iron and Steel Works. He was
also the key in the opening of the Bank of Mysore. He also brought in many hotels into Mysore and played a major role in the laying
of railway lines. Visvesvaraya did in six years what many others could not have accomplished in sixty years. In 1955 when he was
94 years of age, Visvesvaraya was honored and made a 'Bharat Ratna' or the Gem of India. Even at that age he was so particular about
his dressing that people who went to see him were surprised for he was so neat and tidy.His memory even when he was almost a
hundred years old remained pristine. Fifty years after he had tamed river Moosa, at the age of 97, there was a discussion about the
river with certain others where some references were made to some intricate details. Visvesvaraya called a helper and, pointing to a
bookshelf, said, "Bring the three or four books in the middle of the third row." Then he opened one of them and pointed exactly to the
detail under discussion on that page.
Visvesvaraya silently passed away on 14th of April 1962. He was 101. Visvesvaraya led the country to the path of progress, every
one of his creations was considered mighty and magnificent. But far mightier and far more magnificent was the matchless dreamer,
doer and leader who paved the way to modern India. In his honour, his birthday is celebrated all over the country as Engineers Day.

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