General Philosophy: 1.0 - Introduction

Section - 1
GENERAL PHILOSOPHY
1.0 - INTRODUCTION
1.1 In today's competitive market scenario power utilities are under

tremendous pressure to cut down their maintenance costs as they form a
significant portion of the operation costs. This has led the utilities to adopt
condition-based maintenance of the equipments rather than usual preventive
maintenance being carried out at a fixed interval of time. Maintenance
intervals are normally fixed on the basis of type of equipment and sometimes
on the equipment history. However, tests or measurements are also carried
out to assess the condition of the equipment.
2.0 TYPES OF MAINTENANCE
Different types of maintenance being done on equipment are:
i) Breakdown maintenance
ii) Preventive maintenance
iii) Condition based monitoring
iv) Reliability centered maintenance
i) Breakdown Maintenance
As the name implies the maintenance is carried out when the equipment fails.
This type of maintenance may be appropriate for low value items. However
for costly substation equipments, it is not desirable to wait till the breakdown
of the equipment, as this cost more to the utility as well as the availability
and reliability of power gets affected. The revenue loss due to non-availability
of the system shall be much more than the cost of the failed equipment.
Therefore identifying the defect before failure, is more appropriate to plan
repair / replacement.
ii) Preventive Maintenance
The preventive maintenance of equipment is being mostly adopted by almost

all the utilities. In this type of maintenance, the equipments are inspected at
a pre-determined period. The frequency determined based on the past
experience and also guidance from the manufacturer of the equipment. This
type of maintenance would require specific period of shut-down. Maintenance
procedure, periodicity of maintenance and formats for maintaining records for
various types of sub-station equipments have been discussed separately in
detail in a separate section.
iii) Condition Based Monitoring
This type of maintenance technique is adopted to assess the condition of the

equipment. The condition of the equipment is assessed based on different
condition monitoring tests. Some of the tests are done on on-line and some
are done on off-line. However, this type of maintenance would need
sophisticated testing equipments and skills for analyzing the test results.
1
iv) Reliability Centered Maintenance
This is the recent technique being adopted in maintenance philosophy. The

basic objectives of reliability-centered maintenance are:
- Maintenance should keep the equipment at desired level of performance
- Optimizing / minimizing the maintenance / shutdown period so as to

enhance the availability of the equipment.
- Deferring / avoiding the replacement of components and major/minor over-

hauls till it is absolutely necessary.
Reliability centered maintenance policy is based on the life cycle cost concept
and the decision for replacement of the equipment is taken based on techno-
economic considerations. From the view point of RCM our objective should be
to devise a system, which does not need periodic maintenance and at the
same time predict in advance possible failures/problems of the equipment. To
meet this aim we have to develop equipment which require either no or very
little maintenance and on the other hand the concept of condition based
maintenance should be implemented. Realization of this objective will result
in enhancing availability, reliability and reduction in manpower for
maintenance purposes.
3.0 FAILURES OF EQUIPMENTS
3.1 Failure of any equipment should taken up seriously. Detailed analysis of

each failure should be done which will help in reduction/stopping of repeated
failures of same nature. It is general experience that in spite of doing regular
maintenance, failure of the equipment can't be totally eliminated. Number of
EHV equipment failures have been reported practically by all the utilities and
some of them have been quite serious resulting in consequential damage to
the adjoining equipment. Circuit breakers operating on high pressure when
they fail, they explode like a bomb resulting in scattering of insulator pieces
to a larger distance and damage to the adjoining equipment. Similar situation
have also been faced with the failure of surge arrestors and current
transformers. Some of the typical failures of equipment and the remedial
measures adopted have been discussed in a separate section.
4.0 NEED FOR CONDITION BASED ASSESSMENT OF EHV EQUIPEMNT
4.1 In the present competitive environment, all utilities are making efforts to
reduce the O&M expenditure. This puts lot of pressure on the utilities to
minimize the outage period due to failure of equipment. This necessitates
adopting of condition based monitoring as the Need of the Hour. This has
necessitated all the power utilities to introduce condition based monitoring
for EHV class equipment so that actual condition of the equipment and its
residual life could determined. Modern techniques are available for condition
based monitoring and the concept of residual life assessment is picking up
world wide.
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CAUSES OF FAILURES OF MAJOR SUB-STATION
Section -2
EQUIPMENTS AND REMEDIAL MEASURES
1. INTRODUCTION
This section briefly describes about the probable causes of failure of major
sub-station equipment viz. Power Transformers, Reactors, Circuit Breaker,
Instrument Transformers, Surge Arrestors etc. and remedial measures taken
to prevent such failures.
2. POWER TRANSFORMERS
Power Transformers are vital links in the chain of components constituting a

power system, the failure of which affect the supply of electric power to the
consumers. Internationally, the transformers are found to be very reliable but
in our country the failure rates are quite high. Failure analysis quotes a host
of reasons behind the failure of power transformers. These may include
abused operations inept maintenance, substandard techniques adopted
during manufacturing, testing and commissioning, substandard input
materials, inconsistency environment, design deficiencies, abnormal
operating conditions, over voltages, system short circuits etc.
The main causes of failures of transformers in service (CIGRE Survey) is given

below:
Cause % of cases
Design 36
Manufacturing 28
problem
Material defects 13
Poor maintenance 5
Lightning surges 4
Short circuits 2
Components % of cases
Winding 29
3
Terminal 29
Tank and Di-electric 13

fluid
Magnetic Circuit 11
Other accessories 5
However the main causes of failure as pertaining to our country are given
below:
Table
Causes % Failures
Design defects 35.7
Manufacturing problems 28.6
Material defects 13.1
Transport or storage problems 1.2
In-correct maintenance 4.8
Abnormal overload Less than 1
Over-fluxing 1.2
Lightning 3.6
External short circuit 2.4
Loss of cooling 1.2
Unknown 7.1
However, The failures in power transformers can be broadly classified as:
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 Weakness in specification, design / manufacturing deficiency
 Installation / operation / maintenance deficiency
 Adverse operating conditions
 Aging
2.1 Weakness in specifications
Many a times, a customer specification is silent on the various aspects of site

conditions such as loading pattern, over fluxing, over voltage conditions,
various system parameters, environmental conditions. These are some of the
aspects where care has to be taken at the time of drafting of technical
specifications.
2.2 Failure due to defective design
Some of the failures due to defective design are listed in the table given
below.
Cause Effect Remedial Measures
Failure of yoke bolt Causes local short circuit in the Insulated yoke bands preferred
in insulation lamination resulting in intense local or yoke bolt insulation should
eddy currents be class ‘B’ insulation or higher.
High flux density in Causes large amount of force at time Flux density should not exceed
core of switching and repeated switching 1.9 Tesla at maximum
damage winding insulation operating voltage
Narrow oil duct in Results in improper cooling and Adequate duct from point of
winding damages insulation effective cooling
Improper Results in more loss and more heating Adjust the transpositions so
transpositions that all conductors should have
equal reactance
Inadequate May result in short circuit Provide adequate clearance as

clearance between per the voltage class
phases
Clamping ring not May fail during short circuit condition Thickness of clamping ring
properly designed should be designed such as to
withstand short circuit forces
Insufficient bracing May fail during short circuit condition Strong supports are required
of leads for bracing of leads
Radiators not Result in improper cooling causing Proper calculation of radiators is

properly designed higher temperature for oil/windings necessary
2.3 Failures due to manufacturing deficiencies
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Transformer manufacturing is more a craftsmanship rather than the machine
work. The reliability of the transformer depends on the quality of raw
materials and the workmanship. There are certain steps to be taken at
manufacturing stage so that apparently minus slips-ups at that stage do not
get amplified in major defects later on in service. Some of the failures due to
manufacturing deficiencies are listed in Table given below.
Cause Effect Remedial Measure
Loose winding and Result in interturn or interdisc Proper sizing for keeping
improper sizing short circuit winding under clamping
condition
Burrs on lamination Result in local short circuit Burr free condition to be

and result in heating ensured by good
manufacturing facility
Burrs on spacers and Result in damaging conductor Burr free condition to be

blocks insulation ensured by good
manufacturing facility
Bad brazed joints Damage the conductor Adopt good brazing

insulation and winding may procedures
fail
Metallic parts left over May cause partial discharge Better house keeping to
during manufacture ensured
Insulation surface Results in insulation failure Cleanliness to be ensured

contamination
All metal components not Partial discharge may start All metal components are to
earthed and oil quality may get be properly earthed and this
affected is to be added in check-list
Bad and porous welding Result in oil leakage Surface cleanliness to be

of transformer tank ensured and adopt good
welding procedures
Improper drying process Winding and insulation are Extensive drying and oil
not fully stabilized due to impregnation process should
moisture leading to failure be strictly followed as per
voltage class
2.4 Failures due to deffective materials
The quality of material used also reflects on the life of the transformers. A
rigid control of quality at all the successive stages of manufacture right from
raw material to finished product will avoid the failure in transformers. Some
of the failures due to defective material is listed in Table given below:
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Cause Effect Remedial measure
Sharp edges in copper Produce partial discharge The surface finish should be
conductors and damage the conductor smooth
insulation
Improper conductor Deteriorate under influence Check the incoming

insulation of high voltage stress and conductor insulation and
damage insulation also no. of layers for
conductor covering
Poor oil quality Insulation failure Maintain BDV & PPM as per
manufacturer’s
recommendations
Particles in oil held in Temporary breakdown Maintain oil cleanliness

suspension
Bare copper for connection Formation of oxidation and Provide enamel coating or
sludges paper covering on bare
copper
Defective accessories
Results in transformer These accessories to be
OLTC failure procured from well
established supplier in view
of high service reliability
1. Bushings
2. Buchholz relay
3. Protective equipment
2.5 Adverse operating conditions
The life of a transformer is normally dependent on the life of insulation.

During the normal operation of the transformer, the ageing process is also at
normal rate. The rate of ageing is related to temperature, moisture content
and duration of loading conditions. At temperatures more than 140ºC,
the gas bubbles are formed as a result of insulation deterioration. These
bubbles are of potential danger in the vicinity of high voltage stress zone.
This can initiate electrical damage leading to breakdown.
Life expectancy of transformer will get diminished through inadequate

protection while operating in the abnormal conditions such as:
1. Sustained overload conditions

2. Switching surges
3. Lightning surges
4. Transferred surges
2.6 Improper maintenance practices
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Poor/inadequate maintenance in the areas of oil leakage, oil quality, critical
accessories such as tapchangers, bushings, protective instruments etc. will
cause trouble in transformer. In addition to this, there are various trouble-
shooting problems encountered in the field, such as moisture, oxidation, solid
contamination, gas bubbles, overcurrent, overvoltage (transient or dynamic),
over temperatures, short circuit (mechanical forces) etc., for which sufficient
care should be taken to safeguard the transformer. Preventive maintenance is
strongly recommended to improve the reliability of transformer.
Some of the reported failures for transformers have been attributed due to
either of the following causes:
1. Failure of the winding insulation due to short circuit stresses

2. Failure of winding insulation due to surge voltages and transient surges
3. Failure of magnetic circuit
4. Failure of OLTC
5. Failure of bushings and other accessories
6. Failure due to poor insulation and poor cooling arrangements
Some of these failures are briefly described below:
2.7 Failure of HV, LV and Tertiary Winding due to Short Circuit and Surge
Voltages
Safety margin of transformer with reference to short circuit withstand

capability has been reduced widely. ISS stipulates a time of 2 seconds. The
World Bank Specifications recommends a time duration of 1 sec. On account
of the graded time discremination provided on the protective relays, which
are essentially over current and earth fault relays. Bus faults are cleared after
a time delay and many of the transformers have been found failing for bus
faults or a nearby fault on feeder converting into a bus fault due to failure of
feeder breaker to trip.
The tertiary winding provided on the power transformer are not adequately
related to provide insulation to withstand surge voltages as also not rated for
adequate short circuit stresses. Tertiary winding inter-turn insulation failures
have been found to be due to transferred surges also. Based on investigations
of failure of tertiary winding CBIP has already brought out research paper
providing guidelines for protections to be provided on loaded tertiary. As per
CBIP manual on transformers, provision of tertiary winding has now been
deleted upto 100 MVA, 3 phase 3 limbed core type construction. Special
precaution for protection of tertiary is necessary particularly in case of
capcitive/reactive loading. Frequency of switching on/off of
capacitor/reactor, distance of source from the transformer, design and
location of gapless arresters are some of the important factors which have to
be considered before loading of the tertiary. Failure of tertiary windings
generally have been experienced because of:
 Overstressing and inadequate cooling

 Improper implementation of protective schemes
 Frequent switching ON/OFF of capacitive reactive load
 Improper short circuit withstand capability
CBIP’s technical report on causes of failure of tertiary windings and BHEL’s

recommendations for protection of tertiary winding (Journal Vol. 3 No.1 of
1978) provides required guidelines on the subject.
The clamping arrangement provided on the transformer to contain the short

circuit forces were not found to be adequate. In some cases, the interphase
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and phase to ground clearance of the leads were found to be less which
resulted into flash over and damage of insulation due to vibration and
displacement under short circuit current. Damage has taken place in some
cases due to failure of insulating components eg., insulating cylinders,
supports, permalli wood etc. The failure of joints have also been reported
while handling short circuit current. A few cases of failure of transformer on
lighting impulse have been reported inspite of protection provided by
lightning arrestors.
Failure of the transformers have been reported on switching surges. The

transformer failed, when it was being energized after a supply failure form
upper substation on tripping of transformer on external faults. Operation of
differential and bucholz protection took place tripping the transformer
breaker and isolating the transformer. In a few cases, the transformers have
failed where Polarisation Index (P1) of winding insulation had deteriorated to
1.1 or less inspite of moisture content in transformer oil remaining within
limit upto 35 PPM & BDV 50 KV. Deterioration of P1 Index on sustained
temperature on load needs to be specified and examined. In one or two cases,
the substation earth resistence was found to be higher. This resulted into
high voltages to be impressed at neutral end of the winding during phase to
ground short circuit on feeder/bus. This caused failure of interturn insulation
at neutral end.
2.8 Failure of magnetic circuits
There have been failure transformer due to overheating of core and core
burning, failure of core insulation and core assembly getting used, slipping of
stampings and coming in contact with tank bottom. To overcome the above
problems separate provision for core earthing and core fixture earthing
through bushings provided by transformer is being resorted to. This facilitates
monitoring of core leakage current, if any, and in ascertaining that core is not
getting multiple earth and also healthiness of core board insulation.
2.9 Failure of on-load tap changers (oltc)
On –load tap changers are the second largest reason for trouble in power
transformers after short circuit. The defects in OLTC are of the following type:
1. Burning of transition resistance

2. Burning and damage of rollers and fixed contacts
3. Misalignment of the tap changer assembly
4. Error in time sequence operation
5. Defect in tap changing driving gear i.e. mis operation of limit switches
and step-by-step contractors etc.
Some of the common problems noticed in the OLTC compartment,

selector/debetor switch are:
 It appears proper care for selecting current rating of the OLTC is not
exercised by the manufacturer. Factors for efficiency of operation and
over loading capability of transformer have to be accounted for to
arrive at design current rating. The selected current rating normally
should be one step higher than the calculated value. It would be
advisable if purchaser’s technical specifications do not leave this option
to the manufacturer and current/voltage ratings are specifically
stipulated.

 Quality and rating of transition resistors have been one of the main
source of problem in OLTC. Repeated incidences of burning of transition
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resistors is an area which calls for serious attention from OLTC
manufactures.
 Open circuiting or burning of transition resistors leading to selector

switch spark over and fire in tap switch resulted into bursting of
pressure relief diaphram in MR type tap changer.
 Failure of limit switch to stop operation at extreme position of tap
changer have led to severe arcing, pressure build-up and bursting of
OLTC compartment.
 In sealed breathing transformers, defective oil seals and ‘O’ rings have
led to transfer of oil under pressure from main takn to diverter switch
and leakages through silicagel breather resulting into fall in main tank
oil level which is an operational hazard.
 Crack in barrier board has also been a cause of failure owing to non-
equalization of pressure between main tank and OLTC, while applying
vacuum at the time of first erection and drying out.
2.10 Failure of bushings
Condenser type bushings are sent with tip portion sealed and covered by
porcelain rain shade. The bottom condenser portion is sent covered with wax
coated cotton tape. In some of the transformers these transit tapes were
found to have not been removed wqhile hoisting the bushings on the
transformer. Over a period of service, the wax melted on contact with hot oil
inside the tank and the cotton tape opened out and caused discharge inside
the tank. It is better to dispatch bushings from works with bottom portion
sealed in oil filled tanks to be removed at site at the time of erection to avoid
moisture ingress.
2.11 Suggestions to reduce failures
From the foregoing discussion reasons for transformer failure could be

attributed to various causes. Some of the possible corrective steps are
enlisted herein, to reduce such casualty.
2.12 Improved design and manufacturing practice
By adopting CAD and better shop floor management, more reliable units could
be manufactured to eliminate:
 Poor short circuit withstand capability

 Manufacturing defects including cooling system
 Problems associated with bushings
 OLTC including selector/diverter switch
 Tertiary winding failure wherever provided
2.13 Improved testing method
Transformer should be simulated to actual service condition first by

sequential testing and then passing necessary current which could result into
temperature rise. Thereafter conduction of all high voltage application tests
could bring out insulation weakness. Simulated short circuit test if necessary
on scaled model and measurement of magnetic balance and magnetization
current could reveal abnormality. A chart is included at Annesure 1, depicting
testing sequence. Finally oil parameter could be recorded after completion of
all the tests and compared with initial values.
2.14 Erection at site
10
By adopting strict pre-commissioning test and checks possible erection
mistakes and omissions could be avoided. This list is enclosed at Annexure 2
and could be based on site experience.
2.15 Problems external to transformer
Load management
By adopting efficient load frequency management systems could be better

controlled avoiding damages and transformer failure due to
 Overloading
 Over fluxing and over voltage
 Hot joints and spark over
 Frequent feeder tripping due to reflected faults
After every tripping of transformer whether manually or through protective

relay, before recharging the tap switch should be manually operated to bring
the same to No.1 position. After loading, the transformer tap could be
changed to suit bus voltage requirement.
Failure of switchgear and battery
This could be avoided by periodic testing and using proper duty switch-gear
and battery.
2.16 Sub-station layout
Layout
Whenever single phase units are installed it is essential to provide partition

valves of adequate heights and strength to prevent collapse. This will
minimize chances of fire extending to the other units.
Soak pit and drain pit
Provision may be made for the necessary soak pit and drain pit in the
substation layout.
3. FAILURE OF CIRCUIT BARKERS
A circuit breaker is considered to have failed, when the breaker fails to

operates after a command is given or unable to interrupt the arc or withstand
a system voltage. CB failures have resulted in blasting of one or more of the
following components:
1. interrupting chambers
2. pre-insertion resistor chambers
3. grading capacitors
4. support column including tie/operating rods
Besides the above, the failure of breakers could also be attributed due to
following reasons:
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 Mechanical failure of operating lever
 Shearing off of the locking pin of pull rod
 Grading capacitor failure
 Embedding of PIR fixed contact assembly into the moving contact
housing due to loosening of grub screw.
 Dielectric failure inside interrupting chamber due to high moisture in
SF6 gas.
 Insulation failure (live to earth) due to accumulation of moisture on tie
rod during storage.
 Failure of mechanical coupling between tie rod and operating
mechanism.
 Failure of actuating valves in operating mechanism.
 Failure due to foreign particles (eye pieces) inside interrupter.
 Failure due to high transient recovery voltage (TRV). In case of circuit
breakers switching HVDC filter banks, the normal duty of CB is opening,
the resulting TRV can be severely distorted due to presence of filters
and can severely depart from the 1 – cos wave shape which may cause
high TRV and leading to internal breakdown in grading capacitor or
interrupter.
 Dielectric failure in Air Blast CBs.
 Others.
3.1 Preventive Measures for Avoiding CB Failures
The type of failures that have taken place reveals that there is urgent need to
improve manufacturing quality of various components besides, if effective
condition monitoring checks are also carried out, failures could be identified
at the incipient stage and corrective actions can be taken accordingly.
However following areas are suggested for preventive measures.
Design/technical specification modification
The modification required to be done in the technical specifications are as

follows:
 ‘Mechanical Close Interlock’ wherever provided should be identical for

CB with PIR or without PIR in order to avoid mixing of operating drives
during erection and during O&M.
 Interconnecting piping between different poles of CBs have been
removed and individual pole density monitor has been provided.
 SF6 gas cylinder to be tested for dew point, air content etc. as per IEC-
376 and test certificate alone will not be sufficient.
 Minimum time for PIR contacts open prior to opening of minimum
contacts should be 5 msec.
 Routine tests shall include measurement of dynamic contact resistance
measurement and tan delta measurement of grading capacitor in order
to have base values.
 Upto 200 kilometers transmission line length pre insertion resistance
need not be provided with the barkers. This is based on study carried
by a leading power utility.
Stringent quality checks during manufacturing
To avoid failures of CBs due to manufacturing defects, it is required to

introduce a stringent quality checks in the standard manufacturing plans.
Following quality checks are suggested:
 All operating levers to be tested for ultrasonic and radiography.

 PIR contact gap adjustment during assembly was made as 100% CIP.
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 Mechanical endurance test for 10000 operations conducted on 400 kV
CBs.
 Dynamic contact resistance measurement and tan delta measurement
of grading capacitor made as part of routine tests.
 Tensile test on operating levers made as customer inspection point
 Microstructure analysis of operating levers
 HV test on operating rod made as 100% customer inspection point
(CIP)
 Testing SF6 gas foe dew point measurement before supply
 Modification of PIR Pull rod (PTFE) having better tensile strength.
 Improvement in machining of contact surface of pilot valves
 Nitrogen accumulators
 Gaskets: Gaskets can sometime fail to do their job of forming a gas or
liquid seal but care must be exercised against excessive or unevenly
applied greasing of the gasket. Positioning of the gasket is important.
 SF6 gas tightness: The possible origins and causes are various for SF 6
gas leakage, for example:
1. Corrosion near a seal can be avoided by controlling moisture
content in SF6 gas.
2. Damage of a seal
3. Impurity under a seal
4. Porosity of metal component (casting, brazing).
Introduction of state-of-the-art condition monitoring checks during service
Following condition assessment techniques which have been discussed in

detail in the section dealing with the maintenance techniques may be
adopted.
1. Dynamic contact resistance measurement

2. Dew point measurement of SF6 gas.
3. Contact travel measurement
4. Operating timings
5. Tan delta measurement of grading capacitors
6. Trip/close coil currents measurement
7. SF6 gas/hydraulic oil/air leakage monitoring.
4. FAILURES OF INSTRUMENT TRANSFORMERS
4.1 Failure of CTs
Preliminary failure analysis of failed CTs have revealed that most of the CTs
have failed due to pre-mature ageing of primary insulation. Besides, other
probable reasons of failure have been attributed to high system parameters
i.e. voltage and frequency, switching over voltages, lighting over voltages. To
minimize the failure of CTs following tests/checks are suggested for carrying
out at site.
 Measurement of tangent delta and capacitance

 Recovery voltage measurement
 DGA monitoring
 Furan analysis
4.2 Failure of CVTs
Preliminary failure analysis of failed CVTs have revealed that main reasons of
CVT failures are:
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 High value of tan delta
 Secondary voltage abnormal
 High value of capacitance
 Oil leakage
 Humming sound
Besides the above following problems were also observed in one make of CVT:
 Snapping of bellow connection

 Burning of damping resistor
 Burning/failure of lightning arrestor
 Failures of capacitor stacks
 Blackening of insulating oil in EMU tank
The only remedial measures suggested to avoid failures is to do the proper

condition monitoring checks of CVTs at site.
5. FAILURES OF SURGE ARRESTORS
Analysis of failure of surge arrestors have revealed failures mostly due to

premature degradation of ZnO discs. To minimize the failure of surge
arrestors it is suggested that surge arrestors are monitored online for
presence of third harmonic resistive current in the leakage current flowing
through surge arrestors. Leakage current upto 500 micro Amp is generally
considered within acceptable limits.
Testing Sequence for Power Transformers Annexure 1
S.No Test AT While During

Manufactuer’s Commissioning Maintenance
Work
1 Ratio Yes Yes Yes
2 Winding resistance Yes Yes Yes

measurement (at all taps)
3 Insulation resistance and Yes Yes Yes

Polarisation Index
4 Polarity, vector group Yes Yes ---
5 Separate source withstand Yes --- ---

voltage
6 Measurement of No. load Yes Yes ---

losses
7 Load losses and measurement Yes Yes ---

of impedance (at all taps)
8 Temperature rise test Yes Yes ---
14
9 Impulse withstand test Yes --- ---
10 Switching surge withstand Yes --- ---

test
11 Induced voltage withstand Yes --- ---

and partial discharge
measurement
12 Measurement of iron losses Yes Yes ---

(after all type tests)
13 Measurement of insulation Yes Yes Yes

resistance and polarization
index
14 Measurement of capacitance Yes Yes Yes

and tan delta of windings
Annexure 2
Check List for Transformer Assembly
The erection drawings and literature of the transformer is Yes/No

available at site
Checked and found all the component available at site as per Yes/No
drawing (there are no breakages and shortages)
Rinsed all the pipings, radiators, conservator etc. with 60 KV Yes/No

tested oil and blocked with dummy plates
Filtered the oil for 60 KV BD value and recorded in the erection Yes/No
register (with 22.5 mm gap on oil test kit)
Measured the insulation values of the HV, MV condenser type Yes/No

bushing (with a 5 KV megger) found more than 5000 M. ohms
after removing coverings, wrappers etc.
Washed with hot oil (in case of other bushing of plain porcelain Yes/No
type)
Assembled the bushing, after fixing corona shield and Yes/No

removing links and bends in pull through leads, on the turret
at proper incline
Complete assembly of HV, LV T&N bushing done correctly Yes/No
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Completed all piping work consrvator explosion vent, equalisr Yes/No
pipes etc. as per the drawing and filled with oil, Buchholz relay
checked (3º -7º incline)
Filled radiator after washing individually and ensuring removal Yes/No

of blanking plates and free movement of butterfly valves both
top and bottom
Measured IR values with temperature after filling of oil and Yes/No

compared with the test values received from the supplier and
recorded in register
For drying out of transformer Yes/No
a) Applied proper lagging around the transformer. Fire Yes/No

fighting equipments procured and kept at site
b) Filter machine cleaned and filled with the transformer Yes/No

oil
c) Filter connected with outlet into the conservator and Yes/No

inlet from the bottom tank
d) Filter heaters, switched on and the filter temp. Yes/No

maintained less than 60 degree C and filter vacuum
maintained of 755 mm of mercury
e) Dehydration process for 7 days maintained oil Yes/No

temperature 60 degree C in the transformer
(thermometer pockets filled with oil)
Filled the radiators with 60 KV BDV tested oil. Opened the Yes/No
bottom butterfly valves provided between main tank and the
radiators after opening top air release valve to communicate
with main tank
All gases released from different release points in order to Yes/No

ascending heights
HV, LV T Neutral earthing provided Yes/No
Petroleum jelly applied in clamps and connectors in the Yes/No

transformer bushing studs and checked the tightness
Blue slicagel crystals of 2.5 to 4 mm size filled in breather. Yes/No

Breather filled with oil after removing bottom cup, transit
protection cover, cork packing etc.
Removed blanking plates on explosion vent pipe and fixed Yes/No
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diaphram
In case of transformers provided with thermo-syphon filter and Yes/No

air cell (pronol bag) breathing arrangement all precautions
taken as per manufacturer’s recommendations
Section - 3
1.0 INTRODUCTION
1.1 This section briefly describes about the maintenance schedules, which are normally
adopted by the utilities for the various sub-station equipments. The periodicity for the
various tasks to be performed has also been specified. The test results obtained during
the maintenance activity have to be approved by the appropriate authority, which may
vary from utility to utility.
2.0 MAINTENANCE SCHEDULES
2.1 Maintenance schedules as generally adopted by the power utilities for the
various sub-station equipments are given in Annex (1-11).
Annex 1
Preventive Maintenance Schedule for Transformers and Reactors
S. No. Tasks assigned Shut Down (SD) Or Periodicity

Without Shut Down
(WSD)
a. Checking of bushing oil level WSD Monthly
b. Checking of oil level in Conservator WSD Monthly
c. Checking of oil level in OLTC WSD Monthly

Conservator
d. Checking of cooler oil pumps and fans
i) Manual actuation WSD Monthly
ii) Auto Starting SD Yearly
e. Checking of oil leaks WSD Monthly
f. Checking condition of Silicagel in WSD Monthly

breather and regeneration if required
17
g. Measurement of BDV of oil WSD Half Yearly
h. Testing of oil for DGA and other oil WSD Half Yearly
parameters
i. Checking/Topping up of oil level in oil WSD In case of

seal of breather requirement
j. Vibration measurements (for Shunt WSD Half Yearly

Reactors only)
k. Measurement of BDV of OLTC oil SD Yearly
l. Tand measurement for Bushings SD Yearly
m. i) IR! measurement of Windings SD In 3 Years**

(Polarisation Index and DA+ Ratio)
ii) Tand measurement of Windings SD In 3 Years**
iii) Measurement of Windings resistance SD In 3 Years**
iv) Measurement of windings ratio SD In case of

requirement
v) Measurement of short circuit SD In case of

Impedance requirement
n. External cleaning of Radiators SD Yearly
o. Cleaning of all Bushings SD Yearly
p. Frequency Response Analysis SD In case of

requirement
q. Maintenance of OLTC driving SD Yearly

mechanism
r. Checking of all remote indications (STI SD Yearly

and Tap position indicator)
s. Electrical checking / testing of pressure SD Yearly

relief device, Buchholz relay, OLTC
surge Relay and checking/Replacement
of the gaskets of the terminal box
t. Checking/testing of Buchholz relay by SD Yearly

injecting air or nitrogen
18
u. Marshalling boxes of ICT/Reactor of: SD Yearly
i) Cleaning of Marshalling boxes of SD Yearly

ICT/Reactor and OLTC
ii) Tightening of terminations SD Yearly
iii) Checking of contactors, space SD Yearly

heaters, illumination etc.
v. Checking and Cleaning of Diverter SD SOS (50, 000

Contacts Operations)
w. Checking of oil level and calibration of SD Yearly

OTI, WTI
x. Filteration /Replacement of Oil of OLTC SD In case of

requirement
y. Filteration / Degassing of main tank SD In case of

radiator oil requirement
z. Testing of bushing CTs.
i) IR valve SD SOS
*Water content, BDV, SP, Resistance, Tand, IFT. Total Acidity, 2-Furfuraldehyde etc.
**First time after one year from commissioning and then once in every three years.
+Di-electric Absorption Ratio
!To be measured as per the following combinations:
N/E, N/LV and LV/E.
Annex 2
Preventive Maintenance Schedule for Circuit Breakers

Without Shut Down
(WSD)
A. SF6 CIRCUIT BREAKERS
a. Checking of SF6 gas pressures (wherever WSD Monthly

pr. Gauges provided)
19
b. Checking of oil leaks from Grading SD Monthly
Capacitors
c. SF6 gas leakage test SD Yearly
d. Dew Point measurement of SF6 gas SD 2 Yearly@
I. Hyeraulic Operatging Mechanism
a. Checking of oil level and replenishment WSD Monthly

topping up, if necessary
b. Checking of oil pressure WSD Monthly
c. Checking of oil leaks WSD Monthly
d. Checking of oil pressure drop during duty SD Yearly

cycle operation check
e. Checking of auto-starting/stopping of oil SD Yearly

pump
f. N2 Priming Pressure Measurement SD Yearly
II. Pneumatic Operating Mechanism
a. Functional checking of auto-starting of air SD Yearly

compressors and dryers
b. Maintenance of Air Dryer WSD Half Yearly
c. Checking of air pressure drop during duty SD Yearly

cycle operation
B. AIR BLAST CIRCUIT BREAKERS
a. Checking breaker air pressure WSD Monthly
b. Air (Pressure) Leakage check WSD Monthly
c. Dew Point Measurement of operating air WSD Yearly

at the outlet of Air Drier
C. MOCBs
20
a. Checking for oil leakage/oil level WSD Monthly
b. Testing of oil for BDV WSD Yearly
D. BREAKER OPERATION CHECKS
a. CB Operating Timings (Main, PIR, Aux.) SD Yearly*
b. Static Contact Resistance SD 2 Yearly
c. Dynamic Contact resistance (DCRM)** SD 3 Yearly

Contact Travel, Contact Speed, Contact
wipe, Arcing contact length
d. Checking of Pole discrepance relay SD Yearly
e. Functional checks, duty cycle operation SD Yearly

including rapid re-closing (0-0 3s-CO)
f. Checking of all operation lock-outs SD Yearly
g. Checking of all interlocks SD Yearly
h. Checking of pressure settings SD Yearly
i. Cleaning of Breaker Interrupter, Support SD Yearly

insulators, PIRs and Grading Capacitors
E. MEASUREMENT/TESTING
a. Checking of close/trip coil currents SD Yearly
b. Checking of healthiness of Operation SD Yearly

Counter
c. Capacitance and tan measurement of SD 3 Yearly+

grading capacitors
F. CONTROL CABINET
a. Checking of tightness of all cable SD Yearly

terminations in MB
b. Checking of door sealing gasket and WSD Yearly

replacement thereof, if necessary
21
c. Repainting of metallic surfaces (if WSD Yearly
required)
d. Checking of space heater WSD Yearly
@At time of commissioning then after 6 months and one & half years of commissioning
and thereafter once in every two years.
*For All HV/EHV Circuit Breakers only
**For 400 kV BHEL, CGL make CBs only
+First time after one year from commissioning and then once in every three years.
Annex 3
Preventive Maintenance Schedule for Current Transformers

Without Shut Down
(WSD)
A. I R MEASUREMENT
a. I R measurement (Pl. DAR) SD In case of

requirement
b. Measurement of Tan and Capacitance SD 3 Yearly*
c. Measurement of CT Secondary resistance SD In case of

requirement
d. Magnetization Chracteristics SD In case of

requirement
e. CT ratio test SD In case of

requirement
f. DGA and testing of other parameters of oil SD In case of

requirement
g. Thermovision Scanning of CT and Top WSD Yearly

dome
h. Checking of Bellow Expansion WSD Monthly
i. Visual inspection CT for oil leakage and WSD Monthly
22
crack in Insulator etc.
MARSHALLING BOX
a. Checking of oil leakage WSD Monthly
b. Checking of healthiness of gaskets WSD Monthly
c. Checking of space heater & Illumination WSD Yearly
d. Checking the tightness of all connections SD Yearly

including earthing
e. Cleaning of marshalling box and junction SD Yearly

box
B. VISUAL CHECKING OF EARTHING

HF POINT
a. Visual checking of earthing HF point (in SD Yearly

case it is not being used for PLCC)
b. Checking for any breakage or cracks SD Yearly
c. Checking of oil leaks WSD Monthly
d. Cleaning of CVT capacitor stacks and SD Yearly

tightness of terminal connections
e. Capacitance and Tan measurement CVT SD 3 Yearly
f. Measurement of voltage at metering points WSD Monthly

in control Room
g. Testing of EMU tank oil for BDV SD 6 Yearly
h. Thermovision Scanning of Capaacitor WSD Yearly

stacks
MARSHALLING BOX
a. Checking of spacer heater & Illumination WSD Yearly
b. Checking and tightness of all connections SD Yearly

including earth connections
23
c. Clearning of marshalling box and junction SD Yearly
box
d. Checking of healthiness of gaskets SD Yearly
*First time after one year from commissioning and then once in every three years.
Annex 5
Preventive Maintenance Schedule for Isolators and Earth Switches

Without Shut Down
(WSD)
A. Operating Mechanism
Maintenance of
a. Linkages including tramsmission gears SD Yearly
b. Stopper bolts SD Yearly
c. Cleaning of auxilary switch contact & SD Yearly

greasing with silicon grease
d. Lubrication of operating mechanism, SD Yearly

hinges, lock joints on levers, bearings
e. Checking of all mounting bolts for WSD Yearly

tightness
B. MAIN CONTACTS
a. Cleaning and lubrication of main controls SD Yearly
b. Alignment SD Yearly
c. Main contact resistance measurement SD 2 Yearly
d. Tightness of bolds, Nuts and pins etc. SD Yearly
e. Cleaning of support insulators and SD Yearly

checking of insulator cracks, if any
24
C. EARTH SWTICH
a. Checking and Alignment of earthing SD Yearly

blades
b. Cleaning of contacts SD Yearly
c. Contact resistance SD Yearly
d. Operation of earthing switch SD Yearly
e. Checking of aluminium Copper flexible SD Yearly

conductor
f. Checking of earth connections of structure SD Yearly

and MOM box
D. MARSHALLING BOX
a. Visual check of auxiliary contacts SD Yearly
b. Cleaning and terminal tightness in MOM SD Yearly

box
c. Checking of space heaters and illumination WSD Yearly
d. Checking of healthiness of gaskets WSD Yearly
Annex 6
Preventive Maintenance Schedule for Surge Arresters

Without Shut Down
(WSD)
a. Checking of leakage current (Third WSD Yearly

Harmonic Resistive Current)
b. Testing of counters SD Yearly
25
c. Cleaning of LA insulator SD Yearly
d. Measurement of Capacitance and Tan SD In case of

requirement
Annex 7
Preventive Maintenance Schedule for Bus-Bar, Jumpers, Connectors, Clamps,

Switchyard Illumination etc.

Without Shut Down
(WSD)
a. Measurement of station earth resistance WSD Yearly
b. Cleaning of insulators SD Yearly
c. Checking of insulators for cracks SD Yearly
d. Thermovision Scanning of all conductor WSD Yearly

joints. Terminal connectors clamps
e. Removal of hot spots SD Yearly
f. De-weeding of switchyard WSD In case of

requirement
g. Repainting, rust removal of all structures, SD Yearly

equipments etc.
h. Checking of Switchyard lighting WSD In case of

requirement
Annex 8
Preventive Maintenance Schedule for 400 kV Filter Capacitor

Without Shut Down
(WSD)
a. Physical checks, tightness, leakage of oil SD Yearly
26
b. IR Value SD Yearly
c. Leakage current measurement SD Yearly
Annex 9
Preventive Maintenance Schedule for Wave Traps

Without Shut Down
(WSD)
a. Tightness & Cleanliness SD Yearly
b. General inspection / cleaning of tuning SD Yearly

unit
Annex 10
Preventive Maintenance Schedule for Protection Systems

Without Shut Down
(WSD)
a. Testing of DR/EL WSD Monthly
b. Calibration of panel meters (Indicating/Recording WSD Yearly

instruments along with the transducers)
c. Calibration of Non-Tariff Energy meters WSD Yearly
d. Calibration of Tariff Energy Meters
e. Secondary Injection Test of individual protection SD Yearly

schemes
f. Checking of Voltage (in service) for relays WSD Yearly
g. Checking of DC drain of static relays WSD Yearly
h. Checking of DC drain of static relays WSD Yearly
I. LINE PROTECTION
27
A. DISTANCE PROTECTION
MICROMHO
Reach check for all 4 zones* WSD Yearly
Time measurement WSD Yearly
Power swing blocking check WSD Yearly
SOTF WSD Yearly
Level detectors of pps WSD Yearly
Fuse failure check WSD Yearly
Polarization check WSD Yearly
Nps detector check WSD Yearly
YTG
Reach check for all 4 zones** WSD Yearly
Timing check for the same WSD Yearly
PSB check WSD Yearly
DC Supply monitoring WSD Yearly
VT fuse failure check WSD Yearly
RAZFE
LZ 96
28
Opto coupler inputs check
Self diagnostic signals check
SOTF check
THF Reyrolle
SOTF check
B. UNIT PROTECTION
P 40
Starters: NPS – impulse WSD Yearly
Non-impulse WSD Yearly
PPS-impulse WSD Yearly
Phase sequence check WSD Yearly
DC supply check WSD Yearly
Transmitter checks WSD Yearly
Receiver checks WSD Yearly
29
Modulation threshold WSD Yearly
Reflex test WSD Yearly
Comprehensive test WSD Yearly
End to end test WSD Yearly
Trip contacts check SD Yearly
Annunciation check SD Yearly
Check for carrier send SD Yearly
Auxiliary relays healthiness SD Yearly
Over voltage relays SD Yearly
LBB SD Yearly
STUB protection SD Yearly
Fault locater initiation check SD Yearly
DR H initiation check SD Yearly
Auto release check SD Yearly
DC logic SD Yearly
REACTOR PROTECTIONS
Reactor back up impedance SD Yearly
Carrier send for remote trip SD Yearly
Auxiliary relays (Buchholz. PRV. Etc) SD Yearly
Reactor differential protection SD Yearly
REF protection SD Yearly
DC logic SD Yearly
30
AUTO TRANSFORMER PROTECTIONS
Over fluxing relay SD Yearly
Over load SD Yearly
Directional over current SD Yearly
LBB SD Yearly
Auxiliary relays (Buchholz. PRV etc.) SD Yearly
Fuse failure check SD Yearly
Transformer differential protection. SD Yearly
Restricted earth fault SD Yearly
PLCC SYSTEM
Power supply measurements SD Yearly
Transmitter checks SD Yearly
Receiver checks SD Yearly
Checks for Alarms SD Yearly
Reflex test SD Yearly
BUS BAR PROTECTION
Primary injection test SD As per

requirement
Protection stability and sensitivity checks (To be SD As per

done whenever the protection AC circuits are requirement
disturbed like addition of new feeder
*Includes Z1, Z2, Z3 and Z3 (reverse)
**Includes Z1, Z2, Z3 and Z3 (reverse)
Note: The tests listed under (A) and (B) above may be carried out with out a Line SD
ensuring :-- i) Proper isolation of the relay under test
ii) The Other Main Protection of the Line is healthy and is in service
31
.MAINTENANCE TECHNIQUES FOR SWITCHYARD EQUIPMENTS
Section - 4 (CB’s, INSTRUMENT TRANSFORMERS, SURGE ARRESTORS
AND ISOLATORS)
1.0 INTRODUCTION
This section briefly covers the maintenance practices / techniques being adopted by
the power utilities for switch gear equipments installed in EHV/HV stations. However,
in the present scenario competitive market utilities are under tremendous pressure to
bring down the maintenance costs. This has led to the adoption of condition based
monitoring rather than conventional based scheduled maintenance. The frequency of
the condition-based maintenance is fixed based on the type of equipment and its
previous history. Test or measurements are carried to determine the condition of the
equipment. It is general experience of practically all the utilities that most of the
equipment don’t show any abnormality during scheduled maintenance and there is no
guarantee that the equipment shall not fail before the next schedule maintenance.
Thus, the scheduled maintenance efforts are in vain as well as costly in view of shut-
down time and manpower costs. Hence modern condition based techniques are being
adopted which are designed to continuously monitor the function parameters and also
assess the components deterioration before a mal-operation occurs.
2.0 MAINTENANCE TECHNIQUES
The maintenance techniques to be adopted should meet the following criteria:
 Field staff should be able to carry out such tests and interpret the test results
 Testing procedure to be evolved after detailed discussions with the supplier of
the equipment and testing equipment
 Return down procedure to be made available to the operating staff
3.0 GENERAL CHECKS / MAINTENANCE INSPECTION
The equipment should be inspected at the regular interval as per the guidelines given
in Section 3. In addition the manufacturer guidelines should also be followed. The
general checks normally required to be done are:
 General cleaning – cleaning of all insulators of CB/CT/CVT/Isolators for salt/dirt

deposition, if any.
 Dust protection – even though the operating mechanism are made of steel and
surface treated, still some rusting may take place. If any rust stains are
observed the same may be cleaned with emery paper and paint the same
against the rust protection. For protection against rust, grease G or tectyl 506 is
suggested.
 Tightness check – At the time of fuss inspection, all bolted joints on the breaker
and operating mechanism shall be tightened up. All the wiring joints in the
terminal box of the operating mechanism shall be re-tightened at the regular
intervals. Re-tightening has to be repeated only after bigger overhauls. Any SF 6
gas leakage has to be detected with suitable gas leak detector.
 Lubrication – Bearings of the breaker and operation mechanism of isolators and
breaker are to be lubricated with grease G after major overhauls.
 Treatment of gaskets – Any gasket opened once should be replaced by new
one. All sealing surfaces and O-rings shall be sparsely greased of appropriate
type for better sealing against this surface and at the same time providing
protection against rusting/corrosion.
 Treatment of contact surfaces –

32
- Silver contact surfaces if required to be cleaned, the same to be done with
soft cloth and solvent (Trichloroethane). Steel brushing or grinding is not
permitted.
- Copper surfaces should be cleaned and oxide / sulphate free. If required to be

cleaned the same should be done with cloth and solvent (Trichloroethane) or
steel brushing. After steel brushing the surface need to be cleaned for loose
particles and dust with the dry cloth / solvent (Trichloroethane).
- Aluminum contact surfaces should be cleaned with steel brush and emery
cloth. Afterwards, clean it with dry cloth and apply a thin layer of vaseline.
 Moving contact surfaces
- Silvered: Cleaned if necessary, with soft cloth and solvent (tri-chloro ethane).
No steel brushing.

- Non silvered: Cleaned as silvered surfaces, can be steel brushed. After steel
brushing they shall be thoroughly cleaned from loose particles and dust.

- Lubrication: Lubricant - Grease K is applied in a very thin layer on the
surfaces of the male contact and the puffer cylinder. The superfluous grease is
carefully removed.
 Emptying and refilling of SF6 gas – SF6 gas for the circuit breaker is to be
evacuated using the gas treatment equipment. SF 6 gas contained in the
electrical equipments should not be allowed vent into the atmosphere. Before
SF6 gas is removed, the quality of the SF 6 gas has to be checked. The gas after
evacuation has to be stored in a suitable vessel meeting the following criteria
- Material should be such so as to resist the corrosive effects of SF 6

decomposition products.
- Oil free
- Gas tightness of the service device and connecting components
- Gas storage in liquid or gaseous phase
- Suctioning upto 50m Bar
- Transportable and easy to handle
Operational contamination should be absorbed with a suitable filter unit provided in the
gas handling plant. Filter unit should meet the following criteria:
- Dust particles able to be filtered safely
- Molecular sieves / filters remove humidity and SF6 decomposition products
- Desiccative in easily exchangeable cartridges for safe and trouble free disposal
33
- Inputs/outputs should be equipped with self-closing couplings in order to
avoid a saturation of desiccative by ambient air. When SF 6 gas is suctioned from
a gas compartment, the gas is passed automatically through filters which will
dry and purify the gas. Service devices has to be used by the maintenance staff
to fill re-generated SF6 from the storage tanks in SF 6 switch-gear and should
meet the following criteria:
o Oil free
o Easily handling and mobility
o Filling pressure which can be pre-set by pressure reducer. A typical block
diagram of SF6 handling plant is given below:
(Figure 1 )
o Before filling the SF6 gas, the maintenance/over hauled breaker need to
be evacuated by a vacuum pump so that SF 6 gas does not mix with
ambient air and also humidity and dust particles are removed from the
breaker. With the help of vacuum pump a final vacuum should reach
(5m Bar).
4.0 CONDITION BASED MONITORING TECHNIQUES – CIRCUIT

BREAKERS
Following are some of the important condition based maintenance techniques being
adopted for assessing the condition of circuit breaker:
 Operating timings measurement

 Contact resistance measurement
 Contact travel measurement
 Dew point measurement of SF6 gas/air
 Tan delta measurement of grading capacitors
 Vibration measurement
 Operational lock-out checks
 Trip/close coil current measurement
 SF6 gas/hydraulic oil
 Air leakage monitoring
 SF6 gas leakage test
34
Operating timings of Main / PIR contacts
Monitoring of operating timings is basically done with a aim of finding any problem in
operating mechanism, alignment of main/arcing contacts and also discrepancy in
timing between 2 poles and/or between two breaks of the same pole. Closing timing
(maximum 1ms) and trip timing (maximum 25ms) are the most critical to be
monitored very closely. Each type of circuit breaker has different operating timings.
Initial values obtained at the time of commissioning should be taken as the base value.
Any variation / drift in the timings from the guaranteed value/base value may indicate
some type of problem with the operating mechanism or operating levers.
Precautions
 Ensure that SFT/PT is taken

 Ensure that there are no joints in testing cable and the testing leads are not
touching any live point
 Do not connect the test set the energized equipment
 Ground cable must be connected first and removed at last
 Ensure that high voltage plugs are free from moisture during installation
operations
 CB analyzer body should be earthed (if separate earth is provided)
 The testing equipment along with the testing procedure are available at site and
the testing should be done in the presence of testing personal only.
 Clean the surface / terminal where the connection for testing are to be made
 Clean earth point with sand paper / wire brush where earth terminal is to be
provided.
 Ensure that all the pole strips simultaneously through single poles/trip
command.
Testing procedure
A typical arrangement for measurement of operating timings of circuit breaker is given

in Figure 2.
(Figure 2)
 Make connections as per above figure. Ensure that R, Y and B phase marking
cables are connected with proper terminal with the CB (Circuit Breaker)
analyzer and maintained color Coates for all the three poles of CB.
 Connection is to be made for measuring the operating timings of auxiliary
contacts
 AC/DC supply to be extended to CB analyzer
35
 Give closing command to closing coil of CB and note down the PIR and main
contact closing time. Obtain a print from a CB analyzer
 Give tripping command to trip coil 1 of CB and note down the main contact
tripping time.
 Repeat the same for tripping coil 2
 Note the down the timings of various operations of CB viz. CO, OC, OCO by
giving appropriate command.
 In the event of PIR opening time is required the same may be isolated from the
main break and treated as a separate contact using different channel of the
analyzer.
Evolution of test results
The permissible pole discrepancy as per IEC 56 between 2 poles should not be beyond
1/6 of cycle (3.33 ms) and between 2 breaks should not exceed 1/8 th of a cycle (2.5
ms). As per the practice followed by the most power utilities the limit for pole
discrepancy between pole to pole is of the order of 5 ms for breakers under O&M as it
is difficult to make any adjustments at site. If these timings are not within limits it may
lead to over-stressing of one particular interrupting chamber. Switching over voltage
may also be high in case of larger discrepancies in closing timings of the pole because
of presence of trapped charges in the phase of circuit breakers which is going to close
last.
Variation in the operating timing of the order of 3 ms from the base values is generally
considered acceptable. However, if these are not within the limits the same is to be
corrected by:
 Equalising the SF6 pressure in different poles

 Make necessary adjustment plunger of trip of close coil
 Adjustment in operating mechanism
 Changing trip / close coil if required
It is also necessary to measure the timings of auxiliary contacts from the point of view
of variations with respect to main contact. If the difference in timings of the main or
auxiliary contact is maintained within limits this reveals that there is no problem with
the auxiliary contact assembly or with the operating mechanisms or with the operating
levers of the CB.
Contact resistance measurement Purpose of measuring contact resistance

measurement is to assess the condition of the main contacts against erosion or
misalignment of the main contacts. The value of the contact resistance for a new
circuit breaker should be around 50 micro-ohms per break.
Testing procedure
A typical arrangement of measuring the contact resistance is given in Figure 3 below.
Figure 3
36
The ohm meter is employed for measurement of pumping resistance. To measure the
value, connect the leads as per above figure and adjust the varies so that
approximately 100 ampere current flow through the contacts. The value of the contact
resistance is directly displayed on the digital LED display screen. By using the 4
terminal method effects of resistance of test lead is nullified is the input impedance of
the measuring device is very high.
If the value of the contact resistance exceeds the permissible limits given in Section 7.,
this could lead to over heating of contacts. Monitoring contact resistance values is very
good techniques for assessing the condition of main contacts. Resistance values of the
order of the 100-125 micro-ohms per breaker is considered to be alright for the CB in
service.
Dynamic contact resistance measurement
A typical arrangement for measurement of dynamic contact resistance of CB is given in

Figure 4.
(Figure 4 )
This another technique for measuring the contact resistance during dynamic conditions
i.e. during operations (close/trip) of CB. A DC current is injected through the CB and
the current and voltage drop are measured and the resistance is calculated. The
graphs of resistance vs. time data provide useful information on the condition of the
main contact of CB and is considered to be a modern diagnostic tool.
The variation in the measure resistance vs. time will be seen as ‘finger print’ for the
breaker contacts and can be used as reference / base value for comparing future
measurement on the same breaker. If the DCRM values matches with the pre-
commissioning /base value then the arcing contact are considered to be O.K. In case of
wide variation and also there is change in arcing contact insertion time this shows
erosion of arcing contacts. Such as situation may lead of transferring of current from
arcing contacts to main contacts and subsequent commutation failure.
37
Contact Travel Measurement
Transducers and fixtures are attached to operating rod or interrupting chamber for
measuring contact travel. When CB closes contact travel is recorded. Contact bouncing
and any other abnormality is also pointed out by contact travel measurement. If
contact travel is recorded with DCRM the length of the arcing contact shall also be
monitored. It is generally observed that after some time due to erosion of arcing
contact the tip length reduces and such condition may lead of commutation failure.
This may lead to shifting to arc to main contacts and results in faster damage of main
contacts. If contact travel, contact speed and contact restoration signature are
compared with the original signature it shall reveal problems related with the operating
mechanism, operating levers, main / arcing contacts, contact alignments etc.
Dew-point measurement of SF6 gas/air
6.4.3 Dew point is the temperature at which moisture content in SF 6 gas/air starts
condensing. Measurement of dew point of SF 6 gas/air is considered to be a adequate
parameter for monitoring of SF6 gas/air.
Dew-point measurement of SF6 gas in SF6 CB
6.4.4 Measurement of dew point of SF 6 gas in a circuit breaker reveals the change in
the value of dielectric properties of SF6 gas. Dielectric properties of SF6 dew get
changed with time due to mixing of impurities like moisture, decomposition products of
SF6 gas viz. hydroflouride lower valence sulphur fluorides etc. The ingress of moisture
in SF6 gas after filling in CB and during O&M could be due to:
 Exudation of moistures contained during manufacturing from insulation

materials used in circuit breakers.
 Permeation of moisture through sealed sections viz. gaskets ‘O’ rings etc.
 In the event of presence of moisture in SF 6 it gets hydrated to produce highly
reactive H2SO3 and HF (hydrogen fluorides). These chemicals results in
degradation of insulation and corrosion in the interrupting chamber. As such
monitoring of moisture content in SF 6 is considered to be very important.
Chemical reactions taking place during moisture control conditions are given
below:
(a) When moisture density is low
SF4 + H2O ................. SOF2 + 2 HF
SOF2 + H2O ................ SO2 + 2 HF
(b) When Moisture density is high
SF4 + 3H2O ................ H2SO3 + 4 HF
2SF2 + 3H2O ............... H2SO3 + 4 HF
Sulphur oxifulorides, hydrogen fluorides and H 2SO3 formed during these reactions
attack the materials containing silicon-dioxide (SIO 2) viz. glass / porcelain. Primary and
secondary decomposition in the presence of moisture forms corrosive electrolytes
which may cause damage and operation failure.
38
Testing procedure
A typical arrangement for dew point measurement is given below in Figure 5.
(Figure 5)
Make the connection to the kit from circuit breaker ensuring that regulating valve is
fully closed at the time of connection of the dew point kit. Regulate the flow rate of SF 6
(0.2-0.5 L/minute) as per IEC 480, the value of the dew point is observed till it
becomes stable.
Note.: If the regulating valve is provided at the outlet of the dew point kit then dew
point value for rated pressure are to be monitored.
Frequency of Dew Point Measurement
The discharge of moisture from the organic insulating material is faster initially and the
rate of release becomes almost negligible after 4 to 5 year of commissioning, and
thereafter moisture entry in the CB is through permeation. Recommended frequency of
dew point measurement is as given below:
 First time at the time of commissioning

 After six months
 After one year thereafter
 Once in two years
Monitoring of Dew Point Values
Dew point of SF6 gas varies with the pressure due to the fact that saturation vapor
pressure decreases with increase of SF 6 pressure. Dew point of SF 6 at higher pressure
is lower than the dew point at atmospheric pressure. Table given below give the value
of dew point at rated pressure and at atmospheric pressure for various makes of CBs.
Dew point at
Dew point at rated Atmospheric
Sl.No. Make of CB pressure (Min. º Pressure Remarks
C) (limit) (Min º
C)
39
At the time of
-15 - 36
commissioning
1. BHEL
-7 - 29 During O&M
-5 - 27 Critical
At the time of
-- - 39
commissioning
2 M&BG
-- - 32 During O&M
At the time of
- 15 - 35
commissioning
3 CGL
- 10 - 31 During O&M
At the time of
- 15 - 35
commissioning
4 ABB
-5 - 26 During O&M
At the time of
-15 -36
commissioning
5 NGEF
-7 - 29 During O&M
-5 - 27 Critical
Dew Point Measurement of Air in ABCB
The dialectic properties / arc quenching properties of dry air do get change with the
aging of CB and quality of air deterioration if moist air travel to the interrupting
chamber. This will lead to deterioration of internal insulation and resulting in
unsuccessful arc quenching. It is therefore necessary to carryout measurement of dew
point of air in ABCBs. The permissible limits of due point of ABCB is given in Section 7.
Tan Delta and Capacitor Measurement of Grading Capacitor
6.5 The purpose of this measurement is to be detected any incipient weakness in

the HV insulation. The grading capacitor play a vital role when circuit breaker trips TRV
stress conditions and also in open condition of circuit breakers. Electrical and thermal
stresses produced during operation of CB do lead to degradation of paper insulation of
capacitor, capacitor elements and also to the oil in grading capacitors. The value of the
tan delta or loss angle increases with degradation of paper or oil. A typical
arrangement of tan delta measurement is given below in Figure 6.
40
Figure 6
Testing procedure
 Connect LV cable to the middle of the double interrupter

 Connect HV cable to the other end of grading capacitor to be tested
 Ground the opposite end of the grading capacitor using earth switch
 Measurement to be done in UST mode
 Follow the procedure provided by the equipment supplier.
 Measurement to be made at 2 kV first and then at 10 kV.
 Carry out the measurement in the standard mode and also the high quality
mode
Factors affecting test results/measurements
1. Temperature – The dialectic losses of most insulation increases with

temperature. A rising temperature causes a rise in dialectic loss which in turn
causes a further rise in temperature. This is general tendency for capacitance to
increase with the temperature. Deterioration of insulation due to aging causes
exponential rise of tan delta with the increase in temperature and is expressed
as follows:
Tan  T = Tan 
Where T0 = 20° C
T = Temperature of the specimen
Tan  To = Tan T at temp. T
 = Temperature coefficient varies between 0.01 and 0.015° C
(if the  value is between .05 and 0.3 it considered as questionable conditon.
Value of  more than .03 is a sign of alarming condition)
2. Deposit of surface moisture can have significant effect on the surface losses and
consequently on the results. With a view to minimizing the errors the
dissipation measurements may be made when the weather is clear and sunny
and the relative humidity is less than 80%.
3. Surface leakages – Any leakage over the insulation surfaces of the specimen
will get added to the losses in the insulation and make a fake impression about
the condition of specimen. It is recommended that surfaces of insulation should
be cleaned and dry when taking a measurement.
41
4. Electrostatic interference – In the energized switch yard, readings may get
affected by electrostatic interference current resulting from the capacity
coupling between energized line and the bus work to the specimen. To
overcome this all the jumpers connected need to be opened when taking a
measurement. In the modern automatic testing kits the effect of interference
gets nullified due to presence of interference suppression circuits.
Interpretation of test results
A large number of failure of electrical equipment have been reported due to

deteriorated condition of the insulation. The correct interpretation of test results
requires knowledge about the equipment construction and characteristics of particular
type of insulation.
Dissipation factor measurements indicate the following conditions in the insulation of

wide range of electrical equipments:
1. Chemical deterioration due to time and temperature, including certain cases of

acute deterioration caused by localized overheating;
2. Contamination by water, carbon deposits, bad oil, dirt and other chemicals;
3. Severe leakage through cracks and over surfaces;
4. Lonization.
Dialectic strength of insulation decreases with the increase in the moisture content. At
high temperature is pushed out of the paper insulation with oil. As insulation cooled
down water starts migrating from oil into paper. The time for temperature drop may be
faster as compared to water returning to cellulose material. Depending upon the
condition the dissipation factor also changes.
An increase in the value of tan delta indicates the deterioration of cellulose insulation
whereas increase in both tan delta and capacitance reveals entry of moisture in the
insulation.
Ambient temperature
At 20 degree C the value of tan delta should not be more than 0.007. In the present
testing kit available the software is available to give the test results at 20 degree C and
also at rated frequency irrespective of the measurement being made at some other
temperature.
Vibration Measurement
Mechanical vibrations experienced during closing and tripping operations are recorded
with the help of accelerometer and data acquisition system. The same fingerprints are
compared with the reference signature, which have been recorded at the time of pre-
commissioning. Any change in the recorded patterns could be attributed due to any
mechanical malfunctions, excessive contact wear, misalignments of contacts, problems
in damping systems. For a measurement of recording of vibration pattern 2 or 3
accelerometer are installed externally in each phase usually one on arching chamber,
one in operating mechanism and one somewhere in-between.
Other Condition Based Maintenance Techniques
Besides the above mentioned condition based techniques, the other techniques
adopted includes – monitoring of trip / close coil current, coil current measurement,
SF6 gas/air leakage test rate and operating mechanism medium oil/air pressure.
Friction in the plunger movement gap between the plunger and the pin of the coil
assembly are reflected in the recorded current values / wave shapes. Leakage rate of
42
SF6 gas indicates healthiness of the ceiling system, O ring and strength of cementing
joints. SF6 gas leakage upto 1% per annum is considered to be within acceptable
limits.
Operation Lockout Checks for CB Following operation lockout checks are carried
out:
a) SF6 gas pressure lockout:
 Low pressure alarm

 Operation lockout alarm
b) Pneumatic operating system lock-out
 Compressor star / stop switch

 CB auto reclose lock-out switch
 CB closing lockout
 CB operation lockout
 Mechanical closing interlock (applicable for air blasé CBs)
c) Hydraulic operating system lockout
 Pump start/stop
 CB auto re-close lockout
 CB closing lockout
 CB operation lockout
Evaluation of Test Results
a )SF6 gas pressure lockout: All the SF6 gas pressure switches settings should be
checked and corrected with ambient temperature. Settings of SF6 gas pressure
switches should be within + 0.1 bar/Kg/cm2 of the set value (after taking into account
the temperature correction factor).
b) Air pressure lockout: All the air pressure switches settings should be checked and
corrected and should be within + 0.1 bar/Kg/cm2 of the set value.
c) Oil pressure lockout: All the oil pressure switches settings should be checked and
corrected and should be within + 0.1 bar/Kg/cm2 of the set value.
Maintenance Techniques for Instrument Transformer
Instrument transformers are generally the most reliable EHV network equipment.
However, violent failure/blasting due to primary insulation of instrument transformers
may lead to considerable damage to nearby equipments and O&M personals. In order
to avoid violent failures following maintenance techniques have been adopted like
measurement of tan delta and capacitance, insulation measurements, DGA monitoring,
recovery voltage measurement etc.
Tan Delta and Capacitance Measurement (CT/CVT)
1. Testing mode for CTs: CTs provided with test steps have to be tested in UST
mode whereas CT with test step are to be tested in GST mode. Before carrying
out the test it may be ensured that jumpers are disconnected and CT/CVT
porcelene housing / insulators are thoroughly cleaned.
2. Testing mode for CVTs: HF panel and neutral terminal of EMU transformer are
to be disconnected and isolated from ground before carrying out the test. The
testing kit which is similar as used for grading capacitors for CB is to be
43
connected between HV/HF points and measurements are done in UST mode. In
the event of test values deviating from the base values, individual capacitor
stacks are to be tested in UST mode.
Besides the above testing modes the connection to be made as follows:
CTs with test taps
HV terminal of the tan delta kit should be connected to HV (primary) terminal and LV
terminal should be connected to ten delta test tap.
CTs without test taps
HV terminal of the tan delta kit to be connected to the HV (primary) terminal and LV
terminal to be connected to the ground/earth.
Standard procedures as recommended / prescribed by the kit supplier may be

adopted. Measurement may be carried out at 2 kV first and then at 10 kV. Carry out
the measurement in the main and reverse polarity and compute the average value.
Evaluation of test results is just similar to as described for CBs. Major factors affecting
the measurement are also same as applicable to CBs.
Insulation Resistance Measurement (CTs)
Testing procedure: A typical arrangement for IR measurement for CT is given

below:
Figure 7
Connect the megger as shown in the figure. Connect the HV terminal to the primary
terminal of CT by using crocodile clip for firm grip. The measurements may be made as
per the procedure prescribed by the supplier of the kit. A test voltage as specified is
applied as per the above connections and successive readings are taken. Values of IR
should be recorded after 15, 60 and 600 seconds. Ambient temperature and weather
conditions are also to be noted. It is advisable to carry out measurement during sunny
and clear weather.
44
Variation from normal IR value indicate abnormal conditions such as presence of
moisture, dirt, dust, crack in insulation of CT and degradation of insulation.
Analysis of IR values
When a DC voltage is applied to insulation, there will be a flow of conduction current,

dialectic absorption current and charging currents. Dialectic absorption current and
charging currents becomes zero after some times and only conduction current only
flows through the insulation.
Conduction current
The steady straight value of the current after a DC voltage is applied to the capacitor is
known as conduction current. Conduction current is directly affected by temperature,
humidity, contaminants and voltage stress. In a solid insulating material which have
absorbed moisture, there will be a non linear larger increase of conduction current for
increase in the voltage stress.
Test is carried out at 5 kV DC voltage. Any variation with respect to base value indicate
problem in CT insulation.
Polarization index (IR60/IR15) and dialectic absorption ratio (IR 600/IR60) are calculated
and these ratios should be more then 1.5 for good quality insulation. However, exact
values depend on the type of insulation and may vary for different type of equipment.
Secondary Winding Resistance (CTs)
Testing procedure
After ensuring, necessary precautions have been taken, connect leads of O meter
between different terminals of CT secondary course. Select the range of O meter as
per pre-commissioning / factory test results. Following precautions are considered
essential:
1. Test links should be open in the CT MB prior to measurement of secondary

resistance
2. It should be ensured that associated CTs are not in charged condition. For
example main and tie CTs for differential relays should not be in charged
condition.
3. Any earth provided in the secondary circuit of CT should be removed prior to
measurement.
Value of secondary winding resistance should be within the acceptable limits. Extreme
low value of resistance indicates turn-to-turn shorting, whereas, if the value is high it
indicates some loose connection which has to be identified and tightened before
repeating the measurement.
Secondary voltage measurement for CVTs
Failure of capacitor elements in C1 or C2 side results in change in output voltage.

Regular and close monitoring of secondary voltages using 0.2 or 0.5 accuracy class
multimeters, secondary voltage change can be monitored. If voltage of a particular
phase CVT drifts by more than + 1 volts, it requires thorough investigation.
45
DGA monitoring
Due large number of failures of CTs, DGA monitoring has been recently introduced for
checking / assessing the health of insulation of CTs. In this monitoring different
dissolved gases like H2, CH4, C2H6 etc. are tested. DGA results are analysed as per
IEC-60599. It is being proposed to do DGA monitoring on three yearly basis. This shall
require special arrangement for oil sampling as well topping of oil when oil levels falls
down.
N2 pressure monitoring
Some of the CTs are provided with N2 cushion at the top of the CT to avoid ingress of
moist air from atmosphere during normal contraction/expansion of oil due to change in
temperature (due to load or ambient variations). N2 pressure is to be maintained at
about 0.30 to 0.50 bar above atmosphere hence monitoring of the same is very
important. In case of leakage of N2 gas, CT will breathe with atmospheric air moisture
may enter in CT oil/paper insulation. This moisture entry will lead to
abnormal/accelerated ageing of the insulation and may even cause pre-mature
insulation failure.
Magnetic Characteristic of CT Cores
Before carrying out the test following precautions may be taken:
1. Test links should be open in the CT MB prior to measurement of secondary

resistance
2. It should be ensured that associated CTs are not in charged condition. For
example main and tie CTs for differential relays should not be in charged
condition.
3. Any earth provided in the secondary circuit of CT should be removed prior to
measurement.
4. Applied voltage to the CT should not exceed the rated Knee Point Voltage.
Testing procedure
After making proper connections apply voltage is increased from zero to rated Knee
Point Voltage in steps of 25%, 50% 75% and 100%. Measure the current the drawn by
the CT secondary core at respective applied voltage and record the test results as per
the prescribed formats.
The magnetization test is conducted in order to see the condition of turns of CT

secondary. This test shall give indications regarding shorting of turns CT secondary
winding. Magnetisation characteristics also indicate the suitability of CT for keeping it
in service or not.
Knee point voltage is normally defined as the voltage at which 10% increase in the
applied voltage causes 30 to 50% increase in secondary current. The magnetization
current at rated Knee Point Voltage should not be more than the specified/designed
value.
A curve can be drawn between applied voltage and magnetizing current. From the
magnetizing curve it can be implied that up to rated KPV (knee point voltage), the VI
curve should be almost a straight line. However, if this line is not linear, this indicates
that the magnetizing characteristics are not desirable. If the slope of the curve starts
increasing it indicates that magnetizing induction becomes low and total primary
46
current is utilized in exciting the core alone. Consequently, output of CT secondary
disappears.
Maintenance Technique for Surge Arrestors
Presently the monitoring of total leakage current (capacitive and resistive currents) is
being used by many utilities. Leakage current monitors are permanently connected
with the surge arrestors, and in case of high leakage current surge arrestors are
removed from surge arrestors. However, it is felt that this method is not the fool proof
method as the total leakage current, which is purely capacitive, does not give precisely
the health of the surge arrestors. There have been the cases when the surge arrestors
have blasted even though total leakage current value was below the limit prescribed by
the manufacturers. Recently, another monitoring method for monitoring the health of
the surge arrestor have been introduced wherein measurement of resistive current is
done which indicates degradation of ZnO / SiC disc. This method has been prescribed
in IEC 60099 (5). Resistive current is current is 15-30% of total current and since
capacitive and resistive currents are at 90 degree face shift even considerable change
of resistive current results in very small increase in the total current. Hence monitoring
total leakage current may not truly indicate the degradation of ZnO disc. Degradation
of long linear ZnO disc generally leads to harmonics in the leakage current when
system voltage of fundamental frequency is applied. Third harmonic resistive current
measurement is based on filtering of third harmonic component from the total leakage
current. Leakage current of the order of about 500 micro amps is generally considered
to be safe.
Measurement of Resistive Leakage Current or the Power loss
The resistive part of the leakage current or the power loss can be determined by
several methods given below:
Using a voltage signal as reference
The method relies on using a reference signal representing the voltage across the
arrester. The reference signal can be used for direct reading of the resistive component
of the leakage current at the instant when the voltage is at its peak (dU/dt=0). The
voltage and the resistive current level can be read with an oscilloscope or similar
device. This method is commonly used in the laboratory for accurate determination of
the resistive current since the reference signal is easily accessible through a voltage
divider having a sufficiently small phase-shift.
In practice, the accuracy is limited mainly by the phase-shift of the reference signal
and by the deviations in magnitude and phase of the voltage across the non-linear
metal-oxide resistors at the earthed end of the arrester. The presence of harmonics in
the voltage may further reduce the accuracy of the method.
A restriction on the method during measurement in service is the need for a reference
signal. Temporary connection to the secondary side of a potential transformer or to the
capacitive tap of a bushing is necessary and may be complicated to obtain. The
capacitive currents induced in the earth connection of the arrester by adjacent phases
may reduce the accuracy during measurements in service.
Compensating the capacitive component by using a voltage signal
By using a voltage signal to compensate the leakage current for its capacitive
component, the sensitivity in the measurement of the resistive part may be further
increased. The basic principle is a HV bridge where the capacitive-resistive arm is
47
adjusted to balanced the capacitive component of the leakage current so that only the
non-linear resistive part contributes to the output voltage, which can be studies with
the help of an oscilloscope.
The bridge is balanced when the voltage is close to zero and with the capacitive
current being at its peak. Since the differential capacitance of the arrester is voltage
dependent (the capacitance is constant, the remaining current after compensation
comprises not only the resistive component, but also a capacitive part. In this method
also the accuracy may be reduced by phase shifts in voltages and currents due to the
influence of adjacent phases.
Compensating the capacitive component without using a voltage signal
This is a compensation method where the need for a voltage signal is eliminated. The
basic principle is that a reference signal of fundamental frequency is created
synthetically by means of information derived from the leakage current. By proper
adjustment of the amplitude and phase angle, which can be done automatically or
using an oscilloscope, the reference signal can be made to compensate the capacitive
component of the leakage current. The method can be implemented with different
degrees of sophistication.
This method can readily be utilized for measurements in service. A potential problem is
the presence of harmonics in the voltage, which cause harmonic capacitive currents
that may interfere with the resistive component.
Capacitive compensation by combining the leakage current of the three

phases
The method is based on the assumption that the capacitive currents are canceled if the
leakage currents of the arresters in the three phases are summed. The resulting
current is composed of the harmonics of the resistive currents from the three
arresters, since the fundamental components are also canceled as long as they are
equal in magnitude. If there is an increase in the resistive current of any of the
arresters, the capacitive currents remaining constant, the increase will appear in the
summed current. A voltage reference signal is not needed.
For measurements in service, the main disadvantage with the method is that the
capacitive currents of the three phases are not generally equal. Another concern is the
influence of harmonics in the system voltage, which will cause harmonics in the
summed current.
Third order harmonic analysis
The method is based on the fact that harmonics are created in the leakage current by
the non-linear voltage-current characteristic of the arrester. No voltage reference is
needed since it is assumed that all harmonics arise from the non-linear resistive
current. The harmonic content depends on the magnitude of the resistive current and
on the degree of non-linearity of the voltage-current characteristics.
The third harmonic is the largest harmonic component of the resistive current, and it is
the most commonly used for diagnostic measurements. The conversion from harmonic
to resistive current level, if required, relies on information supplied by the arrester
manufacturer or from measurements in the laboratory.
The method can be readily used for measurements in service. The main problem is the
sensitivity to harmonics in the system voltage. The harmonics in the voltage may
48
create capacitive harmonic current that are comparable in size with the harmonic
currents generated by the non-linear resistance of the arrester. As a result, the error in
the measured harmonic current may be considerable. This is shown in Figure -, where
leakage current is given as function of the third harmonic content in the system
voltage. The figure includes the effects of different voltage-current characteristics and
capacitances, as well as the influence of the phase angle of the third harmonic in the
voltage. It is seen that 1% third harmonic in voltage may give + 100% measuring
error in the current.
Figure---------
Third order harmonic analysis with compensation for harmonics in the voltage
The method is based on the same principle as mentioned above, but the sensitivity to
harmonics in the voltage is greatly reduced by the introduction of a compensating
current signal for the capacitive third harmonic current in the arrester. The
compensating current signal is derived from a "field probe"L positioned at the base of
the arrester. After proper scaling, the harmonic current induced in the probe by the
electric field in subtracted from the total harmonic current. The result is the harmonic
current generated by the non-linear resistive current of the arrester. The conversion
from third harmonic to resistive current if wanted requires additional information from
the arrester manufacturer. The method is suitable for measurements in service and is
described in more detail below.
Direct determination of the power losses
The power loss is the integral of the product of the instantaneous values of the voltage
and leakage current divided by time. The power loss may be expressed in terms of the
product of the r.m.s. value of the resistive component of leakage current and the
r.m.s. value of the voltage across the arrester. The influence of the harmonics in the
voltage is greatly reduced by the multiplication and integration procedure. The main
disadvantage is the need for a voltage signal. The accuracy during measurements in
the service may be limited by phase shifts in voltages and currents, caused by the
adjacent phases.
Monitoring System with Compensation of the Third Harmonic Current

Generated by the System Voltage
The use of modern diagnostic techniques means generally increased service reliability
and cost savings for the electric power industry. It is therefore desirable to check the
condition of surge arresters at regular time intervals, by measuring the resistive
component of the continuous leakage current in service without deenergising the
arrester. Reliable measurements are achieved by introduction of a field probe as
illustrated in Figure -, which allows a compensation for the harmonic currents
generated by the harmonics in the voltage.
Experience from measurements on arresters for system voltages from 66 kV to 765 kV

have prevented arrester failures and increased the operation reliability.
The leakage current monitor system is used for gap less metal oxide surge arresters
and is connected to the arrester as illustrated in Figure-. It consists of three main
parts:
49
 A current probe attached to the connector of either a clip-on current
transformer or a toroid-transformer in case of permanent installation.
 A field probe positioned near the base of the arrester to pick up the capacitive
current component, is connected to the current probe via coax cable and an
adaptor. A telescope rod of insulating material is used to locate the field probe
at the correct position
 A leakage current instrument, using harmonic analysis of current and field
probe signals to determination of the resistive component of the leakage
current.
The equipment may be used in three different ways:
 As a portable instrument for checking the conditions of the surge arresters on a

regular basis.
 To Monitor the condition of an arrester during a shorter or longer period of
time, for instance to investigate in more detail the behavior of an arrester that
shows a leakage current higher than expected.
 Permanently installed for continuous registration in substations of big
importance to the operation reliability of the system.
Resistive Leakage Current Measurement for LA
Testing procedure
1. Make the connections as per the diagram given below in Figure-.

2. The kit should be properly earthed as per the recommendations of the kit
suppliers.
3. Clamp On type CT should be placed above the surge monitor to pick up total
leakage current.
4. Carry out the measurement as per standard procedure supplied by the test kit
supplier.
5. Note down the system voltage and ambient temperature along with the test
current value.
6. Avoid measurement during monsoon.
Evaluation of test results
1. ZnO surge arrester continuously conducts a small leakage current Figure-. The
resistive component of this leakage current may increase with time due to
different stresses causing ageing and finally cause arrester failure.
2. The value of third harmonic resistive current shall depend on type and make of
surge arrester. A value of 500 micro-ampere is considered to be safe limit for
third harmonic resistive currents based on technical papers/reports (IEEE etc.).
3. While monitoring third harmonic resistive current, temperature and voltage
correction factors are to be applied because leakage resistive current also
depends on these factors apart from ageing of the arrester discs. These factors
shall be circulated to sites after receipt from suppliers. For the time being as far
as possible, measurements should be carried at temperature from 30 to 30
degree centigrade.
4. Effect of Harmonics in the system voltage: If harmonics are present in the
system voltage, it shall effect the value of the measured third harmonic current
since it shall introduce capacitive third harmonic current in the total current. By
using suitable compensating device, the effect of harmonics in the system
voltage can be nullified.
Battery and Battery Charger
50
Following test may be carried out for determining the health of battery/battery
charger.
a) Battery
 Capacity test/discharge test of battery bank

 Measurement of impendence of battery cell
 Checking of electrolyte level and topping up with DM water
 Checking of emergency DC lighting to control room
 Checking of electrical connection of charger panel for tightens and cleaning
 Checking of electrical connection for battery for tightness
 Checking of tightness of all electrical connection of DC distribution board
b) Battery charger
 Procedures/checks for identifying the probable faults. Following are the

procedures for identifying the probable faults
S.No. Problem Possible cause Remedial measures
1. No DC output - Problem in control - Check the control cards as per details

cards given below
- Transformer supply - Replace if found defective

failure
- Fuse blown - Replace
- Loose connections in - Tight if found loose

transformer and
controller
2. DC voltage not - Rectifier fuse blown Replace blown fuse

building up or
dropped on
load
- Current limit in - Check current limit setting and adjust

operation
- Problem in control - Check the control cards as per details

cards given below
3. Output ripple - Filter fuse blown - Replace blown fuse

high
- One SCR not - Rectify

conducting
- Potentiometer - Adjust the setting with skilled

setting disturbed in hand/carefully or card to be sent to
51
Firing card factory/replace with new card
4. Output voltage - problem in control - Check amplifier card for reference level
shooting high card and comparator output as per description
in auto mode given below.
5. Output voltage - Loose connection - Tighten all connections

low
- Stability Adjust carefylly the stability pot. In

potentiometer amplifier card.
disturbed in amplifier
card
 Test of control cards
1. Power supply card
2. Firing card
3. Amplifier card
4. Current limit indication card
5. Pulse card
6. Over current/over voltage card
E. Power Line Carrier Communication
Various maintenance test required to be carried out are normally done as per suppliers
guidelines. However various equipments required for conducting the test are covered
in Section 8.
F. Protective Relays
A large number of different types of protection schemes / arrangements have been

under use at different sub-station. Their quite diverse due to their being supplied by
different manufacturers having various design philosophy. In order ensure healthiness
and maximum availability of protective relays it is necessary to carryout periodic
testing. Presently, manual as well as microprocessor based automatic testing kits are
available. While the manual kits have been in use by utility engineers in past,
automatic test kits are relatively recent introduction. Apart from automatic testing
capability, these kits are also capable of replaying the fault recordings captured by
disturbance recorders as well as transient simulation done using Electro Magnetic
Transient Programme (EMTP). Also, it is possible to do comprehensive end to end
testing of line protections including protection signaling with use of these automatic
kits in conjunction with time synchronizing equipment. Utilities may decide on
requirement of manual or automatic kits depending on size of their network and
testing practices.
Testing requirements
 Manual test kits

1. Portable cover current relays testing equipment. The input rating shall
be between 200-250 V. 50 Hz., AC supply and the current output range
shall be 0.05-200 amps. With negligible harmonic distortion of less than
1%. A time interval meter shall be fitted to read and display 0-10
seconds with an accuracy of + 10 milliseconds.
52
2. Portable test equipment for testing distance relays comprising supply
unit, control unit and fault impedance unit. Suitable for AC voltage from
380-440 V, three phase, 3 wire system 20 Ampere (short time rated)
with built in safety devices.
 Automatic test kits
1. It shall be suitable to test all types of distance, over current, ground

relays, synchronizing, transformer, reactor and busbar protection relays
of major manufacturers in automatic as well as manual mode.
2. It shall include all the accessories required for making the complete test
set up.
3. It shall have three phase current output range 0-30 amps. (rms) and
three phase voltage range 0-110 voltage (PH-G).
4. It shall work on single phase 240 V, 50 Hz + 10% SUPPLY
5. Shall include necessary software and hardware
i) To accept fault recording available from fault data recorder/numerical relay/EMTP

simulation and relay these on the relay under test.
ii) To draw the relay characteristics
6. The accuracy of relay test kit shall be as follows:
i)1 % for voltage and current output and resolution of time measurement of 1 ms or
better
Details of various testing equipments are covered in Section 8.
ACCEPTABLE / PERMISSIBLE LIMITS FOR MAINTENANCE

Section - 5
TEST RESULTS OF SUB-STATION EQUIPMENTS
INTRODUCTION
53
The acceptable / permissible limits for values obtained during maintenance test results
as discussed in the earlier section in respect of sub-station equipment which are
considered safe is given in Annexure 1, 2, and 3.
Annexure 1
Sl. No. Equipment / test data Permissible limits Reference
1. Transformer/Reactor
(A) Transformer oil
a) BDV
- At the time of first charging 600 kV (Gap – 2.5 mm) – Minimum IS – 1866
- During O&M 50 kV (Gap – 2.5 mm) – Minimum IS – 1866
b) Moisture content
- At the time of first charging 15 PPM (Max.) IS – 1866
- During O&M 25 PPM (Max.) -do-
c) Resistivity at 90 degree C 0.1-1012 Ohm-CM (Min.) -do-
d) Acidity 0.2 mg KOH/gm (Max.)
e) IFT at 27 degree C 0.018 N/M (Min.) IS – 1866
f) Tan delta at 90 degree C 0.20 (Max.) -do-
g) Glash point 126 Deg. C (Min.) -do-
B) Vibration level for reactors 200 Microns (Peak to Peak)
60 Microns (Average)
C) Tan delta for bushing at 20 Deg. 0.007* IEC – 137

C
D) Capacitance for bushing + 5% variation
E) IR value for winding 1000 M-Ohm By 5.0/10.0 kV Megger
F) Tan delta for windings at 20 Deg. 0.007* IEEE/C57.12.90.1980
54
C
G) Contact resistance of bushing 10 M. Ohm / Connector NGC.UK

terminal connectors Recommendations
H) Turret Neutral CT ratio erros + 39 IS – 2705
2. Circuit Breakers
A) Dew point of SF6 gas Dew point values as per Annexure – II
B) Dew point of operating air -45 Deg. C at ATM. Pressure
C) CB Operating timings 400 kV 220 kV
a) Closing time (Max.) 150 MS 200 MS
b) Trip time (Max.) 25 MS 35 MS
c) Close/trip time, Pole

discrepancy
– Phase to Phase (Max.) 3.33 MS 3.33 MS
- Break to break (Max.) of same 2.5 MS 2.5 MS

phase
D) PIR time
BHEL make 12-16 MS Manufacturers

Recommendations
CGL make 8-12 MS
ABB make 8-12 MS -do-
NGEF make 8-12 MS
M&G make 8-12 MS
TELK make 8-12 MS
ABB make (HVDC) 8-12 MS
E) PIR opening time prior to 5 MS (Min.) at rated pressure

opening of main contacts (ABB,
CGL, NGEF make CBs)
55
F) Pir and main contacts overlap 5 MS (Min.) – at rated pressure
time [BHEL, M&G, ABB
(imported) make CBs]
G) Tan delta of grading capacitors 0.007 at 20 Deg. C
H) Capacitance of grading Within + 10% / - 5% of the rated value IEC 358

capacitors
I) Contact resistance of CB 150 M. Ohm
J) Contact resistance of CB 10 M. Ohm per connector NGC, UK

terminal connector recommendations
K) IR value:
1. Phase – earth 1000 M Ohm (Min.) by 5.0 / 10.0 kV

Megger
2. Across open contacts 1000 M Ohm (Min.) by 5.0/10.0 kV Megger
3. Control cables 50 M Ohm (Min.) by 0.5 kV Megger
L) Pressure switch settings
- SF6 gas pressure switches Within + 0.1 Bar of set value
- Operating air pr. Switches Within + 0.1 Bar of set value
- Operating oil pr. Switches Within + 1.0 Bar of set value
M) BDV of oil used for MoCB
- At the time of filling 40 kV at 2.5 mm Gap (Min.) Mfgs.

Recommendation
- During O&M 20 kV at 2.5 mm Gap. (Min.) Mfgs.

Recommendation
3. Current Transformers
A) IR value
1. Primary – earth 1000 M – Ohm (Min.) by 5.0/10.0 kV

Megger
2. Secondary – earth 50 M – Ohm (Min.) by 0.5 kV Megger
56
3. Control cables 50 M-Ohm (Min.) by 0.5 kV Megger
B) Tan delta value 0.007* at 20 Deg. C
C) Terminal Connector 10 M-Ohm per connector NGC, UK

Recommendations
D) CT ratio errors + 3% - Protection cores IS – 2705
+ 1% - Metering cores -do-
Capacitive Voltage Transformers

4.
A) Tan Delta 0.007* at 20 Deg. C
B) Capacitance Within +10%/-5% of the rated value IEC – 358
C Contact resistance of terminal 10 M-Ohm per connector NGC, UK

connector Recommendations
D) IR Value
1. Primary – earth 1000 M – Ohm (Min.) by 5.0/10.0 kV

Megger
2. Secondary – earth 50 M – Ohm (Min.) by 0.5 kV Megger
E) EMU tank oil parameters
a) BDV (Min.) 30 kV (Gap. –2.5 mm) IS – 1866
b) Moisture content (Max.) 35 ppm -do-
c) Resistivity at 90 Deg. C 0.1 – 1012 Ohm. – CM -do-
d) Acidity 0.5 mg kOH /gm (Max.) -do-
e) IFT at 27 Deg. C 0.018 N/M (Min.) -do-
f) Tan delta at 90 Deg. C 1.0 Max. -do-
g) Flash point 125 Deg. C (Min.) -do-
57
F) CVT voltage ratio errors + 5% protection cores IEEE/C93.1.1990
+ 0.5% metering cores IEC 186
Sl. No. Equipment / test data Permissible limits Reference
5. Isolators
A) Contact resistance 300 M-Ohm. (Max.)
B) Contact resistance of terminal 10 M – Ohm per connector NGC, UK

connector Recommendations
C) IR value
1. Phase – earth 1000 M – Ohm (Min.) by 5.0/10.0 kV Megger
2. Across open contacts 1000 M – Ohm (Min.) by 5.0/10.0 kV Megger
6. Surge Arrester
A) Leakage current 500 M-Amp. (Resistive) Hitachi, Japan

Recom.
B) IR value 1000 M-Ohm. (Min.)
7. Miscellaneous
A) Station earth resistance 1.0 Ohm (Max.)
B) Thermovision scanning
Temp. upto 15 Deg. C (above Normal

ambient)
Temp. above 15-50 Deg. C Alert

(above ambient)
Temp. above 50 Deg. C (above To be immediately attended

ambient)
C) Terminal connectors – Contact 10 M- Ohm per connector HGC, UK

resistance Recommendations
58
D) IR values
1. All electrical motors 50 M- Ohm (Min.) by 0.5 kV Megger
2. Control cables 50 M- Ohm (Min) by 0.5 kV Megger
3. Lt. Transformers 100 M.- Ohm (Min.) by Megger
4. Lt. Switchgears 100 M – Ohm (Min.) by 0.5 kV Megger
8. Batteries
A) Terminal connector resistance 10 M – Ohm + 20% ANSI/IEEE – 450

1987
B) Specific gravity 1200 + 5 GM/L at 27 Deg. C
*Temperature correction factor for measured values of Tan Delta to be applied which given
in Annexure&ldots;&ldots;&ldots;&ldots;.
Temperature Correction Factor for Tan Delta Measurement
Sl. No. Oil temperature Deg. C Correction factor (K)
1 10 0.8
2 15 0.9
3 20 1.0
4 25 1.12
5 30 1.25
6 35 1.40
7 40 1.55
8 45 1.75
59
9 50 1.95
10 55 2.18
11 60 2.42
12 65 2.70
13 70 3.00
If Tan Delta of bushing/winding/CVT/CT is measured at oil temperature T Deg. C. Then Tan Delta at 20 Deg.
C shall be as given below:
Tan Delta at 20 Deg. C = Tan Delta at Temp T Deg. C / Factor K.
Annexure 2
Dew Point Limits for SF6 Gas in EHV Circuit Breakers
Sl. No. Make of CB Dew point at rated Corresponding Remarks

Pr. Deg. C dew point at
Atmo. Pr.
At the time of
1. BHEL -15 -36
commissioning
-7 -29 During O&M
-5 -27 Critical
At the time of
2. M&G -- -39
commissioning
-32 During O&M
At the time of
3. CGL -15 -35
commissioning
-10 -31 During O&M
60
At the time of
4. ABB -15 -35
commissioning
-5 -26 During O&M
At the time of
5. NGEF -15 -36
commissioning
-7 -29 During O&M
-5 -27 Critical
Note: Dew point of SF6 gas varies with pressure at which measurement is carried
out. So it is to be ensured that if measurement is done at pressure other than
atmospheric pressure, it needs to be converted to the atmospheric pressure as given
below.
TECHNICAL SPECIFICATIONS FOR TESTING EQUIPMENTS AND

Section -6
MAINTENANCE KIT FOR SUB-STATION
1.0 INTRODUCTION
The testing and maintenance equipment covered in this section are generally meant
for carrying testing and maintenance at site and shall be complete with all material and
accessories. These shall be robust in design, so that they give accurate results even in
adverse site conditions.
All equipments shall be of reputed make, type tested, and shall be subjected to
acceptance and routine test in accordance with the requirements stipulated under the
respective equipment specification.
61
2.0 NEED FOR SELECTION OF TESTING EQUIPMENT
It is generally observed that testing instruments do not work satisfactorily under

induced voltage conditions and test results are not repeatable. Hence, it is necessary
to specify stringent requirements in technical specifications. Some of the problems
faced during the testing hour are described below:
Performance under induced voltage condition
Most of the testing equipment don’t give satisfactory performance under induced
voltage conditions. Tan delta/capacitance measurement and winding resistance
measurement kits etc. very often don’t give stable readings. In case of tan delta
measurement it is very difficult to carry out these measurements specially in GST,
GSTg modes or if capacitance value is low say 100 pF.
Performance of instruments after transportation
It is generally seen that testing equipments, which are required to be transported from
one sub-station to another sub-station, don’t work as desired.
Repeatability of test results
Out put of testing equipments is not consistent and when measurements are repeated,
same test results are not achieved.
After sales-service
Supplier of testing equipment generally have tendency to "Supply and Forget It’ and
don’t provide adequate after sales service. In case of imported kits, Indian agents are
frequently changed and there is always a problem of after sales service.
Performance under adverse ambient conditions
Under very high/low ambient temperatures, high humidity, electronic equipments

generally behave abnormally and it is difficult to carry out measurement under these
conditions.
Lead length
For out-door testing it is generally found that supply lead length is not adequate and it
becomes difficult to carry out measurements.
3.0 TESTING EQUIPMENT REQUIRED FOR SWITCH YARD MAINTENANCE
Some of the main testing equipments required for switchyard maintenance are given
below:
 Tan delta (dissipation factor) and capacitance measuring kit

 CB operation analyzer with DCRM
 Dew point measuring instrument
 Winding resistance meter
 Transformer turns ratio meter
 Contact resistance measuring instrument
 Thermovision camera
 CT primary injection kit
62
 CT secondary injection kit
 Earth tester
 Insulation tester
 LA leakage current analyzer
 Clamp – on meters
 BDV-on meters
 BDV kit for oil
 Other test kits like single/three phase varic etc.
4.0 GUIDELINES FOR FINALISATION OF TECHNICAL SPECIFICATIONS
In order to overcome the problems as discussed above, it is necessary to specify

special requirements in the technical specifications. Moreover, one should be very clear
in mind about the requirements of testing equipments, which has to be procured.
Some of the requirements are discussed below:
Electrostatic interference
The testing equipment should be properly shielded / screened so that performance

under induced voltage conditions is not affected. If the interference is more,
interference suppression unit which nullifies the effect of electrostatic interference is
required to be procured. It is suggested that before procurement, testing instruments
should be successfully field demonstrated so that they work under induced
voltage/interference conditions.
Technical requirements
It is very essential to specify technical requirements, which are actually needed for site
testing. It is generally observed that utilities do not specify such requirements and it
results in procuring instruments which may not be useful at the site. In the technical
specifications we should specify both functional and general requirements. Under
functional requirement we have to specify range, accuracy and resolution and sampling
frequency. For general requirements the following parameters may be specified.
 Ambient and environmental requirements as per IS 9000/9001.

 EMC compatibility
 Lead length
 Repeatability of test results
 Adequate after sales services in India
 Software for evaluation of test results
 Voltage and frequency 220 V ± 15% and 50 V ± 5% respectively. Most of the
instruments are now available with chargeable DC batteries, which may be
opted for field measurements.
 Calibration facility
Some of the essential requirements are described below:
CB operation analyzer
Accuracy and resolution of operating timings and contract travel are to be specified
correctly for achieving this CB analyzer should have a resolution of ± 0.1 ms in respect
of operating timings and a resolution of ± 1mm for contract travel. For both this a
sampling rate of 10 Kz is required.
Dew point measurement for SF6 gas
As per IEC the following are the 2 techniques for measurement of dew point of SF 6 gas.
63
1. Direct method using dry ice and acetonel/methyated sprit: This gives a direct
reading but availability of dry ice at remote site is a problem. Besides,
measurement accuracy varies with the operator as it requires human skill for
correct measurement. Hence, this method is not preferred.
2. Indirect method based on capacitance/impedance measurement: The
principle involved in this method is change in capacitance or impedance of
the sensor changing with moisture content of SF6 gas. Connecting pipe
should be made of PTFE or having stainless steel. Flow rate as per IEC has
to be maintained.
Tan delta can capacitance measurement:
The kit to be procured should be suitable for working under induced voltage conditions.
The kit should be field test before deciding about the procurement. It may be ensured that
HV led is double shielded and LV led single shielded.
3rd harmonic leakage current analyzer for surge arrestors: Two methods available are:
Method 1 - Measurement of fundamental resistive current: This requires inputs

pumps CVT to filter resistive components of total leakage current of surge arrestors,
which is troublesome and not convenient to measure. This method is not being
accepted world-wide.
Method 2 - Measurement of 3rd harmonic component of leakage current: This is

based on measurement of 3rd harmonic component of leakage current which is
mainly resistive. It is generally observed that degradation of ZnO disc of surge
arrestors leads to increase in resistive current mainly fundamental, 3 rd harmonic and
other odd harmonic currents. Rate of rise of 3rd harmonic current is large as
compared to other harmonics and hence this may be used as an indicator of health
of surge arrestors. Clamp on type CT (used for this measurement) if not properly
shielded shall introduce errors in the measured value due to electro-magnetic
interference. Therefore core of CT should be shielded as well as also lead
connecting CT and leakage analyzer.
Thermo vision camera:

The principle of measurement is based on infra red radiation. The minimum object size
needs to be specified which is to be scanned for temperature measurement.
Electro-magnetic compatibility (EMC):

Is the ability of device, equipments or system to function satisfactorily in its electro-
magnetic environment without introducing intolerable electro-magnetic disturbances to any
thing in that environment. Testing equipment should be EMC compatible.
Lead length:
Proper selection of cable, proper size for carrying current and adequate length is very much
essential.
Transportation and environmental hazards:

Testing equipment are to be type tested as per IS: 9000/9001 to meet the following:
a) Ability to operate within specified limits of temperature, pressure, humidity,
64
mechanical stress or other environmental conditions and certain combination of these
conditions and
b) Ability to withstand storage and transport. Some of the requirements are given
below:
Parameter Number
Shock 1000 m/s
Bump 400 m/sec2 for 4 times
Drop and tropple 100 mm fall
Free fall 1000 mm
Vibration 5-95 Hz
c) Other requirements like tests for

repeatability, resolution and accuracy, are
to be witnessed in government labs.
Some of the functional requirement to be specified are:
- Range
- Accuracy
- Resolution / sampling frequency
5.0 Technical specifications:

Based on above, we can specify following parameters for technical specifications
On-line Dissolved Gas Monitoring System
The equipment offered shall be suitable for on line dissolved gas monitoring required
for detection of incipient fault in oil filled electrical equipment i.e. transformers and
rectors. The equipment shall at least respond to dissolved gases such as H2, CO,
C2H2, & C2H4 in transformer oil.
The equipment shall have suitable sensing device to accurately detect and measure the
hydrogen equivalent of H2, CO, C2H2, & C2H4 in oil filled electrical equipment. The
sensor assembly shall be robust in design shall be suitable for operation in tropical site
condition and complete in all respects. The sensor assembly shall be suitable for
connection to any transformer and reactor in service and bidder shall provide
necessary adapter/fittings required for this purpose along with the sensor assembly.
The sensor assembly shall be rated for oil temperature range from 10 Deg. C to 100
Deg. C and give accurate detection of dissolved gases. Supplier shall provide
recommended location of fixing sensor assembly in the transformer and reactor.
The equipment shall be provided with a digital display unit to indicate the dissolved gas
concentration level in ppm. The digital display shall be provided in such a way that it is
suitable for reading from ground in day light and should be used in a dust and weather
65
proof enclosure as per IP55 in accordance with IS: 2147. Connection from sensor unit
shall be provided to display unit by weatherproof-shielded cable. Suitable provision
shall be made at the display unit to give alarm and trip signal at the Owner’s control
panel housed in control room. Any special cables (other than normal shielded PVC
control cable) if required for connection between control panel and display unit shall be
supplied by the supplier. Supplier shall also furnish sufficient literature along with their
recommended gas level for setting of alarm and trip contacts.
The equipment shall also have RS-232 port for down loading data to purchaser’s PC.
The suitable software in Windows environment shall be supplied.
Major Technical Parameter
Application On line continuous monitoring of dissolved

gas in mineral insulating oil.
Detection & measurement H2, CO, C2H2, C2H4 with sensitivity of 100%
of gas of H2.
Range 2000 ppm (V/V)
Accuracy + 10%
Response time 10-15 minutes, (Maximum)
Oil temperature range of 10 Deg. C to 100 Deg. C

sensor
Operating voltage 240 V, 1 ph AC or 220 V DC
Pressure range 0-100 psi
Display LCD/LED digital display atleast 4 1/2 digits
Alarm/Trip circuit Two alarm contacts with dual stage variable

alarm setting provision in increments of 10
ppm (approx)
Mounting threads on probe 1" NPT
The supplier shall also supply a suitable calibration equipment for calibrating the on
line dissolved gas monitoring system.
The equipment offered shall be of reputed make such as Syprotec, Canada (Hydran
20IR), Morgan Schaffeur, mocromonitors or equivalent.
As per ISO – 9001, calibration certificate of each instrument shall be supplied along
with the test kit at the time of supply.
Portable Dissolved Gas Analyser
General
66
The equipment offered shall be suitable for dissolved gas analyzer of a small quantity
of insulating mineral oil of oil filled electrical equipment such as transformers, reactor,
instrument transformers, bushings etc. The equipment shall be robust in design and of
portable type so that the same can be used at site conditions. The equipment shall at
least be able to analyse H 2 and CO in oil. The equipment offered shall consist of oil
sampling device, oil collecting bottles, sensing device, display unit etc. and shall be
complete in all respect to carry out on the spot dissolved gas analysis at site.
The sensing device of the equipment shall be suitable for accurate detection and
measurement of hydrogen equivalent of H2 and CO. The sensor assembly shall be
rated for oil temperature range from 10° C to 50° C and give accurate detection of
dissolved gases.
The display unit shall be of digital type and shall indicate the dissolved gas
concentration level in ppm.
A suitable device such as syringe required for collecting oil from the electrical
equipment and the oil storage bottles (at least 5 No.) shall be made of unbreakable
material. These devices shall be suitable for handling oil in temperature range from
10°C to 100°C.
Major technical parameters
Application Dissolved gas analysis of mineral insulating oil.
Detection and measurement of H2, CO with sensitivity of 100% of H2,

gas
Range 0-2000 ppm (v/v)
Accuracy ± 10%
Repeatability ± 2%
Total analysis time 30 minutes
Oil temperature range of 10° C to 50° C

sensor
Operating voltage As defined in the relevant sections of the

technical specification
Display LCD digital display at least 4 ½ digits.
Calibration equipment The contractor shall also supply a suitable

calibration equipment for calibrating the portable
dissolved gas analyzer.
Make The equipment offered shall be of reputed make,

preferably SYPROTEC Canada (Hydran 103B) or
equivalent.
67
Micro-processor based Gas Chromatograph
General
Key board operated micro-processor based, gas chromatograph with automatic

attenuator, precision, integrator, chart recorder, data station, memory battery, back
up and temperature, flow control and measurement facility for transformer oil gas
analysis.
Power supply
230 V AC, single phase, 50 Hz.
Compatibility
ASTM - D3612 - 77
Mainframe
Complete with injection part, columns, oven, detector gas flow regulation and
measurement system, related electronic and battery back up for a minimum of half an
hour power interruption. Suitable accessories such as sampling syringe, drier, oven
etc. shall be provided.
Columns
The standard system should have 3 columns and appropriate automatic valve
switching to provide rapid determination of the following components:
Main trans tank oil OLTC oil
H2 (Hydrogen) Benzene
O2 (Oxygen) Toluene
N2 (Nitrogen) Tehyl benezene
CH4 (Methane) M + p xylene
CO (Carbon Di Oxide) O xylene
C2H4 (Ethylene) 1,3,5 Tri methyl benzene
C2H6 (Ethane) 1,2,4 Tri methyl benzene
C2H2 (Acetylene) Napthalene
C3H6 (Proplyene)
C3H8 (Propane)
68
Recorders
A suitable chart recorder with full range of 10 mv or less. A maximum full scale
balance time of 2 sec. And minimum chart speed of ½ inch/min. (time programmable).
Detectors
Thermal conductivity detector or equivalent in range sensibility and stability. It should

be sufficiently sensitive to produce a peak height on the recorder chart of at least 20
mm for 1% n-Butane in a o.5 ml sample.
Note: Any other detector suitable for the above application may also be quoted.
Integrator
A suitable integrator to integrate all the component peaks precisely matching the
detectors sensitivity. Display or results shall be directly in ppm on PC screen
compatable H/w with RS – 232 interface shall be provided.
Carrier gas flow system
The instrument shall be equipped with suitable facilities to provide a flow of carrier gas
through columns at a flow that is constant to 1% throughout even during temperature
programming.
Data station and terminal Module
IBM-PC compatible. The data station should have capabilities for:
Data processing of high speed, high resolution chromatograph.
 A chromatograph interface, a CRT and A keyboard

 Double channel data acquisition
 Reduction and plotting
 Real time and post-run graphic display
 Qualitative and quantitative report generation
 Floppy disk storage or equivalent
 Post run data manipulation and reintegration capability
 Hard copy print – outs.
 Cleaning, recalling and reprocessing chromatograph and chromatographic
reports.
Reference standard gas
Reference gas shall be supplied in four standards (in ppm) for calibration as given
below:
CH4 10 50 250 1000
C2H6 10 50 250 1000
C2H4 10 50 250 1000
C2H2 10 50 250 1000
69
H2 50 150 500 2000
CO 25 500 1000 3000
These shall be supplied in pressure cylinders in sufficient quantity for atleast to last 2
years or 1000 samples/instrument. Reference gases for benzene, toluene,
ethybenzene, xylene etc. shall be provided for 3 years or 1000 samples/instrument.
Accessories
Gas extraction apparatus as per IEC 567 ASTM method D2995-71 (ASTM standards,
Vol. 40). Guide for sampling of gases of oil from oil filled electrical equipment and for
the analysis of free and dissolved gases. Any other accessories required for
independent operation of the equipment.
Spares
Spares for at least 3 years of trouble free operation.
Operational manual
6 copies
Service manual
6 copies
Other requirements
 The equipment must be installed commissioned at the site by the supplier/their

authorized agent.
 Supplier must have service contract facility in India.
 Supplier must ensure availability of spares in case of the absolence of the
instrument.
 Supplier should give offer for service contract for 2 years after the expiry of
warranty period. The service contract should include replacement of failed
equipment.
 The equipment offered shall be reputed make, user certificates to be enclosed
with bid for evaluation.
 As per requirement of ISO – 9001, calibration certificates of each instrument
shall be supplied alongwith the test kit at the time of supply.
Transformer Testing Instrument
General
The instruments shall be used for testing of EHV transformers/reactors in the charged
switchyard (upto 400 kV AC and 500 kV DC) and facility to store data ana analyse the
data on PC.
Functional requirements
The kit shall be suitable to measure the following:
 Tan delta/power factor and capacitance of windings and condenser bushings
70
 Excitation current/power
 Insulation resistance
 Winding resistance
 Transformer turns ratio
Range and accuracy
1. Output voltage: Output of the kit shall be from 0 to 17 kV.

2. Tan delta: The kit shall measure Tan delta ranging from 1 x 10-4 to 10 with an
accuracy of ± 1% of the measured value.
3. Capacitance: The kit shall measure capacitance ranging from 1.0 pF to 0.1
Micro Farads with a accuracy of ± 1% of the measured value.
4. Excitation current: The kit shall measure excitation current ranging from 0 to
500 mA with an accuracy of ± 1% of the measured value.
5. Insulation resistance: The kit shall measure insulation resistance ranging from 0
to 1 giga-ohm with a 1, 5, and kV.
6. Winding d.c. resistance: The kit shall measure winding resistance ranging from
0 to 10 ohm with an accuracy of ± 0.5% of the measured value. The source for
winding d.c. reactance shall be atleast of 25 ampere.
7. Transformer turns ratio: The kit shall measure transformer turns ratio ranging
from 1 to 2000 with an accuracy of ± 1% to ± 0.25%.
General requirements
1. The instruments shall contain all standard accessories including testing lead of
20 meters with wuitable clamps/connectors and carrying case.
2. The instrument should have been proved for repeatability of test results in
charged switchyard conditions. Documentary evidence for this should be
furnished along with the bid in the form of certificate.
3. The kit should be capable of operating and storing data at temperature from 0-
50 ° C and humidity 10 to 100%.
4. Functional requirements for parameters as mentioned above, shall be achieved
with the help of one or more instruments. Software suitable for operating on
windows 95 for data storage and comparison of past data for operating on
purchasers PC shall be supplied.
5. Input supply of the kit shall be AC 230 Volts, 50 Hz, variations ± 15% and 5%
in voltage and frequency respectively.
6. The kit shall be compatible for electromagnetic and electrostatic environment
arising out of equipments charged at 400 kV/800 kV.
7. For tan delta, capacitance and winding resistance measurement /turns ratio
readings shall be displayed automatically. It shall use 4 wire method and shall
withstand induction kicks for transformer/reactor windings. Kit shall have
transformer winding/core discharge facility.
8. The testing kit shall be suitable for measuring capacitance and tan delta of bus
and line CVTs, grading capacitors of CBs, CTs, transformer and reactor windings
and bushings successfully in charged upto 420 kV swithyard.
9. As per ISO- 9001 calibration certificate shall be supplied with each instrument
at the time of supply.
100 kV Transformer Oil Breakdown Voltage Test Set
 The equipment offered shall be suitable for determination of electric strength

(breakdown voltage) of insulting oil upto 100 kV to IS:335 when measured in
accordance with IS:6792.
 The test cell shall be as per IS: 6792 suitable for BDV upto 100 kV without
external flashover.
 The unit shall be of composite type having control unit and high voltage
transformer in a common cabinet with necessary partition. HV chamber
interlocking and zero start interlocking shall be provided.
71
 The unit shall have motorized drive to increase voltage linearly as per the rate
specified in IS:6792. Provision should also be available for manual increase of
voltage. The unit shall be complete with test cell, stirrer and "GO" and "NO GO"
gauge for adjusting the gap.
 The equipment shall be suitable for operation at 240 volts 50 Hz. Single-phase
AC supply.
Precision Low Resistance Measuring Kelvin Double Bridge
 The equipment offered shall be suitable for precision measurement of low

resistance such as transformer winding at site conditions. The equipment shall
employ the Kelvin Double Bridge principle for accurate low resistance
measurement. The equipment shall be robust in construction so that it can be
used in tropical site conditions and complete in all respect.
 The equipment shall be fitted with high current DC power supply of at least 10
A to have very small internal drop of DC supply.
 The equipment shall be provided with two terminal rows with two current and
potential terminals each for connecting unknown resistance.
 A reversing switch shall be provided so that measurement can be taken by
changing polarity of test current in order to take into account small errors which
might arise due to thermo-electric meters.
 Measuring Range: 0.1 micro ohm to 100 ohm (with multiple
ranges)
 Accuracy: ± 0.02%
 The equipment shall be housed in a metal case and shall be suitable for
portable use. The equipment shall be complete with null indicator/electronic
galvanometer, ratio resistors, power source, connecting clamps and all other
standard accessories so that the equipment is complete for precision
measurement of low resistance.
 The equipment offered shall be of reputed make preferably Tetlex or equivalent.
Transformer Turn Ratio Tester
Operation voltage 240 Volts 50 Hz; 1- phase AC
Test voltage 240 Volts to H.T. of the transformer under test
Measuring It should measures actual turns ratio of different

principle vector groups in three phase transformers without
conversion
Measuring range 0.18:9999
Accuracy ± 0.1%
Following test will be conducted in addition to all
Acceptance test routine tests as per relevant standards.
 Dielectric test
 I.R. measurement
 Functional test
 Verification of calibration
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Make The equipment offered shall be of reputed make
preferably Tettex (2791) or equivalent
Vibration Meter / Noise Meter
This portable equipment is required for measurement of vibration and noise level of
transformers, reactors and other machinery at shops and sites in line with IEC, ISO or
other international standards. Equipment shall have provision for fixing of vibration
probes for vibration readings and will meet the following requirement.
 Range
- Frequency range 10-100 Hz.
- Noise range 45 dB to 140 dB
- Sensitivity 0.03 Micron
- Amplitude range Peak to peak displacement 0-3000 microns in

suitable overlapping ranges
 Vibration pickup Seismic velocity. Self-generation type. The

Sensitive axis is the longitudinal axis and is
perpendicular to the mounting surface
 Orientation Can be used in any mounting position without

adjustment and correction
 Natural resonant < 20 Hz.

frequency
 Amplitude range 30 g peak acceleration above 70 Hz.

displacement up 70 Hz.
 Amplitude linearity ± 5% from .0025 to 2.54 mm peak to peak

displacement
 Amplitude 0.15 mm/s pk. Velocity
 Sensitivity
- Max. acceleration 2.5 g at 20 Hz. To 30 g above 70 Hz continuous
- Magnetic field sensitivity Equipment shall be suitable for measurement of

vibrations in electro-magnetic field developed
by transformers/reactors
 Battery requirement Equipment shall be battery operated
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 Environmental condition Temperature – 15 ° C to 50 ° C
 Relative humidity Upto 100%
 Mounting Suitable mounting arrangement with

magnets/studs etc.
 Standard accessories
- Vibration pick up 1 No.
- Straight probe 1 No.
- Pick up cable (1.2 m) 1 No.
- Retractable pick up cable (2 m) 1 No.
- Carrying strap 1 No.
- Plug, recorder output 1 No.
- Carrying case 1 No.
 Make The equipment offered shall be of reputed

make
Insulation Resistance Tester (Megger)
The equipment offered shall be used for measurement of insulation resistance of

electrical equipment
 Rated voltage selection 1,2,3,4, and 5 kV (DC Volts)
 Rated resistance (megohms) 0 to 100000 multi-range type. Resistance range for

each rated voltage shall be indicated in the offer.
 Type Portable, compact and direct reading type of multi-

voltage with multi-rated resistance ranges. The
tester shall be suitable for hand operation as well as
operation by a continuously rated motor with AC
mains supply of 230 V, single phase, 50 Hz.
 Ambient temperature 0 to 50 ° C
 Infinity adjustment There should be provision
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 Leather carrying case The instrument shall be supplied with 2 meter long
mains lead and leather carrying case.
 Standards The tester shall generally comply with the

requirements of IS:2992-1987 and IS:11994-1986
 Preferable make The equipment offered shall be of reputed make

preferably Evershed make or equivalent.
Test requirement
Type of test certificate for all ten tests as per C1.11.1 of IS:2992
All routine tests as per c1.11.3 of IS:2992 shall be conducted. –
Circuit Breaker Operation Analyser
General
This instrument shall be used for testing of EHV circuit breakers (up to 800 kV) in the
charged switchyard (800 kV AC and 520 kV DC). Data shall be stored and analysed on
PC with software to be supplied by the manufactuer/supplier.
The kit shall be suitable to measure the following:
1. The CB contact movement during opening, closing, auto-reclosing and make

break operation. Contact speed at various stages of operation, travel of
contacts, contact wipe, main and auxiliary contacts (wet and dry), opening
time, closing time and make break time, closing resister pre-insertion time etc.
2. Dynamic contact resistance measurement of arcing and main contact with
minimum 100 am d.c. current while closing / opening of CB. The kit shall have
facility to co-relate dynamic contact resistance with contact travel.
3. Contact resistance of main contacts in closed position.
4. Closing resistance value.
5. Trip/closing coil currents.
6. Minimum number of channels: Digital channels – 24
7. Analog channels – 6.
Range and accuracy
1. Main contacts timings: the kit shall measure operating timings of CBs from 0 to
1500 msec in multiple ranges with an accuracy of ± 1 msec, resolution of ± 1
msec and minimum sampling rate at 10 KHz.
2. Contact travel: The kit shall record the contact travel from 0 to 500 mm with an
accuracy of ± 0.1 mm.
3. Contact speed: The kit shall record the contact speed ranging from 0 to 10
m/sec with an accuracy of ± 1%.
4. Dynamic contact resistance: The kit shall record dynamic contact resistance of
main/arcing contacts ranging from 0 to 2000 micro-ohm with an accuracy of ±
2% of the measured value.
5. Static contact resistance: The kit shall be used to measure contact resistance of
main contacts ranging from 0 to 1000 micro-ohm with an accuracy of ± 1%.
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6. Trip/closing coil currents: The kit shall be able to record trip/close coil currents
ranging from 0 to 25 amp with an accuracy of 2%.
1. The instruments shall contain all standard accessories including testing lead of
20 meters with suitable clamps/connectors and carrying case.
2. The instrument should have been proven for repeatability of test results in
furnished along with the bid.
3. The kit should be capable of operating and storing data at temperature from 10
° C to 50 ° C and humidity 10 to 99%.
4. The notebook PC Pentium 166 MHz – or above with Windows – 95 software
(latest version), 16 MB RAM, 2 GB hard disc storage, 1.44 MB floppy drive, CD
ROM drive, inkjet printer, FAX/Modem shall be supplied along with test kit. The
software supplied along with the kit should have facility to display and generate
reports in graphical and numerical formats and compare results obtained at
different times.
5. The kit should have facility to get hard copy through plain paper printer by
directly connecting printer to Test Kit.
6. Travel adapter and transducers along with the various clamps to suit all
400/220/132 kV CB models/types available in (BHEL, M&G, CGL, NGEF, HBB,
ABB, COGLEX make) shall be supplied with each test kit.
7. The functional requirements as mentioned above can either be achieved with
one or more kits. In case of more than one kit, facility shall be there to co-
relate various parameters. Necessary interface cards shall be supplied along
with the kit.
8. Input supply of the kit shall be AC 230 Volts, 50 Hz, variations ± 15% and 5%
in voltage and frequency.
9. The kit shall be compatible for EMI/EMC environment.
Digital Micro-ohm meter
General
The equipment should be microprocessor based for measuring the resistance of circuit
breaker and bus-bar joints. The system should incorporate built-in software to carry
out different tests and store the results. There should be provision for connecting a PC
to the equipment so that test results could be analyzed further. The design of the
equipment should enable quick demagnetization of CT after testing breaker. An AC
output should be available in this regard.
The system should meet the following minimum specifications:
Test current output 0-600 A (Full-wave rectified)
No load voltage 9 V DC
Output voltage across output Terminal at 5 V DC

600 A
Max. load time at 600 A (Single test) 15 S
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Measurement range 0-200 micro ohm.
Resolution 1 micro ohm.
Accuracy ± 1% + 1 digit of displayed value
Operating temperature 0 to 50 ° C.
Power supply 230 V 50 Hz ± 10%
Display Results are to be displayed on LCD display.

It should also indicate whether the current is
above or below a pre-selected value.
Information about current generation or
memory location should also be available.
Protection via miniature circuit breaker, thermal fuse should be available. Manufacturer
should supply a robust transport case and operational manual along with the
equipment.
Dew Point Meter
 The meter shall be capable of measuring the dew point of SF 6 gas of the circuit
breaker, nitrogen gas, air etc. in transformer tank. It may be a moisture
measuring device to know the dew point temperature of SF 6 gas, Nitrogen gas,
air, etc. It should be portable and adequately protected for out door use. The
meter shall be provided with dew point hygrometer with digital/analog
indication unit to display the dew point temperature, corresponding to pressure
at which the dew point is being measured.
 The calibration and measurement of the instrument must be simple, direct
without the use of any other material/chemical like dryice/acetone etc. it should
be battery operated with rechargeable batteries.
 It shall have suitable couplings/valves and suitable length of connecting tube to

connect with the SF6 gas sampling point of the breakers, transformer and
reactor tank. The range of measurement shall be from 5 to 60 ° C. Equipment
offered shall be of reputed make. Requirements of dew point measurement of
gas should conform to IEC 480 in regard to accuracy of dew point and
connecting pipes etc.
 As per ISO – 9001, calibration certificate of each instrument shall be supplied

along with the test kit at the time of supply.
SF6 Gas Leak Detector
 The SF6 gas leak detector shall meet the following requirements.
 The detector shall be free from induced voltage effects.
 The sensing probe shall be such that it can reach all the points on the breaker
where leakage is to be sensed.
SF6 Gas Filtering and Evacuating Equipment (Portable)
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 The capacity of this plant shall be such that it shall not take appreciable time for
filling or evacuating the breaker. The required vacuum for complete evacuation
shall be attained with the help of this plant
SF6 Gas Filtering, drying, storage and recycling plant
 This shall include all the necessary devices for measurement of purity, moisture
content, decomposition products etc., of SF6 gas. Mixing with air/oil/moisture
during the above process should be proved to be Nil during testing. The storage
capacity of the reservoir should be sufficient for storing complete SF6 gas for at
least one 420 kV vircuit breaker (3 poles) or 105 kg whichever is higher.
 The plant shall be complete with accessories and fittings so that SF6 gas from
the breaker can be directly filled in the plant storage reservoir.
 In case purging of the equipment before filling with SF6 gas is desirable, then
the required equipment for dry gases etc. shall be furnished as a part of the
plant.
 For heavy items within the plant lifting hooks shall be provided for lifting and
moving with the overhead cranes.
- The SF6 gas handling plants shall comply to following requirements
a) the plant shall be complete with all the necessary pipes, couplings, flexible tubes
and valves for coupling to the equipment for the filling or evacuating SF6 gas to be
used with all necessary instructions for storage and handling of the plant.
b) The design and construction of the plant, valves, coupling, connections shall be such
that leakage of SF6 gas shall be minimum. Similarly valves, couplings and pipe work
shall be so arranged that accidental loss of gas to the atmosphere shall be minimum.
c) Facilities shall be provided to reduce SF6 gas pressure within the circuit breaker to a
value not less than 8 millibars.
LA Leakage Current Analyser
General
The analyzer shall measure total leakage current, capacitive current, resistive current
and third harmonic resistive current components of leakage current of surge arrester
(upto 800 kV AC).
Kit shall be suitable to measure the following
1. Total leakage current

2. Capacitive component of total leakage current
3. Resistive component of total leakage current
4. Third harmonic resistive current
5. Range and accuracy:
Total leakage current 0 to 5 mA
Accuracy ± 1% of measured
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value
Third harmonic resistive current:
Range 0 to 1 mA
Accuracy ± 1% of measured
value
1. All accessories including probe, transducers etc. to be supplied alongwith the

analyzer
2. Analyzer should be suitable to measure and analyse leakage current of surge
arrestor upto 800 kV AC in charged condition without removing surge monitor
and earth connection.
3. Analyser should be able to operate from 15 ° C to 50 ° C ambient temperature
and relative humidity from 10 to 100%
4. Analyser shall be battery operated (Nickel – Cadmium cell rechargeable
batteries). Battery charger should be suitable for 230 V, AC 50 Hz variations ±
15% and ± 5% in voltage and frequency respectively.
5. Facility to give printout of leakage current wave shall be there in it
6. The kit shall be able to operate satisfactorily in electromagnetic and
electrostatic environment arising out of equipment being charged at 400 kV /
800 kV.
7. The analyzer should have been proven for repeatability of test results in
furnished.
8. As per requirement of ISO – 9001 calibration certificates of each instrument
shall be supplied along with the test kit at the time of supply.
Ultrasonic Fault Detector
1. The equipment should be light weight (Not exceeding 1.5 kg), portable and
suitable for predictive maintenance of power transformers.
2. It should detect partial discharge, corona, and other ultrasonic activities
happening inside the equipment. The equipment should be able to detect
transformer defects viz. loose parts, defective tap changers, restricted /
turbulent flow in oil cooling pumps and thus provide a predictive maintenance
schedule to periodically inspect transformers to prevent failures and maintain
safe operating conditions.
3. Frequency range: The equipment should band pass the following frequencies:
(100 Hz to 11KHz, 3 KHz to 11 KHz and 20 KHz to 250 KHz).
4. The equipment should incorporate a piezoelectric sensor to detect defects by
making a contact with the transformer shell. The instrument must also comprise
of a highly sensitive air probe for detection of corona discharge with centre
frequency 40 KHz ± 10%.
5. The instrument should be supplied with a noise attenuating head set (with
volume control) to hear the ultrasonic noise. It should have noise reduction
rating of 24 db or better. Supplier should also supply a cordless headset
operable on rechargeable NiCd battery.
6. The equipment should be battery operated (lead acid battery). A single battery
should ensure at least 08 (eight) hours of operation. Indication of battery status
should be available.
79
7. Display: Ultrasonic activities in selected frequency range should be displayed
digitally (LED display with 0 1999 counts).
8. All necessary leads, cables etc. required for measurement are to be supplied
with the instrument. Operating and instruction manual and carrying case are to
be supplied.
Thermovision Camera
General
The instrument shall be thermal imaging system based on principle of infra-red

radiation detection to identify hot spots and loose connections in substations and
transmission lines up to 800 kV AC and 500 kV DC. The instrument shall be battery
operated.
The thermovision camera shall have the facility to measure the following
temperatures:
1. Absolute value of hot spot temperature

2. Colour thermal image of focused object
3. Isotherm temperature
4. Dual spot delta temperatures
5. Measured temperatures shall be corrected for effects of solar emittance,
atmospheric temperature.
Range and accuracy
1. Temperature measurement: The camera shall be able to measure the hot spot
temperatures ranging from 0 to 500 Deg. C with accuracy of + 1 Deg. C. Focal
range shall be from 0.4m to infinity.
 The instrument shall be handy, light weight so that operator can easily scan the
switchyard equipment for hot spots.
 The instrument shall have storage capacity up to 200 thermal images.
 The instrument should have been proven for repeatability of test results in
charged switchyard conditions.
 The kit should be capable of operating and storing data at temperature from –
10 Deg. C to 50 Deg. C and humidity of 10 to 90%.
 The notebook PC of Pentium 166 MHz – or above with Windows – 95 software
ROM drive, inkjet printer shall be supplied along with the test kit. The software
supplied along with the kit should have facility to display and generate reports
in Graphical and Numerical formats and compare results obtained at different
times.
 The kit shall be compatible for EMI/EMC environment
 The hot spot focusing shall be motorized.
 The accessories shall also include FOV wide angle lens of 32 Deg. Or better, 8
Deg. GOV telephoto lens for detailed scanning.
 Battery and Battery charger: a) Battery shall be re-chargeable Ni-cd battery, b)
Battery charger should be suitable for 230 V AC, 50 Hz, variations + 15% and
+ 5% in voltage and frequency.
 Infrared detectors shall use micro coolers and scanning techniques shall be
based on focal plane array.
80
 Software for retrieval of data to maintain database and preparation of reports
shall be supplied along with the kit.
 Instrument shall be capable of measuring hot temperature from 1m to 1000
meter distance.
 Video recording for thermal image with a facility to replay through display unit
shall be provided.
Relay Testing Equipment
General
In order to ensure healthiness and maximum availability of protective relays it is

necessary to carry out periodic testing. Presently, manual as well as microprocessor
based automatic testing kits are available. While the manual kits have been used in the
past, automatic test kits are relatively recent introduction. Apart from automatic
testing capability, these kits are also capable of replaying the fault recording captured
by disturbance recorders as well as transient simulation done using Electro Magnetic
Transient Programme (EMTP). Also, it is possible to do comprehensive end to end
testing of line protections including protection signaling with use of these automatic
kits in conjunction with Time synchronizing equipment. Utilities may decide on
requirement of manual or automatic kits depending on size of their network and
testing practices.
Technical specifications
Manual test kits
1. Portable over current relays testing equipment. The input rating shall be
between 200-250 V. 50 Hz, AC supply and the current output range shall be
0.05-200 amps. With negligible harmonic distortion of less than 1%. A time
interval meter shall be fitted to read and display 0-10 seconds with an accuracy
of ± 10 miliseconds.
2. Portable test equipment for testing distance relays comprising supply unit,
control unit and fault impedance unit. Suitable for AC voltage from 380-440 V,
three phase, 3 wire system 20 Ampere (short time rated) with built in safety
devices.
Automatic test kits
It shall be suitable to test all thypes of distance, overcurrent ground relays,

synchronizing, transformer, reactor and busbar protection relays of major
manufacturers in automatic as well as manual mode. It shall include all the accessories
required for making the complete test set up. It shall have three phase current output
range 0-30 amps. (rms) and three phase voltage range 0-110 V (PH-G). It shall work
on single phase 240 V, 50 Hz ± 10% supply. It shall include necessary softwares and
hardware – i) To accept fault recording available from fault data recorder/numerical
relay/EMTP simulation and relay these on the relay under test, and ii) draw the relay
characteristics.
Primary Current Injection Sets
The equipment offered shall be trolley mounted and shall consist of double wound
transformer having primary rated for 230 V and four secondary windings each rated for
750 A, 5 V. By connecting secondary windings in series, parallel and in series parallel –
the following ranges shall be obtainable
1. All the secondaries in series – 20 V, 750 A

2. Secondaries in series and in parallel – 10V, 1500A
81
3. All the secondaries in Parallel – 5V, 3000A
All the secondary windings shall be brought out which shall be selectable by means of
links for the above arrangement. Oil cooled type continuous rated Auto Transformer for
obtaining stepless variation on output shall be provided.
Ratings
Input 230 V, single phase, AC, 50 Hz.

0-20 V, 750 A
Output
0-10V, 1500 A
0-5 V, 3000 A
Duty cycle Continuous
Capacity 15 kVA
Accuracy ± 1%
Unit shall be supplied with first filling of oil plus 10% extra oil and output connecting
cable suitable for 3000 Amps and of 20 mtr. Length. The cable should have two cores
and should have two cores and should be provided with suitable clamps at both the
end of the cable for testing of any outdoor EHV equipment.
The unit will comprise of:
 AC input terminal
 AC input fuses
 Pilot lamp to indicate main ON
 Single phase dimerstat continuously variable voltage transformer
 Single phase, double would loading transformer with graded secondary
 Multi ratio current transformer (750/1500/3000/5A) for measuring current
output
 144x144 mm square type moving iron ammeter of 0.5 amps range.
 3 Pin plug socket with on/off switch to provide 230 V to external timer etc.
The set should have operating instructions printed on the set for convenience of
operator. As per ISO-9001, calibration certificate of each instrument shall be supplied
along with the test kit at the time of supply.
Single Phase Relay Testing Kit (Secondary Injection Kit)
 The equipment offered shall be compact, enclosed in a single carrying case and
suitable for routine testing and timing of protective relays and equipment
including directional relays, differential relays, automatic-reclosing devices etc.
The testing kit shall measure and display voltage, current, impedance, power,
power factor, phase angle and time via an easy to read liquid crystal display.
The equipment should be supplied with an additional current source for testing
of differential relays.
82
 The unit shall be operatable both with a P.C. (as RS 232 interface should be
available) and without a P.C. Any software if required for data transfer to a PC
should also be supplied.
 A hold function shall be provided which will allow voltage and current readings
to be taken for duration of half a cycle or less. The timer start-stop input shall
respond to change of voltage or contact opening and closing.
 Indication shall be provided to show status of timer start – stop inputs and
normally open (N.O.) and normally closed (N.C.) contacts. The testing kit must
incorporate a provision for continues phase shifting and fine adjustment of
voltage and current.
 The equipment shall be complete with memory storage for a minimum of ten
test results and instrument settings.
 The offered kit must meet the following minimum specifications:
0-10 A, 90 V (no – load voltage)

AC output
0-40 A, 25 V (no-load voltage)
0-100 A, 10 V (no – load

voltage)
0-250 V AC
AD/DC output
0-300 V DC
Separate AC voltage output 0-120 V AC
DC Auxiliary output 220 V DC

Range: 0.0 – 999.9 S
Timer
Accuracy: 1mS
Ammeter (0-250) (Internal)
Range (0-6A) External
Voltmeter Range (0-600) V
Max. number of reclosings 49
Max. testing time 9999 S
Weight Not exceedings 20 kg in

complete operational mode.
Relay Testing Kit

General
83
The instrument shall be suitable for testing all types of three phase relays (both static
and electromagnetic type). Shall be portable and handy for each transportation to be
carried by one Person. It should be able to test all protection relays based on
impedance, voltage, current, frequency, harmonics, synchronization. The equipment
must be capable of efficiently testing all types of electronic and electro-mechanical
relays with a high degree of accuracy. The testing systdem shall be able to simulate all
the waveforms and transients as recorded on the disturbance recorder. The system
should be operable manually, semi-automatic and automatic and should meet the
following specifications:
The testing system must generate at least four independent voltages and three
independent currents with the facility to control their amplitudes and phase angles
independently. The kit should have df/dt facility (i.e. frequency variation with respect
to time).
Voltage and current outputs
 Four phase voltage output: (0-150) V

 Three phase current output: (0-15) A. There should be provision for increasing
three phase current upto 30A using external current amplifier.
 Three phase output powr for voltage should be 80 VA or better
 Three phase output power for current should be 70 VA or better
Power supply requirements
Nominal input voltage 220 V ± 10% V AC, single

phase
Frequency 50 Hz ± 5%
Power consumption 600 VA (Max.)
Timer section
There should be at least 10 inputs (binary) in 2 groups of 5 independent contacts each

with voltage more than 220 V DC and AC. The two groups should be galvanically
separated.
Measuring time 0-1 hr.
Resolution 1 ms
To ensure extra protection of relay, the relay testing kit must incorporate auxiliary DC
voltage with range (25 V l- 210 V) and output power minimum 70 W.
Phase angle range 0-360º
Phase resolution 0.1"
Phase accuracy 0.1"
84
Generator frequency range
Continuous signals DC – 2000 Hz
Transient signals DC – 3000 Hz
Frequency accuracy ± 1 ppm
Frequency resolution 1 MHz
Weight of the instrument should not be more than 25. the relay testing kit offered mus
be computer compatible. It should be capable of being operated with a computer and
also without a computer. A knob on the front panel of the equipment should be
provided for the manual operation for variation of all parameters. An on-board digital
display should also be provided on the system for visual display of parameters. (This is
essential for use of system without laptop). A laptop computer pre-loaded with the
easy to use relay testing software should be provided for fully automatic operation of
the relay testing set.
Software
The software should be easy to use without the requirement of extensive computer
literacy and should be possible to use in manual, semi-automatic and fully automatic
mode. It should be possible to automatically create the IEC and IEEE standard waves
and/or creates other characteristics using the standard circular lens and linear
elements. The software should also contain an automatic test plan editor to create
automatic test plans for new/unknown relays easily and without programming
knowledge. The kit should have the capability to accept transient fault data recorded
by disturbance recorder from 3.5" floppy and relay these on the relay under test. It
should be able to perform both static and dynamic testing such as fault and prefault
generation, simultaneous ramping of quantities and editing waveforms etc. The kit
offered must have provision for generating COMTRADE and EMTP files (EMTP PC
programmes also) as well as editing the wave forms.
Calibration
Apart from self-calibration (software), the system should also be provided with an
independent calibration box as an independent external means of verifying the
relevant parameters. It should be possible to calibrate the calibration box and
therefore the kit to relevant International traceable standards.
Analog inputs
The kit shall also have anlog inputs for measurement of AC/DC current and voltages
(both low and high) as per the following specifications.
DC Current measuring inputs (Low)
Measuring range ± 20mA
85
Accuracy 0.03%
DC voltage measuring input (Low)
Measuring range ± 10V
Accuracy 0.03%
AC/DC current measuring input (High)
Measuring range ± 10A DC, 10A AC RMS
Accuracy DC < 0.1%, AC < 0.03%
AC/DC voltage measuring input (High)
Measuring range ± 220 V DC, 150 V AC RMS
Accuracy DC < 0.05%, AC <0.2%
The equipment should be designed to operate under the adverse conditions of external
influence like electrostatic discharge, magnetic field, electromagnetic field induction, RF
Interference, input waveform distortion and harmonics, input voltage and frequency
variation.
Phase Shifting Kit
The phase shifting kit should be ideal for testing relays in situations where current,
voltage and phase angle must be varied independently. It should perform satisfactorily
in high voltage environments and should conform to relevant IEC/VDE standards. The
instrument must incorporate in-built over current and over-voltage protection and
should meet the following minimum specifications but not limited to:
Input voltage Single phase (230 V, 50 Hz) ±

10%
Output voltage At least (0-100) V, Variable

(Manually)
Phase angle
Range 0-360º, Variable (Manually)
86
Accuracy ±1º or better
Resolution 0.1º or better
With provision of displaying the phase angle in digital manner in the equipment.
Weight the instrument should be light weight (not exceeding 20

Kgs.) and portable enough for ease of use in field
conditions.
Party should supply a sturdy and shock-proof transport case so that the equipment
could be properly housed in to avoid any damage when used at site. Operating and
instruction manual is also to be supplied along with the equipment. Party must have
supplied atleast one number of similar equipment to any power utility.
DC Earth Fault Locator with Digital Display
The equipment should be able to precisely detect any earth fault occurring in DC
systems (24 V upto 360 V) to ensure operational safety and availability of electrical
systems. It should ensure fast location of the insulation fault and no disconnection of
the electrical system should be required so that insulation fault could be located during
operation of the system itself.
Maximum test current: 25mA and 10mA selectable in two ranges
The equipment should comprise of a test device and an evaluator unit. A clamp – on
probe is to be supplied for embracing the conductors under test. The evaluator unit
should be immediately ready for operation without any need for balancing. The
equipment should be light weight, portable and rechargeable battery operated. Party
should supply one battery charger along with the equipment.
Display: There should be provision for a liquid crystal display to indicate test currents
of respective conductors. Indication of battery status should be available on the LC
display. It should also indicate whether the connection to the clamp on probe is
interrupted. All necessary cables, leads required for measurement are to be supplied
with the equipment. Party should also supply operating and instruction manual.
Selective Level Meter (SLM)
200 Hz to 620 kHz (Balanced)

Frequency
50 Hz to 620 kHz (unbalanced)
It should include impedance & return loss measuring attachment compatible with level
generator
Input impedances 75,125,150,600 ohm
87
With balanced input –60 to +20 db/dbm
Sensitively in steps of 10 db
With unbalanced input –70 to +10 db/dbm
Min readable level -90 db/dbm
Automatic tuning Between level meter and generator to be provided

10 + 55º C (for limit range of operation)
Ambient temperature
+ 5 - +40º C (Rated range of operation)
230 V ±10%, 50 Hz.
Supply
± 2 Hz.
< 0.1 db at
Error of level measurement
0 db level at
0 scale division
Frequency accuracy 2x10-5 ± 1 digit or better
Resolution 5 Hz.
Configuration Selectable, balanced or unbalanced selectable, terminated

or unterminated
Image, frequency rejection ³ 70 db
Power supply One internal rechargeable batter of 230 V AC. 50 Hz. for
AC operation and for charging battery. Battery charger is
included in the scope.
Battery capacity 8 hours between charges. A discharged battery will

recharge overnight
The equipment shall also have the provision for impedance measurement and return
loss measurement. The technical parameters for these measurements are given below.
Impedance measurement
i) Frequency range 300 Hz to 600 KHz
ii) Measuring range 50 to 1000 ohms
iii) Accuracy ± 10%
Balance & return loss

measurement
88
i) Frequency range 300 Hz – 600 KHz
ii) Impedance limits 60-1000 ohms
iii) Max. return loss to be 40 db

measured
iv) accuracy ± 1 db
Accessories Measuring cable, power cable, synchronizer cable, fuse

and any other accessories required for use of the specified
equipment.
As per ISO –m9001, calibration certificate of each instrument shall be supplied

alongwith the test kit at the time of supply.
Level Generator (Signals Generator)
Signal generator freq. range 200 Ha to 620 KHz.
It should be compatible with signal generator
Output impedances 75,125,150,600 oh.
Output level -60% + 10 db/dbm
Frequency display 6 digit
Frequency accuracy 2x10-5 ± 1 digit
Spurious signals at 0 db (dbm) ³ 60 below fundamental

Supply from mains & 230 V ± 10%
Supply from battery Replaceable rechargeable batteries

+ 5 to + 40º C (rated range)
Ambient temperature
- 10 to + 53º C (limit range of operation)
Accuracy of level indicator ± 0.15 db at an output level of db/dbm

2nd and 3rd product
Harmonic distortion
50 db below fundamental frequency
89
Spurious signal At 0 db – 60 db below fundamental
frequency
Power supply 230 V + 10% 50 Hz. Ac with internal

rechargeable battery
Automatic tuning/ Synchronisation of To be provided

generator
Accessories Measuring cable, power cable. Add any

other accessories required for use of the
specified equipment
As per ISO – 9001, calibration certificate of each instrument shall be supplied along with
the test kit at the time of supply.
Dual Trace Oscilioscope
The dual trace oscilloscope offered shall include suitable printer/plotter. The
oscilloscope shall have the following features:
 Variable hold-off function

 Level-locking facility
 Facility for measurement of one-shot signal
 Facility for external triggering
 The range of oscilloscope shall be suitable for 60 Mhz.
 Sensitivity shall be 10 mV/div to 5 V/div at full band width
 Both channels (normal or invert) shall be available for display in plotting,
chopped headed board
 Max. input shall be of the order of 350 V at 1 kHz. Or lower frequency
 Horizontal accuracy ± 0.01%
 It shall have RS 232 communication port conforming to IEEE std 488.
 It shall have printer port and one printer is to be supplied with each
oscilloscope. Printout shall be possible directly from oscilloscope.
 It shall have non-volatile storage capacity.
 The temperature range for storage and operation shall be to suit ambient
temperature conditions mentioned in Section 1 of the specification
 The input impedance shall be of the order of 1M W / 25 pf
 The accuracy shall be of the order ± 3%
 As per ISO – 9001, calibration certificate of each instrument shall be supplied
alongwith the test kit at the time of supply.
Vacuum Tester
The vacuum tester should permit to select among six test voltage from 10 to 60 kV DC
and should have following minimum specifications
Output voltage, standard : 10,14,25,40 and 60 kV DC
Output voltage, customized : Between 10 and 60 kV DC
Ripple : Max. 3%
90
Maximum permissible transient current through : 12mA
external load
Maximum discharge time for internal high voltage : 0.3x

current
Indication : Through lamps
The unit should weigh about 6 Kg. (approx) and easy to use. It should be supplied with
permanently mounted cables set of 5m length, ground cable and transport case.
Battery management Unit
The battery management system should be portable, light weight and hand held type.
It should be able to measure and store cell voltage. There should also be provision for
measurement and storage ;of temperature, density, ripple voltage and voltage drip
across connections. The equipment must have data logging as well as data storage
facility. Audible as well as usual indication should be available when a value is stored.
An alarm should also be generated if a value exceeds the limit value. It should
incorporate a serial interface as well as a parallel interface so that test data can be
printed immediately after a test in tabular form or can be transferred to a PC for
further analysis. Suitable Windows Based Software shall also be supplied which should
be cable of providing results in the form of curves or bar charts. The software should
also incorporate a convenient cut and paste function for transferring values to other
programs. The equipment should meet the vollowing minimum technical specifications.
DC voltage range : 245mV, 2.45V, 245V, 600V with resolution 0.01 mV, 0.1mV,
1.0mV, 10mV and 100 mV respectively.
Accuracy : + 0.2% or better
Input impedance : > 10 MW
AC voltage : 2-160mV
Accuracy : + 0.2% or better
Input Impedance : 1 MW
Memory : Minimum 128 KB RAM (with battery back up)
Clock : Real time clock (with battery back up)
Interface : RS 232 for computer and parallel interface for printer
Display : Min four (04) Sixteen (16) character lines LCD.
Buzzer : Integrated piezo buzzer
Insulation : 3kV voltage withstand
91
Storage capacity : Minimum 25,000 measurement values
Power input : Rechargeable NiMH battery
Accessories : Test cables, printer cable, datacom cable for computer, batter
charger, software, transport case, instruction manual etc.
Battery Testing Unit
The unit is intended to test sub-station batteries. The load unit should be able to
discharge the batteries at constant current, constant output, constant resistance or as
per a pre-selected load profile. It should also have current voltage time measurement
capability. The detailed specifications are as under:
Minimum voltage : 480 V
Maximum current : 110 A
Maximum power : 15kW
Load pattern : Constant current, constant power, constant

resistance, current profile and power profile
Current Measurement : Display: 0-2999 A, Resolution: 0.1A
Internal current : 0-120 A

measurement
Voltage measurement : Page to be set automatically at start of test
Resolution : 0.02 V
Portable Moisture Content Measurement Set
The equipment offered shall be suitable to measure, in the field or laboratory, the total
amount of water contained in mineral dielectric oil. The result in PPM shall directly
correlate with the Karl Fischer Colorimetric Titration method. It shall be useful for
onsite routine testing of transformer mineral oil, on site acceptance tests of reclaimed
and reconditioned mineral dielectric oil and onsite tests of oil before re-energizing oil-
filled electrical equipment. The equipment should be portable, rugged and user friendly
and should meet the following specifications:
Measurement : The equipment should measure the total amount of

water contained in mineral dielectric oil. The result
should be displayed in ppm (by weight) and shall
directly correlate with the Karl Fischer Colorimetric
Titration method
92
Range of measurement : 0-50 ppm (by weight)
Repeatability : + 5% of the reading
Time required
Measurement time : Should not exceed 10 minutes
Recovery time : Should not exceet 15 minutes
Total analysis time : Should not exceed 25 minutes
Display : 3 ½ digits liquid crystal display
Battery : The equipment should be rechargeable battery

operated. The equipment should also incorporate a
built-in charger operable on (230 V, 50Hz) + 10% AC
supply.
Battery low indication : There should be battery status indication to enable the
user to know the charging time in advance.
Automated operation : The equipment should be automated and also

automatically reset to zero after each test.
Calibration : Calibration of the equipment is to be carried out

through injection of an oil sample with a known water
level measured by the Karl Fischer Method. Party should
supply 05 (five) nos. of calibration ampoules alongwith
the equipment. Exact water level value must be
indicated on each calibration ampoule. There should
also be provision of readjustment with a potentiometer
in case calibration is found to be off.
Waste Oil Reservoir : The equipment should also incorporate a waste oil
reservoir of capacity minimum 50 ml.
Weight : Net weight of the offered system in full operational

mode should not exceed 10 Kgms.
The offered equipment should be CE marked and shall meet low voltage and EMC
directives. Party should supply a oil injection syringe, a reinforced carrying case and
operational manual alongwith the equipment.
DC Earth Fault Locator with Digital Display
 The equipment should be able to precisely detect any earth fault occurring in
DC systems (24 V upto 360 V) to ensure operational safety and availability of
electrical systems.
 It should ensure fast location of the insulation fault and no disconnection of the
electrical system should be required so that insulation fault could be located
during operation of the system itself.
 Maximum test current: 25mA and 10mA selectable in two ranges
93
 The equipment should comprise of a test device and an evaluator unit. A clamp-
on probe is to be supplied for embracing the conductors under test. The
evaluator unit should be immediately ready for operation without any need of
balancing.
 The equipment should be light weight, portable and rechargeable battery
operated. Party should supply one battery charger along with the equipment.
 Display: There should be provision for a liquid crystal display to indicate test
currents of respective conductors. Indication of battery status should be
available on the LC display. It should also indicate whether the connection to
the clamp on probe is interrupted.
 All necessary cables, leads required for measurement are to be supplied with
the equipment. Part should also supply operating and instruction manual.
Calibration Equipment
The calibration kit shall be suitable for calibration of multimeters, wattmeter,

ammeters, volt-meters, oscilloscopes. Thermometers, strip chart recorders and clip on
ammeters, freq. Meters etc.
The Kit shall be suitable for periodic calibration of meters mentioned at clause 12.0
against the following parameters:
 Voltage (DC and AC)

 Current (DC and AC)
 Resistance
 Capacitance
 Frequency
 Power (DC and AC)
 Temperature
 Phase angle (Power factor)
Range and Accuracy
DC Voltage
Range: + 1000 volts

Accuracy: + 0.05%
DC Current
Range: + 10 Amp
Accuracy: + 0.05%
AC Voltage
Range: 1 mV to 1000 volts

Accuracy: + 0.05%
AC Current
Range: 100 micro Amp – 10 Amp

Accuracy: + 0.1%
Resistance
94
Range: 0 to 5000 ;Mohm
Accuracy: + 0.01%
Capacitance
Range: 100 pF to 1mF

Accuracy: + 0.2%
Frequency
Range: 10 Hz to 20 MHz
Accuracy: + 0.01%
 Accessories required for calibrating oscilloscope, clip on ammeter and other

meters shall also be supplied with the test set.
 The instruments shall contain all standard accessories and carrying case.
 The instrument should have been proven for repeatability of test results.
Documentary evidence for this should be furnished along with the bid.
 The kit should be capable of operating and storing data at temperature from 0°
C to 50° C and humidity 10 to 100%
 The desk top PC of Pentium 166 MHz or above with Windows – 95 software
ROM drive, inkjet printer shall be supplied along with test kit. The software
supplied along with the kit should have facility to display and generate reports
in Graphical and Numerical formats and compare results obtained at different
times.
 The functional requirements as mentioned above can either be achieved with
one or more kits. Software suitable for operating on Windows 95 for data
storage and comparison of past data for operating on purchaser’s PC shall be
supplied.
 Input supply of the kit shall be A.C. 230 Volts, 50 Hz., Variations + 15% and +
5% in Voltage and frequency, respectively.
 As per requirements of ISO-9001, calibration certificate shall be supplied along
with each test kit at the time of supply.
95
Section -7 EQUIPMENT FAILURE REPORT
INTRODUCTION
Though there have been reported failure of equipment in all the power utilities,
however the details and causes of the failures are not being compiled in a systematic
manner. In the absence of this data it is difficult to set indices for the reliability of the
various sub-station equipment. A need has been felt for some time for standardization
of reporting of failure equipment, which should be uniformly followed by all the power
utilities. Equipment failure report is just like a FIR (First Information Report).
A PROCEDURE FOR FILLING OF EQUIPMENT FAILURE REPORT (EFR)
 Whenever there is a failure of any equipment or part of any equipment during

operation and maintenance which may result in the outage of the said
equipment the EFR is required to be filled up.
 Each failure report has to be given a specific report number followed by the
name of the sub-station / serial number of the failed equipment and date of
failure.
 Time of occurrence of equipment failure or noticing of failed equipment also to
be written.
 Mention to be made as to when the fault was discovered i.e. during testing,
commissioning, operation and maintenance.
 Name of the main equipment which has failed may be given along with the
name of the manufacturer / supplier / sub-vendor.
 Specify the type of faulty unit/equipment as given by the manufacturer for
example in breakers it could be SF 6 3AT3/3AT2; SF6 HPL, ABCB DLF 245 NC2
etc.
 Specify the item designation i.e. bay name in which faulty equipment was
erected / located, including the Sr. No. / Badge Number as given on the name
plate.
 Specify the faulty component in the unit and the part number as per the O&M
manual of the manufacturer
 Specify the type of failure i.e. burnt / flashover / mal-operation / mechanical
fault / open circuit / short circuit / operating error / setting etc.
 Specify short / brief description of occurrence of fault and cause thereof
 Specify the remedial action taken.
 Specify the reference of the document from which part number / fault diagnosis
has been done, so that it may help in analysis of fault.
 Equipment failure may occur during tripping / due to suspected fault / mal-
functioning of some other equipment. Report number therefore to be specified.
The above documents should be signed by the maintenance engineer and counter
signed by the DIVISONAL incharge.
96

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Section - 1

1.1 In today's competitive market scenario power utilities are under

2.0 TYPES OF MAINTENANCE

Different types of maintenance being done on equipment are:

ii) Preventive Maintenance

The preventive maintenance of equipment is being mostly adopted by almost

iii) Condition Based Monitoring

This type of maintenance technique is adopted to assess the condition of the

This is the recent technique being adopted in maintenance philosophy. The

- Maintenance should keep the equipment at desired level of performance

- Optimizing / minimizing the maintenance / shutdown period so as to

- Deferring / avoiding the replacement of components and major/minor over-

3.0 FAILURES OF EQUIPMENTS

3.1 Failure of any equipment should taken up seriously. Detailed analysis of

4.0 NEED FOR CONDITION BASED ASSESSMENT OF EHV EQUIPEMNT

Power Transformers are vital links in the chain of components constituting a

The main causes of failures of transformers in service (CIGRE Survey) is given

Tank and Di-electric 13

Design defects 35.7

Manufacturing problems 28.6

Material defects 13.1

Transport or storage problems 1.2

In-correct maintenance 4.8

Abnormal overload Less than 1

External short circuit 2.4

Loss of cooling 1.2

However, The failures in power transformers can be broadly classified as:

2.1 Weakness in specifications

Many a times, a customer specification is silent on the various aspects of site

2.2 Failure due to defective design

Cause Effect Remedial Measures

Inadequate May result in short circuit Provide adequate clearance as

Radiators not Result in improper cooling causing Proper calculation of radiators is

2.3 Failures due to manufacturing deficiencies

Cause Effect Remedial Measure

Burrs on lamination Result in local short circuit Burr free condition to be

Burrs on spacers and Result in damaging conductor Burr free condition to be

Bad brazed joints Damage the conductor Adopt good brazing

Insulation surface Results in insulation failure Cleanliness to be ensured

Bad and porous welding Result in oil leakage Surface cleanliness to be

2.4 Failures due to deffective materials

Improper conductor Deteriorate under influence Check the incoming

Particles in oil held in Temporary breakdown Maintain oil cleanliness

2.5 Adverse operating conditions

The life of a transformer is normally dependent on the life of insulation.

Life expectancy of transformer will get diminished through inadequate

1. Sustained overload conditions

2.6 Improper maintenance practices

1. Failure of the winding insulation due to short circuit stresses

Some of these failures are briefly described below:

Safety margin of transformer with reference to short circuit withstand

 Overstressing and inadequate cooling

CBIP’s technical report on causes of failure of tertiary windings and BHEL’s

The clamping arrangement provided on the transformer to contain the short

Failure of the transformers have been reported on switching surges. The

2.8 Failure of magnetic circuits

2.9 Failure of on-load tap changers (oltc)