TURNAROUND

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 CONTENTS
Company Overview
1. Vision……………………………………………………………………………………………………………………......6
2. Mission……………………………………………………………………………………….……………………………..7
3. Core Values………………………………………………………………………………………….…………………….8
Special Project Overview
4. Naphtha…………………………………………………………………………………………..…………………………9
5. Sulphur Block….…………………………………………………………………………….……………………………9
6. HPU/DHT…………………………………………………………………………………….……………………………..9
7. Utilities……………………………………………………………………………………….……………………………..9
Turnaround of Special Project
8. Objectives of Turnaround……………………………………………………………………….………………..10
9. Transformer…….……………………………………………………………………………….………………………10
9.1. Transformer Testing………………………………………………………………………………………………11
9.2. Transformers of SP…………………………………………………………………………………………………13
10. Switchgear………………………………….…………………………………………………………………………...36
10.1. Maintenance of Switchgear…………………………………………………………………………………36
10.2. Switchgear of SP………………………………………………………………………………………………….38
11. Induction Motor…………………………….…………………………………………………………………………44
11.1. Maintenance of Motor……..…………………………………………………………………………………44
11.2. LT Motors of SP……………………………………………………………………………………………………45
11.3. HT Motors of SP……………………………………………………………………………………………………53
12. Protection Relays Inspection and Test Procedure………….…………………………………………..61
12.1. Over current Relay……………………………………………………………………………………………….61
12.2. Earth Fault Relay………………………………………………………………………………………………….63
12.3. Under Voltage Protection Relay…………………………………………………………………………..64
12.4. Neutral Over Voltage Protection Relay………………………………………………………………..64
VISION
Our passion is to attain distinctive leadership amongst the corporate success
stories of tomorrow.

We at NRL recognize that realization of this passion needs superior professional

competencies, continuous value addition and improvising, development of
human capital and complete commitment to safety, occupational health and
environment.
National Refinery Limited

CORE VALUES
Following concepts and ideas guide the Management and Staff of National Refinery Limited
in conducting its business practices in most ethical ways:

1. Ethical Conduct and Integrity

We value lifestyle in our organization where ethics like truth, honesty, integrity and fair
play are basic ingredients while interacting within the organization or dealing with the
outside world.

2. Teamwork and Responsibility

We share information and resources and step in to help out other team members.
Conflicts are worked out in spite of obstacles and difficulties. We accept responsibility with
“can do” attitude.
3. Customer Satisfaction
We endeavor to provide quality products to our customers at competitive prices. We value
their satisfaction essential for continued growth of our business.

4. Continuous improvement
We generate new ideas and creative approaches to upgrade and update our refinery
to best available technology and processes so that our products are at the level of
internationally accepted standards.

5. Profitability
We believe in enhancing our profitability to the maximum so that Employees, Shareholders
and Government all benefit from it.

6. Corporate Citizenship
As a good Corporate Citizen, we are more than willing and happy to meet our social
responsibilities towards the community around us. We are also committed to meet
requirements of health, safety and environment.

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There are four units in Special Projects, Naphtha, Sulphur Block, HPU/DHT and Utilities.

1. Naphtha (307, 308, 309)

The main uses of petroleum naphtha fall into the general areas of (1) precursor to gasoline
and other liquid fuels, (2) solvents (diluents) for paints, (3) dry-cleaning solvents, (4)
solvents for cutback asphalts, (5) solvents in rubber industry, and (6) solvents for industrial
extraction processes.

2. Sulphur Block (310, 311, 312, 312X)

The sulphur block is an essential part of any new or revamp refinery project and its cost
contributes significantly to the overall cost of a project. A typical sulphur block includes
facilities for hydrogen sulphide removal, amine regeneration, sour water treating, sulphur
recovery, tail gas treating, sulphur degassing, sulphur granulation and sulphur storage.

3. HPU/ DHT (305, 306)

Refineries use hydrogen to lower the sulfur content of diesel fuel. Refinery demand for
hydrogen has increased as demand for diesel fuel has risen both domestically and
internationally, and as sulfur-content regulations have become more stringent.
A diesel hydrotreater (DHT) is a critical unit within an oil refinery. A DHT processes the
diesel range fractions obtained from different units of the refinery—such as from the
crude distillation unit and the delayed coker unit—to adhere to diesel fuel market
specifications.

4. Utilities (313, 314, 316, 375, 376, 377, 378, 379, 380, 381, 570)
National Refinery utilizes a large number of utilities to support the manufacturing at
production units. The supply of water, steam, fuel and air is the assignment of Utilities
Department. A comprehensive utilities complex exists to meet the refinery’s requirements
of utilities, steam, and condensate, cooling water, instrument/plant air and fuels.

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A Turnaround is a scheduled period of non-production within the plant. That means that
day-to-day operations cease completely during the duration of a turnaround and instead
the focus shifts to maintenance related activities, cleaning, inspection, and repair. During
this time the plant’s employees, and often outside contractors, work around the clock to
get everything ready for the plant or unit to resume its regular operations. Speed is of the
essence when it comes to shutdowns because they are extremely expensive in terms of
production lost, increased labor and equipment expenses.

OBJECTIVES OF TURN AROUND

Followings are the main objectives of Turnaround;

1. To improve efficiency and throughput of plant by suitable modification;

2. To increase reliability/availability of equipment during operation;
3. To make plant safe to operate till next Turnaround;
4. To achieve the best quality of workmanship;
5. To reduce routine maintenance costs;
6. To upgrade technology by introducing modern equipment and techniques;

During Turnaround, the following types of work are usually performed:

1. Work on equipment which cannot be done unless the whole plant is shutdown;
2. Work which can be done while equipment is in operation but requires a lengthy period of
maintenance work and a large number of maintenance personnel;
3. Upgrading equipment and introducing new technologies to improve speed and efficiency.

TRANSFORMERS
A transformer is a passive component that transfers electrical energy from one electrical
circuit to another circuit through the process of electromagnetic induction. It is most
commonly used to step up or step down voltage levels between circuits.

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MAINTENANCE OF TRANSFORMER
Since transformer is very important capital equipment for an industry, therefore its proper
maintenance is very important to allow the transformer for working with its full efficiency.
Following actions are performed during the maintenance of transformer:
1. Checked the oil level of Magnetic oil Gauge of main tank and conservator, found below
the specified level then filled it up to the specified level.
2. Checked the color of silica gel in breather, replaced the silica gel.
3. Checked the leakage of oil from any point of a transformer, leakage is detected then
sealed it.
4. Cleaned the LT/ HT bushings of transformer with only soft cotton cloth.
5. Checked the tripping of Buchholz relay.
6. Checked the tightness of all the terminal connections of LT/HT sides.
7. Checked the resistance of the earthing wire.
8. Checked the insulation resistance with megger.
9. Cleaned the overall transformer properly.
10. Centrifuging is performed to purify the oil of transformer.

TRANSFORMER TESTING
1. Transformer Turns Ratio (TTR)
The transformer turns ratio test is used to make sure that the ratio between the windings of
the primary and secondary coils follow the proper specifications. This test ensures that the
transformer will provide the proper step-up or step down in voltage.

Fig 1: Transformer Turns Ratio (TTR)

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2. Winding Resistance Test (WRT)

The main purpose of this test is to check for gross differences between windings and for
opens in the connections. Measuring the resistance of transformer windings assures that
each circuit is wired properly and that all connections are tight.

Fig 2: Winding Resistance Test (WRT)

3. Insulation Resistance Test (Megger)

Insulation resistance is the ratio of applied voltage to the resulting current at a specified time
after the voltage is applied. This test is carried out to ensure the healthiness of overall
insulation system of an electrical power transformer.

Fig 3: Insulation Resistance Test (Megger)

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CENTRIFUGING OF TRANSFORMER OIL

Transformer life mainly depends on the quality of oil volume it contains. Regular transformer
oil filtration assures long and consistent results from the transformer.
Centrifuging of transformer oil is a process to remove sludge, dissolved moisture and
dissolved gases from the oil. Transformer oil conditioning may also include to some extent
improving the acidity of the oil.

Fig 4: Centrifuging of Transformer Oil

TRANSFORMERS OF SPECIAL PROJECT (SP)

There are four substations in Special Project and each substations have four transformers
namely;
1. Substation 14
1.1. 344-XRM-4001A
1.2. 344-XRM-4001B
1.3. 344-XRM-5001A
1.4. 344-XRM-5001B
2. Substation 15
2.1. 345-XRM-4001A
2.2. 345-XRM-4001B
2.3. 345-XRM-5001A
2.4. 345-XRM-5001B
3. Substation 16
3.1. 346-XRM-4001A
3.2. 346-XRM-4001B
3.3. 346-XRM-5001A
3.4. 346-XRM-5001B

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4. Substation 18
4.1. 348-XRM-4001A
4.2. 348-XRM-4001B
4.3. 348-XRM-5001A
4.4. 348-XRM-5001B
Where, 4001 A/B represents 11/6 kV and 5001 A/B represents 11/0.4 kV transformers.

1.1. 344-XRM-4001A (Dd0)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 1.1.1: TTR Test Result
S.No HV/LV Tap Position Phases Turns Ratio
1 A 1.8330
2 07 B 1.8331
3 C 1.8331

Winding Resistance Test:

Table 1.1.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 11.31 0.086
2 YB 11.25 0.088
3 RB 11.25 0.087

Table 1.1.3: WRT Test Result for LT side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 11.35 0.065
2 YB 11.30 0.066
3 RB 11.31 0.066

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Insulation Resistance Test:

Table 1.1.4: IR Test Result for HV/LV
S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 118
2 30 4.98 89.5

Table 1.1.5: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 58.4
2 30 4.98 60.9

Table 1.1.6: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 47.4
2 30 4.98 48.4

1.2. 344-XRM-4001B (Dd0)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 1.2.1: TTR Test Result
S.No HV/LV Tap Position Phases Turns Ratio
1 A 1.8330
2 07 B 1.8332
3 C 1.8331

Winding Resistance Test:

Table 1.2.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.109 1.464
2 YB 1.110 1.465
3 RB 1.110 1.464

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Table 1.2.3: WRT Test Result for LT side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.188 0.367
2 YB 1.215 0.355
3 RB 1.110 0.360

Insulation Resistance Test:

Table 1.2.4: IR Test Result for HV/LV
S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 45.8
2 30 4.98 120

Table 1.2.5: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 30
2 30 4.98 33.2

Table 1.2.6: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 19.2
2 30 4.98 23.6

1.3. 344-XRM-5001A (DYn11)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 1.3.1: TTR Test Result
S.No HV/LV Tap Position Phases Turns Ratio
1 A 27.484
2 03 B 27.486
3 C 27.484

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Winding Resistance Test:

Table 1.3.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.404 0.324
2 YB 1.404 0.325
3 RB 1.404 0.326

Table 1.3.3: WRT Test Result for LT side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.418 0.077
2 YB 1.418 0.081
3 RB 1.419 0.067

Table 1.3.4: WRT Test Result for LT/G

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RG 1.419 0.071
2 YG 1.418 0.072
3 RG 1.419 0.065

Insulation Resistance Test:

Table 1.3.5: IR Test Result for HV/LV
S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 15.4
2 30 4.98 18.4

Table 1.3.6: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 20.2
2 30 4.98 21.2

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Table 1.3.7: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 1.00 7.90
2 30 1.00 8.80

1.4. 344-XRM-5001B (DYn11)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 1.4.1: TTR Test Result
S.No HV/LV Tap Position Phases Turns Ratio
1 A 27.485
2 03 B 27.486
3 C 27.486

Winding Resistance Test:

Table 1.4.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.075 0.33
2 YB 1.236 0.327
3 RB 1.092 0.331

Table 1.4.3: WRT Test Result for LT side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.100 0.070
2 YB 1.100 0.075
3 RB 1.100 0.069

Table 1.4.4: WRT Test Result for LT/G

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RG 1.102 0.079
2 YG 1.101 0.074
3 RG 1.100 0.074

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Insulation Resistance Test:

Table 1.4.5: IR Test Result for HV/LV
S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 14.4
2 30 4.98 20.2

Table 1.4.6: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 20.1
2 30 4.98 22.0

Table 1.4.7: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 1.00 6.47
2 30 1.00 7.29

2.1. 345-XRM-4001A (Dd0)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 2.1.1: TTR Test Result
S.No HV/LV Tap Position Phases Turns Ratio
1 A 1.829
2 07 B 1.8293
3 C 1.829

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Winding Resistance Test:

Table 2.1.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 11.25 0.0933
2 YB 11.24 0.0939
3 RB 11.26 0.089

Table 2.1.3: WRT Test Result for LT side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 11.35 0.0727
2 YB 11.34 0.0737
3 RB 11.28 0.075

Insulation Resistance Test:

Table 2.1.4: IR Test Result for HV/LV
S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 158
2 30 4.98 144

Table 2.1.5: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 132
2 30 4.98 125

Table 2.1.6: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 74.2
2 30 4.98 68.7

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Silica Gel:
Silica gel of this transformer has been changed.

Fig 5: Silica Gel before changed Fig 6: Silica Gel after changed

2.2. 345-XRM-4001B (Dd0)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 2.2.1: TTR Test Result
S.No HV/LV Tap Position Phases Turns Ratio
1 A 1.829
2 07 B 1.829
3 C 1.829

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Winding Resistance Test:

Table 2.2.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 11.31 0.08606
2 YB 11.25 0.08853
3 RB 11.25 0.08753

Table 2.2.3: WRT Test Result for LT side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 11.35 0.065
2 YB 11.30 0.066
3 RB 11.31 0.066

Insulation Resistance Test:

Table 2.2.4: IR Test Result for HV/LV
S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 118
2 30 4.98 89.5

Table 2.2.5: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 58.4
2 30 4.98 60.9

Table 2.2.6: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 47.4
2 30 4.98 48.4

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Silica Gel:
Silica gel of this transformer has been changed.

Fig 7: Silica Gel before changed Fig 8: Silica Gel after changed

2.3. 345-XRM-5001A (DYn11)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 2.3.1: TTR Test Result
S.No HV/LV Tap Position Phases Turns Ratio
1 A 27.496
2 03 B 27.497
3 C 27.495

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Winding Resistance Test:

Table 2.3.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.399 0.404
2 YB 1.398 0.408
3 RB 1.398 0.408

Table 2.3.3: WRT Test Result for LT side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.419 0.072
2 YB 1.418 0.072
3 RB 1.419 0.068

Table 2.3.4: WRT Test Result for LT/G side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RG 1.419 0.069
2 YG 1.418 0.069
3 RG 1.418 0.066

Insulation Resistance Test:

Table 2.3.5: IR Test Result for HV/LV

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 18.8
2 30 4.98 26.5

Table 2.3.6: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 28.8
2 30 4.98 31.0

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Table 2.3.7: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 1.00 6.53
2 30 1.00 8.57

2.4. 345-XRM-5001B (DYn11)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 2.4.1: TTR Test Result
S.No HV/LV Tap Position Test Voltage Phases Turns Ratio
1 A 27.497
2 03 B 27.498
3 C 27.495

Winding Resistance Test:

Table 2.4.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 10.27 0.382
2 YB 10.16 0.386
3 RB 10.22 0.387

Table 2.4.3: WRT Test Result for LT side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 11.36 0.0624
2 YB 11.35 0.06
3 RB 11.35 0.063

Table 2.4.4: WRT Test Result for LT/G side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RG 11.41 0.0615
2 YG 11.40 0.0672
3 RG 11.38 0.066

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Insulation Resistance Test:

Table 2.4.5: IR Test Result for HV/LV

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 41.0
2 30 4.98 60.6

Table 2.4.6: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 69.5
2 30 4.98 67.1

Table 2.4.7: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 1.00 22.2
2 30 1.00 23.5

3.1. 346-XRM-4001A (Dd0)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 3.1.1: TTR Test Result
S.No HV/LV Tap Position Phases Turns Ratio
1 A 1.8315
2 07 B 1.8317
3 C 1.8317

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Winding Resistance Test:

Table 3.1.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.400 0.378
2 YB 1.399 0.379
3 RB 1.400 0.381

Table 3.1.3: WRT Test Result for LT side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.414 0.145
2 YB 1.413 0.149
3 RB 1.414 0.150

Insulation Resistance Test:

Table 3.1.4: IR Test Result for HV/LV
S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 26.5
2 30 4.98 38.2

Table 3.1.5: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 36.3
2 30 4.98 39.3

Table 3.1.6: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 24.3
2 30 4.98 30.5

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3.2. 346-XRM-4001B (Dd0)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 3.2.1: TTR Test Result
S.No HV/LV Tap Position Phases Turns Ratio
1 A 1.8314
2 07 B 1.8316
3 C 1.8316

Winding Resistance Test:

Table 3.2.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.400 0.382
2 YB 1.399 0.388
3 RB 1.399 0.392

Table 3.2.3: WRT Test Result for LT side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.414 0.153
2 YB 1.413 0.150
3 RB 1.414 0.153

Insulation Resistance Test:

Table 3.2.4: IR Test Result for HV/LV
S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 26.5
2 30 4.98 38.2

Table 3.2.5: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 36.3
2 30 4.98 39.3

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Table 3.2.6: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 24.3
2 30 4.98 30.5

3.3. 346-XRM-5001A (DYn11)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 3.3.1: TTR Test Result
S.No HV/LV Tap Position Phases Turns Ratio
1 A 27.483
2 03 B 27.484
3 C 27.483

Winding Resistance Test:

Table 3.3.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.393 0.512
2 YB 1.392 0.512
3 RB 1.392 0.515
Table 3.3.3: WRT Test Result for LT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.419 0.059
2 YB 1.420 0.061
3 RB 1.419 0.061

Table 3.3.4: WRT Test Result for LT/G

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RG 1.418 0.0876
2 YG 1.418 0.0795
3 RG 1.419 0.0874

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Insulation Resistance Test:

Table 3.3.5: IR Test Result for HV/LV
S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 77.2
2 30 4.98 95

Table 3.3.6: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 98
2 30 4.98 104

Table 3.3.7: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 1.00 35
2 30 1.00 34.6

4.1. 348-XRM-4001A (Dd0)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 4.1.1: TTR Test Result
S.No HV/LV Tap Position Phases Turns Ratio
1 A 1.8328
2 07 B 1.833
3 C 1.833

Winding Resistance Test:

Table 4.1.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.117 0.349
2 YB 1.116 0.342
3 RB 1.117 0.347

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Table 4.1.3: WRT Test Result for LT side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.126 0.122
2 YB 1.126 0.121
3 RB 1.127 0.121

Insulation Resistance Test:

Table 4.1.4: IR Test Result for HV/LV
S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 31.9
2 30 4.98 54.3

Table 4.1.5: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 45.3
2 30 4.98 51.9

Table 4.1.6: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 50.4
2 30 4.98 49.8

4.2. 348-XRM-4001B (Dd0)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 4.2.1: TTR Test Result
S.No HV/LV Tap Position Phases Turns Ratio
1 A 1.8328
2 07 B 1.833
3 C 1.833

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Winding Resistance Test:

Table 4.2.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.110 0.353
2 YB 1.109 0.348
3 RB 1.108 0.345

Table 4.2.3: WRT Test Result for LT side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.118 0.125
2 YB 1.119 0.124
3 RB 1.117 0.125

Insulation Resistance Test:

Table 4.2.4: IR Test Result for HV/LV
S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 38.4
2 30 4.98 63.4

Table 4.2.5: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 47.6
2 30 4.98 57.2

Table 4.2.6: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 39.3
2 30 4.98 46.2

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4.3. 348-XRM-5001A (DYn11)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 4.3.1: TTR Test Result
S.No HV/LV Tap Position Phases Turns Ratio
1 A 27.516
2 03 B 27.517
3 C 27.514

Winding Resistance Test:

Table 4.3.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.084 0.64
2 YB 1.083 0.631
3 RB 1.084 0.633
Table 4.3.3: WRT Test Result for LT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.254 0.077
2 YB 1.130 0.077
3 RB 1.129 0.066
Table 4.3.4: WRT Test Result for LT/G
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RG 1.07 0.083
2 YG 1.107 0.080
3 RG 1.106 0.083

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Insulation Resistance Test:

Table 4.3.5: IR Test Result for HV/LV
S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 68.7
2 30 4.98 95

Table 4.3.6: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 104
2 30 4.98 105

Table 4.3.7: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 1.00 28.8
2 30 1.00 29.9

4.4. 348-XRM-5001A (DYn11)

Three tests are performed on transformers and their results are shown below.
Transformer Turns Ratio:
Table 4.4.1: TTR Test Result
S.No HV/LV Tap Position Phases Turns Ratio
1 A 27.521
2 03 B 27.522
3 C 27.521

Winding Resistance Test:

Table 4.4.2: WRT Test Result for HT side
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.091 0.636
2 YB 1.090 0.635
3 RB 1.080 0.633

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Table 4.4.3: WRT Test Result for LT side

S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RY 1.121 0.068
2 YB 1.120 0.069
3 RB 1.122 0.070
Table 4.4.4: WRT Test Result for LT/G
S.No Phases Injected Current (A) Contact Resistance
(Ω)
1 RG 1.111 0.061
2 YG 1.111 0.060
3 RG 1.256 0.064

Insulation Resistance Test:

Table 4.4.5: IR Test Result for HV/LV
S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 109
2 30 4.98 110

Table 4.4.6: IR Test Result for HV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 4.98 63.1
2 30 4.98 69.5

Table 4.4.7: IR Test Result for LV/G

S.No Time Test Voltage (kV) Contact Resistance
(sec) (GΩ)
1 15 1.00 24.2
2 30 1.00 23.1

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SWITCHGEAR
In an electric power system, switchgear is composed of electrical disconnect
switches, fuses or circuit breakers used to control, protect and isolate electrical equipment.
Switchgear is used both to de-energize equipment to allow work to be done and to
clear faults downstream. This type of equipment is directly linked to the reliability of
the electricity supply.

MAINTENANCE OF SWITCHGEAR
Switchgear power systems are very reliable and rarely need maintenance at all. Because of
their reliable reputation, they also can be the most overlooked element in the whole power
control system. If there does happen to be a problem in the switchgear, it could keep the
whole power grid in question from coming online at all or even worse, damage to
the switchgear power systems could occur.

Figure 9: Maintenance of Switchgear

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Following actions are performed during the maintenance of Switchgear:

1. Cleaned Top Panel.
2. Cleaned Vacuum Circuit Breaker.
3. Cleaned CT Chamber.
4. Checked Vacuuming of Top Duct.
5. Checked Miniature Circuit breaker.
6. Done greasing of wheels.
7. Checked contact resistance.
8. Checked pole to breaker body megger.
9. Cleaned socopax terminal.
10. Checked spring charging mechanism.
11. Checked manual switching ON.
12. Checked manual switching OFF.
13. Testing of breaker at 2nd position.

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SWITCHGEAR OF SPECIAL PROJECT (SP)

There are four substations in Special Project and each substations have many switchgears
namely;
1. Substation 14
1.1. 344-SWG-3003A
1.2. 344-SWG-3002A
1.3. 344-SWG-3005B
1.4. 344-SWG-3007B
1.5. 344-SWG-3006B
2. Substation 15
2.1. 345-SWG-3008B
2.2. 345-SWG-3007B
2.3. 345-SWG-3004B
2.4. 345-SWG-3003B
2.5. 345-SWG-3004A
2.6. 345-SWG-3006A
2.7. 345-MCC-4014
2.8. 345-MCC-4013
2.9. 345-MCC-4012
2.10. 345-MCC-4011
2.11. 345-MCC-4010
2.12. 345-MCC-4009
2.13. 345-MCC-4008
2.14. 345-MCC-4007
3. Substation 18
3.1. 348-MCC-4001B
3.2. 348-MCC-4000A
3.3. 348-SWG-3007B
3.4. 348- SWG-3006B
3.5. 348- SWG-3002
3.6. 348- SWG-3006A
3.7. 348- SWG-3007A
3.8. 348- SWG-3008A
3.9. 348- SWG-3011A

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1. Switchgears of S/S 14:

Following points have been checked of the switchgears of S/S 14;

Table 1.1: Results of Switchgear Maintenance

Switchgear Tag 3003A 3002A 3005B 3007B 3006B
S.No Checking Points Status Status Status Status Status
1 Top Panel cleaning OK OK OK OK OK
2 VCB Cleaning OK OK OK OK OK
3 CT chamber cleaning OK OK OK OK OK
4 Vacuuming of Top Duct OK OK OK OK OK
5 Miniature CB status OK OK OK OK OK
6 Greasing of wheels Yes Yes Yes Yes Yes
7 Contact resistance - 0.6Ω 0.6Ω 0.5Ω 0.5Ω
8 Pole of breaker body 11GΩ 11GΩ 11GΩ 11GΩ 11GΩ
megger
9 Socopax terminal OK OK OK OK OK
cleaning
10 Spring charging OK OK OK OK OK
mechanism
11 Manual switching ON OK OK OK OK OK
12 Manual switching OFF OK OK OK OK OK
13 Rack out Testing OK OK OK OK OK

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2. Switchgears of S/S 15:

Following points have been checked of the switchgears of S/S 15;

Table 2.1: Results of Switchgear Maintenance

Switchgear Tag 3008B 3007B 3004B 3003B 3004A 3006A 4014
S.No Checking Points Status Status Status Status Status Status Status
1 Top Panel cleaning OK OK OK OK OK OK OK
2 VCB Cleaning OK OK OK OK OK OK OK
3 CT chamber cleaning OK OK OK OK OK OK OK
4 Vacuuming of Top Duct OK OK OK OK OK OK OK
5 Miniature CB status OK OK OK OK OK OK OK
6 Greasing of wheels Yes Yes Yes Yes Yes Yes Yes
7 Contact resistance 0.44Ω 0.32Ω 0.5Ω 0.34Ω 0.52Ω 0.48Ω 0.4Ω
8 Pole of breaker body 11GΩ 11GΩ 11GΩ 11GΩ 11GΩ 11GΩ 11GΩ
megger
9 Socopax terminal OK OK OK OK OK OK OK
cleaning
10 Spring charging OK OK OK OK OK OK OK
mechanism
11 Manual switching ON OK OK OK No OK OK OK
12 Manual switching OFF OK OK OK No OK OK OK
13 Rack out Testing OK OK OK OK OK OK OK

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Table 2.2: Results of Switchgear Maintenance

Switchgear Tag 4013 4012 4011 4010 4009 4008 4007
S.No Checking Points Status Status Status Status Status Status Status
1 Top Panel cleaning OK OK OK OK OK OK OK
2 VCB Cleaning OK OK OK OK OK OK OK
3 CT chamber cleaning OK OK OK OK OK OK OK
4 Vacuuming of Top Duct OK OK OK OK OK OK OK
5 Miniature CB status OK OK OK OK OK OK OK
6 Greasing of wheels Yes Yes Yes Yes Yes Yes Yes
7 Contact resistance 0.35Ω 0.5Ω 0.4Ω 0.7Ω 0.42Ω 0.45Ω 0.4Ω
8 Pole of breaker body 11GΩ 11GΩ 11GΩ 11GΩ 11GΩ 11GΩ 11GΩ
megger
9 Socopax terminal OK OK OK OK OK OK OK
cleaning
10 Spring charging OK OK OK OK OK OK OK
mechanism
11 Manual switching ON OK OK OK No OK OK OK
12 Manual switching OFF OK OK OK No OK OK OK
13 Rack out Testing OK OK OK OK OK OK OK

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3. Switchgears of S/S 18:

Following points have been checked of the switchgears of S/S 15;

Table 3.1: Results of Switchgear Maintenance

Switchgear Tag 4001B 4000A 3007B 3006B 3002
S.No Checking Points Status Status Status Status Status
1 Top Panel cleaning OK OK OK OK OK
2 VCB Cleaning OK OK OK OK OK
3 CT chamber cleaning OK No CT OK OK Not checked
due to 11kV
4 Vacuuming of Top Duct OK OK OK OK OK
5 Miniature CB status OK OK OK OK OK
6 Greasing of wheels Yes Yes Yes Yes Yes
7 Contact resistance - No 0.43Ω 0.43Ω -
8 Pole of breaker body 11GΩ 11GΩ 11GΩ 11GΩ 11GΩ
megger
9 Socopax terminal OK OK OK OK OK
cleaning
10 Spring charging OK OK OK OK OK
mechanism
11 Manual switching ON Not checked OK OK No Not checked
due to due to
12 Manual switching OFF OK OK No
Incoming incomer
breaker
13 Rack out Testing OK OK OK OK OK

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Table 3.2: Results of Switchgear Maintenance

Switchgear Tag 3006A 3007A 3008A 3011A
S.No Checking Points Status Status Status Status
1 Top Panel cleaning OK OK OK OK
2 VCB Cleaning OK OK OK OK
3 CT chamber cleaning OK OK OK OK
4 Vacuuming of Top Duct OK OK OK OK
5 Miniature CB status OK OK OK OK
6 Greasing of wheels Yes Yes Yes Yes
7 Contact resistance 0.38Ω 0.69Ω 0.43Ω 0.38Ω
8 Pole of breaker body 11GΩ 11GΩ 11GΩ 11GΩ
megger
9 Socopax terminal OK OK OK OK
cleaning
10 Spring charging OK OK OK OK
mechanism
11 Manual switching ON - OK OK No
12 Manual switching OFF - OK OK No
13 Rack out Testing OK OK OK OK

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INDUCTION MOTOR
An induction motor (also known as asynchronous motor) is a commonly used AC electric
motor. In an induction motor the electric current in the rotor needed to produce torque is
obtained via electromagnetic induction from the rotating magnetic field of the stator
winding.

MAINTENANCE OF MOTOR
Motors need maintenance regularly in order to ovoid failure and prolong their lifespan.
Generally speaking, motors and motor parts should be maintained and tested at least every
six months. Only then it is possible to maintain a motor’s life and its efficiency.

Figure 10: Maintenance of Motor

Following actions are performed during the maintenance of Motor:

1. Fan cover cleaning.
2. Cleaning of Motor body.
3. Painting of motor.
4. Replacement of bearing.
5. Greasing of bearing.
6. Motor boxup.
7. Power cable connection.
8. Off load testing (Ampere).

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LT MOTOR OF SPECIAL PROJECT (SP)

Maintenance of LT Motors of HPU (305), DHT (306) and Sulphur Block (310, 311, 312, 312X)
have been done.
1. Hydrogen Production Unit (HPU-305)
1.1. 305-EA01A
1.2. 305-EA01B
1.3. 305-EA02A
1.4. 305-EA02B
1.5. 305-EA03A
1.6. 305-EA03B
1.7. 305-EA04A
1.8. 305-EA04B
1.9. 305-P01B
1.10. 305-K04A
1.11. 305-K05B
1.12. 305-K03
1.13. 305-P02A
2. Diesel Hydro Treater (DHT-306)
2.1. 306-P07A
2.2. 306-P08A
2.3. 306-P14
2.4. 306-EA01A
2.5. 306-EA01B
2.6. 306-EA01C
2.7. 306-EA01D
2.8. 306-EA02A
2.9. 306-EA02B
2.10. 306-EA02C
2.11. 306-EA03A
2.12. 306-EA03B
2.13. 306-EA05A
2.14. 306-EA05B
2.15. 306-P05A
2.16. 306-P04B

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3. Sulphur Block (310, 311, 312, 312X)

3.1. 310-EA01E
3.2. 310-EA01F
3.3. 310-EA01G
3.4. 310-EA01H
3.5. 310-P01A
3.6. 310-P03B
3.7. 310-P03C
3.8. 310-P04A
3.9. 310-P04B
3.10. 310-P04C
3.11. 312-K01A
3.12. 312-K02A
3.13. 312-P01A
3.14. 312-P02B
3.15. 312-P04B
3.16. 312-P05

1. Motors of HPU (305):

Following points have been checked of the motors of HPU (305);
Table 1.1: Results of Motor Maintenance
Motor Tag EA01A EA01B EA02A EA02B EA03A
S.No Checking Points Status Status Status Status Status
1 Cleaning of Fan cover Yes Yes Yes Yes Yes
2 Cleaning of Motor Body Yes Yes Yes Yes Yes
3 Painting of Motor Yes Yes Yes Yes Yes
4 Replacement of Bearing Yes Yes Yes Yes Yes
5 Greasing of Bearing Yes Yes Yes Yes Yes
6 Motor Boxup Yes Yes Yes Yes Yes
7 Power cable connection Yes Yes Yes Yes Yes
8 Off load testing Yes Yes Yes Yes Yes

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Table 1.2: Results of Motor Maintenance

Motor Tag EA03B EA04A EA04B P01B
S.No Checking Points Status Status Status Status
1 Cleaning of Fan cover Yes Yes Yes Yes
2 Cleaning of Motor Body Yes Yes Yes Yes
3 Painting of Motor Yes Yes Yes Yes
4 Replacement of Bearing Yes Yes Yes Yes
5 Greasing of Bearing Yes Yes Yes Yes
6 Motor Boxup Yes Yes Yes Yes
7 Power cable connection Yes Yes Yes Yes
8 Off load testing Yes Yes Yes Yes

Following motors of HPU (305) have been sent to SIEMENS for overhauling purpose:

1. 305-K03

Figure 11: 305-K03

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2. 305-K05B

Figure 12: 305-K05B

3. 305-K04A

Figure 13: 305-K04A

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Following motors of HPU (305) have been sent to TURBO for overhauling purpose:
4. 305-P02A

Figure 14: 305-P02A

2. Motors of DHT (306):

Following points have been checked of the motors of DHT (306);
Table 2.1: Results of Motor Maintenance
Motor Tag P07A P08A P14 EA01A EA01B EA01C EA01D
S.No Checking Points Status Status Status Status Status Status Status
1 Cleaning of Fan cover Yes Yes Yes Yes Yes Yes Yes
2 Cleaning of Motor Body Yes Yes Yes Yes Yes Yes Yes
3 Painting of Motor Yes Yes Yes Yes Yes Yes Yes
4 Replacement of Bearing Yes Yes Yes Yes Yes Yes Yes
5 Greasing of Bearing Yes Yes Yes Yes Yes Yes Yes
6 Motor Boxup Yes Yes Yes Yes Yes Yes Yes
7 Power cable connection Yes Yes Yes Yes Yes Yes Yes
8 Off load testing Yes Yes Yes Yes Yes Yes Yes

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Table 2.2: Results of Motor Maintenance

Motor Tag EA02A EA02B EA02C EA03A EA03B EA05A EA05B
S.No Checking Points Status Status Status Status Status Status Status
1 Cleaning of Fan cover Yes Yes Yes Yes Yes Yes Yes
2 Cleaning of Motor Body Yes Yes Yes Yes Yes Yes Yes
3 Painting of Motor Yes Yes Yes Yes Yes Yes Yes
4 Replacement of Bearing Yes Yes Yes Yes Yes Yes Yes
5 Greasing of Bearing Yes Yes Yes Yes Yes Yes Yes
6 Motor Boxup Yes Yes Yes Yes Yes Yes Yes
7 Power cable connection Yes Yes Yes Yes Yes Yes Yes
8 Off load testing Yes Yes Yes Yes Yes Yes Yes

Following motors of DHT (306) have been sent to TURBO for overhauling purpose:
5. 306-P05A

Figure 15: 306-P05A

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6. 306-P04B

Figure 16: 306-P04B

3. Motors of Sulphur Block (310, 311, 312, 312X):

Following points have been checked of the motors of Sulphur Block (310);
Table 3.1: Results of Motor Maintenance
Motor Tag EA01E EA01F EA01G EA01H P01A
S.No Checking Points Status Status Status Status Status
1 Cleaning of Fan cover Yes Yes Yes Yes Yes
2 Cleaning of Motor Body Yes Yes Yes Yes Yes
3 Painting of Motor Yes Yes Yes Yes Yes
4 Replacement of Bearing Yes Yes Yes Yes Yes
5 Greasing of Bearing Yes Yes Yes Yes Yes
6 Motor Boxup Yes Yes Yes Yes Yes
7 Power cable connection Yes Yes Yes Yes Yes
8 Off load testing Yes Yes Yes Yes Yes

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Table 3.2: Results of Motor Maintenance

Motor Tag P03B P03C P04A P04B P04C P05
S.No Checking Points Status Status Status Status Status Status
1 Cleaning of Fan cover Yes Yes Yes Yes Yes Yes
2 Cleaning of Motor Body Yes Yes Yes Yes Yes Yes
3 Painting of Motor Yes Yes Yes Yes Yes Yes
4 Replacement of Bearing Yes Yes Yes Yes Yes Yes
5 Greasing of Bearing Yes Yes Yes Yes Yes Yes
6 Motor Boxup Yes Yes Yes Yes Yes Yes
7 Power cable connection Yes Yes Yes Yes Yes Yes
8 Off load testing Yes Yes Yes Yes Yes Yes

Following points have been checked of the motors of Sulphur Block (312);
Table 3.3: Results of Motor Maintenance
Motor Tag K01A K02A P01A P02B P04B
S.No Checking Points Status Status Status Status Status
1 Cleaning of Fan cover Yes Yes Yes Yes Yes
2 Cleaning of Motor Body Yes Yes Yes Yes Yes
3 Painting of Motor Yes Yes Yes Yes Yes
4 Replacement of Bearing Yes Yes Yes Yes Yes
5 Greasing of Bearing Yes Yes Yes Yes Yes
6 Motor Boxup Yes Yes Yes Yes Yes
7 Power cable connection Yes Yes Yes Yes Yes
8 Off load testing Yes Yes Yes Yes Yes

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HT MOTOR OF SPECIAL PROJECT (SP)

Maintenance of HT Motors of DHT (306) and Boiler 8 (570, 313) have been done.
4. Hydrogen Production Unit (HPU-305)
4.1. 305-K01A
4.2. 305-K01B
5. Diesel Hydro Treater (DHT-306)
5.1. 306-K01A
5.2. 306-K01B
5.3. 306-P13B
5.4. 306-P02B
5.5. 306-P01A
6. Boiler 8 (570, 313)
6.1. 313-P01
6.2. 570-P01
6.3. 570-K01
1. Motors of HPU (305):
Following motors have been checked by SIEMENS at NRL.
7. 305-K01A
Three tests are performed on 305-K01A and their results are shown below.

Winding Resistance Test:

Table 7.1: WRT Test Result
S.No Phases Contact Resistance
(Ω)
1 UV 0.366
2 VW 0.365
3 UW 0.366

Polarization Index Test:

Table 7.2: PI Test Result
S.No Time Resistance Ratio
(min) (GΩ)
1 1 22.5
4.92
2 10 110.7

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Surge Waveform Comparison Test:

Waves of all three phases are found Super Imposed.

Figure 17: Surge Comparison Test of 305-K01A

8. 305-K01B
Three tests are performed on 305-K01B and their results are shown below.

Winding Resistance Test:

Table 8.1: WRT Test Result
S.No Phases Contact Resistance
(Ω)
1 UV 0.365
2 VW 0.365
3 UW 0.366

Polarization Index Test:

Table 8.2: PI Test Result
S.No Time Resistance Ratio
(min) (GΩ)
1 1 19.5
5.42
2 10 105.8

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Surge Waveform Comparison Test:

Waves of all three phases are found Super Imposed.

Figure 18: Surge Comparison Test of 305-K01B

2. Motors of DHT (306):

Following motors have been checked by SIEMENS at NRL.
9. 306-K01A
Three tests are performed on 306-K01A and their results are shown below.

Winding Resistance Test:

Table 9.1: WRT Test Result
S.No Phases Contact Resistance
(Ω)
1 UV 0.219
2 VW 0.219
3 UW 0.219

Polarization Index Test:

Table 9.2: PI Test Result
S.No Time Resistance Ratio
(min) (GΩ)
1 1 14.0
5.2
2 10 72.8

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Surge Waveform Comparison Test:

Waves of all three phases are found Super Imposed.

Figure 19: Surge Comparison Test of 306-K01A

10. 306-K01B
Three tests are performed on 306-K01A and their results are shown below.

Winding Resistance Test:

Table 10.1: WRT Test Result
S.No Phases Contact Resistance
(Ω)
1 UV 0.216
2 VW 0.216
3 UW 0.216

Polarization Index Test:

Table 10.2: PI Test Result
S.No Time Resistance Ratio
(min) (GΩ)
1 1 14.1
4.7
2 10 66.3

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Surge Waveform Comparison Test:

Waves of all three phases are found Super Imposed.

Figure 20: Surge Comparison Test of 306-K01B

11. 306-P02B

Figure 21: 306-P02B

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Following motors of DHT (306) have been sent to TURBO for overhauling purpose:
12. 306-P01A

Figure 22: 306-P01A

13. 306-P13B

Figure 23: 306-P13B

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3. Motors of Boiler 8 (570, 313):

Following motors of Boiler 8 (570, 313) have been sent to SIEMENS for overhauling
purpose:

14. 313-P01

Figure 24: 313-P01

15. 570-P01

Figure 25: 570-P01

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Following motors of Boiler 8 (570, 313) have been sent to TURBO for overhauling
purpose:

16. 570-K01

Figure 26: 570-K01

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PROTECTION RELAYS INSPECTION

AND TEST PROCEDURE
Testing of Protection relays by secondary injection:
1. Testing Engineers should provide the commissioning manuals and have the detailed
understanding for testing and commissioning procedure.
2. All outputs / indications to be tested.
3. Initial tests of new protective relays must include operating characteristics checks for a
representative range of available settings with Company approved computer operated
test equipment running routines developed for the specific relay and test set involved.
4. Relay auxiliary devices such as external resistors, metrosils, etc. to be tested to
conform to required ratings and manufacturer’s information.
5. Final calibration test of all protective relays must be carried out on approved settings,
by secondary injection at the front panel mounted test facilities.
6. Auxiliary and tripping relay testing shall include,
7. Pickup and dropout voltage, verification of all contacts.
8. Operation timing at 80% and 100% nominal voltage.
9. Time delay relays shall be tested at 0%, set point and 100% delay.
10. Use of red and green tags for tested relays, meters, etc.
11. All the relays and meters which have been tested and found ok must have green tags.
12. The relays and meters found defective during tests should be tagged red.

OVER CURRENT RELAY

Over Current Pick-Up
♦ Apply the testing relays setting for over current on the relay as following.
 Definite Time Curve with minimum time delay.
 Disable all other protection elements.
♦ Connect the current test set on the relay current terminals one at a time as
following.
 Red phase to Neutral.
 Yellow phase to Neutral.
 Blue phase to neutral.
♦ Connect the timer to the relay tripping contact
♦ Slowly increase the current until the relay picked-up.
♦ Record the operating current.

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Operating Time Verification

♦ Apply the testing relays setting for over current on the relay as following.
 Disable all other protection elements.
 DT curve with 500ms delay.
 IEC SI curve with 0.1 TMS.
 IEC VI curve with 0.1 TMS.
 IEC EI urve with 0.1 TMS.
 IEC STI curve with 0.1 TMS.
♦ Select the time over current curve one at a time on the relay.
♦ Connect the current test set on the relay current terminals one at a time as
following.
 Red phase to Neutral.
 Yellow phase to Neutral.
 Blue phase to neutral.
♦ Connect the timer to the relay tripping contact.
♦ Inject testing current and monitor the operating time of the relay.
♦ Record the operating time.

Instantaneous Unit Verification

♦ Apply the testing relays setting for over current on the relay as following.
 Disable all other protection elements.
♦ Connect the current test set on the relay current terminals one at a time as
following.
 Red phase to Neutral.
 Yellow phase to Neutral.
 Blue phase to neutral.
♦ Connect the timer to the relay tripping contact.
♦ Slowly increase the current until the relay picked-up.
♦ Record the operating time.

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EARTH FAULT RELAY

Earth Fault Pick-Up
♦ Apply the testing relays setting for earth fault on the relay as following.
 Definite Time Curve with minimum time delay.
 Disable all other protection elements.
♦ Connect the current test set on the relay current terminals one at a time as
following.
 Any phase to Neutral.
♦ Connect the timer to the relay tripping contact
♦ Slowly increase the current until the relay picked-up.
♦ Record the operating current.

Operating Time Verification

♦ Apply the testing relays setting for earth fault on the relay as following.
 Disable all other protection elements.
 DT curve with 500ms delay.
 IEC SI curve with 0.1 TMS.
 IEC VI curve with 0.1 TMS.
 IEC EI curve with 0.1 TMS.
 IEC STI curve with 0.1 TMS.
♦ Select the time earth fault curve one at a time on the relay.
♦ Connect the current test set on the relay current terminals one at a time as
following.
 Any phase to Neutral.
♦ Connect the timer to the relay tripping contact.
♦ Inject testing current and monitor the operating time of the relay.
♦ Record the operating time.

Instantaneous Unit Verification

♦ Apply the testing relays setting for earth fault on the relay as following.
 Disable all other protection elements.
♦ Connect the current test set on the relay current terminals one at a time as
following.
 Any phase to Neutral.

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♦ Connect the timer to the relay tripping contact.

♦ Slowly increase the current until the relay picked-up.
♦ Record the operating time.

UNDER VOLTAGE PROTECTION RELAY

Under Voltage Verification
♦ Apply the testing relays setting with instantaneous tripping time on the relay
as following.
♦ Connect the voltage test set on the relay voltage terminals .
♦ Connect the timer to the relay tripping contact.
♦ Slowly decrease the applied voltage until the relay pick-up.
♦ Record the pick-up voltage.

Delay Time Verification

♦ Select the operating time on the relay
♦ Connect the voltage test set on the relay voltage terminals
♦ Connect the timer to the relay tripping contact
♦ Apply the testing voltage and monitor the operating time of the relay
♦ Record the operating time.

NEUTRAL OVER VOLTAGE PROTECTION RELAY

Neutral Over Voltage Verification
♦ Apply the testing relays setting with instantaneous tripping time on the relay
as following.
♦ Connect the voltage test set on the relay terminals.
♦ Connect the timer to the relay tripping contact.
♦ Slowly increase the applied voltage until the relay pick-up.
♦ Record the pick-up voltage.
Delay Time Verification
♦ Select the operating time on the relay
♦ Connect the voltage test set on the relay voltage terminals
♦ Connect the timer to the relay tripping contact
♦ Apply the testing voltage and monitor the operating time of the relay
♦ Record the operating time.

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