Instrumental Analysis 27-08-2023

Internship Report
By,
Rahulganth E N
21BEE0092
Restricted | © Siemens 2023 | Author | EL TPS AC |

Table of contents Page no
 SIEMENS MOBILITY- COBRA
3
9
 Rail Electrification
 Traction Power Supply

 AC and DC Traction
 Power Supply Configuration (AC)
 Overhead Equipment
 Testing Equipment Analysis
 ATS
 WESTRACE MKII
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SIEMENS MOBILITY- COBRA
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COBRA
 COBRA stands for Competitive Operation Business for Rail Automation.

 Siemens Mobility back in 2019 launched a project called COBRA (Competitive Operation
Business for Rail Automation) to help Siemens Mobility Rail Infrastructure to achieve this by
creating a new Centre of Competence for project execution.

Rail Electrification

Rail Electrification
Rail electrification team in siemens design the complete electrification,

process for a railway project. Electrification team gets the required
basic details of a project, prepares design according to the customer
needs and satisfies the siemens standards and sends it to the Head
Quarters and on site team. There are four main teams that comes
under electrification
1. AC traction power supply
2. DC traction power supply
3. Contact lines
4. Network control

TRACTION
POWER SUPPLY

CMCs are used in a variety of applications:
1. Substations
2. Power plants
3. Industrial plants
4. Distribution systems
5. Transmission lines
CMC Manufacturers:
1. OMICRON Energy
2. METREL
3. Megger
4. ABB
5. SEL

SECONDARY INJECTION KIT
FREJA:
• FREJA is a secondary injection test kit . It is a versatile and powerful tool that can be used to test a
wide range of protection relays and CTs. It features a powerful current source, a high-accuracy voltage
source, and a user-friendly control unit.
The working principle of the FREJA secondary injection kit is as follows:
• The current source in the kit generates the desired current.
• The current is injected into the secondary winding of the CT through the test leads.
• The current flowing through the CT's secondary winding creates a voltage drop across the CT's
secondary terminals.
• The voltage drop across the CT's secondary terminals is applied to the relay.
• The relay operates based on the voltage applied to it.
Advantages of using the FREJA secondary injection kit:
• It is a safe and convenient way to test relays.
• It can be used to test a variety of protection relays and CTs.
• It is a reliable and accurate tool.
• It is easy to use.

The FREJA kit is used to test the following aspects of a relay:
• Pickup current or voltage
• Time delay
• Hysteresis
• Directionality
• Timing
Freja Manufacture:
• Megger
• OMICRON Energy
• Seaward Electronics
• SELECTRIX

Sweep Frequency Response
Analyzer (SFRA)

SFRA:
Sweep Frequency Response Analyzer
• Frequency response analysis is a powerful and sensitive method for testing
the mechanical integrity of transformer cores, windings, and press
frames, in power transformers.
PRINCIPLE
• An SFRA instrument sends a signal into the transformer winding at a
number of discrete frequencies and measures the returning signals.
SFRA is typically performed in a frequency range of 20 Hz up to 2 MHz and
output voltages between 0.1 and 10 V are used.
Three methods are commonly used to assess the measured traces:
• Time-based – current SFRA results will be compared to previous results of the
same unit.
• Type-based – SFRA of one transformer will be compared to an equal type of
transformer.
• Phase comparison – SFRA results of one phase will be compared to the
results of the other phases of the same transformer.

• Since the signal are measured to dispersed to the transformer tanks we will make
connection between busing flanch and c clamp
• 45 degree of the response trace is a indicating of good instrument condition

Problem detection
• Winding deformation – axial & radial, like hoop buckling, tilting,
spiraling
• Displacements between high and low voltage windings
• Partial winding collapse
• Shorted or open turns
• Core movement
Uses
• To obtain initial signature of healthy transformer for future
comparisons
• Periodic checks as part of regular maintenance
• Immediately after a major external event like short circuit
• Transportation or relocation of transformer
• Studying earthquakes
• Pre-commissioning check

Insulating Oil Test Set
(Breakdown Voltage Test)

IOTS(BDV):
• Insulating Oil Test Set (Breakdown Voltage Test)
• OTS BDV test means the Breakdown Voltage Test. This test is performed for
verifying the dielectric strength of the oil of the transformer. Dielectric
Strength is the maximum capacity to resist the voltage of insulating oil. This test
demonstrates the dielectric Strength of Transformer Oil.
PRINCIPLE :
• A sample of the insulating oil is taken from the drain valve of the transformer and
its breakdown voltage is measured. A test voltage is applied to the electrodes
immersed in the insulating oil and is gradually increased up to the breakdown
voltage with a constant, standard-compliant slew rate .
• Timer of 60 seconds is provided for conducting withstand tests.
• This measurement is taken 3 to 6 times in the same sample of oil, and we take
the average value of these readings
• The BDV test kit is basically a high voltage unit and the voltage can be regulated
from 0–70 KV. The BDV tester has two electrodes separated by 2.5 mm
distance( 4.00 mm separation units are also available).

Transformer Oil Types
There are two main types of transformer oil used in transformers:
• Paraffin based transformer oil
• Naphtha based transformer oil
paraffin-based oil is still commonly used in many countries (such as India) due to its high
availability.

Steps for Transformer oil BDV Testing
1. Collect the 300-400 ml oil sample of transformer oil from the bottom valve of the transformer in a
glass or plastic vessel.
2. Pour the oil sample in oil pot of the machine.
3. Keep the oil pot in open air for 5 Minutes so that air bubble if any gets out. Further,the vessel should
be disturbed to get out of the air bubbles and for homogeneous distribution of impurities.
4. Now put the oil sample in the machine.
5. Increase the KV at the rate of 2 KV/Sec and observe the oil sample through a glass window.
6. Continuously observe the oil sample through an inspection window while increasing the voltage.
7. Note down the KV at which sparking is observed in the oil. The voltage at which sparking observed is
the breakdown voltage of oil.
8. Repeat the step No. 4,5,6 and 7 for the same sample for six times and note down the breakdown KV
in each case.
9. Take the average of BDV values observed in step 7 and 8.
10. If oil BDV value is above 30 KV, transformer oil is good.

Important’s of Transformer Oil Testing
• Determine essential electrical properties of transformer oil
• Identify if a certain oil is suitable for future use
• Detect whether regeneration or filtration is needed
• Reduce oil costs and enhance component life
• Prevent untimely failures and maximize safety
APPLICATION
• OTS completely self contained, compact & portable unit giving smooth variable output
voltage from zero to 60/80/100KV for testing the dielectric strength of insulating oil.
• The set has been specially designed for testing the dielectric breakdown Voltage of
insulating liquids as per the directions mentioned in IS 6792.
MANUFACTURERS

Load Bank

LOAD BANK:
• A load bank is a device that generates a prescribed amount of
electricity draw to test the reliability of electrical switching,
generator output, uninterruptable power supply (UPS) systems and
cooling in a data center.
PRINCIPLE:
• The load bank applies an electrical load to the power source and
dissipates the resulting electrical energy through resistive elements
as heat.
Load bank types:
• Resistive load bank
• Inductive load bank
• Capacitive load bank
• Resistive Reactive (Combined) load bank
• Electronic load bank

Resistive load bank
• A resistive load bank, the most common type.
• Provides equivalent loading for both generators and prime movers.
Inductive load banks
• This provides the capability to test the generator set fully at 100% nameplate kVA rating.
• Inductive load banks add inductance to the load and therefore reduce the PF to less than unity (typically 0.8pf on
diesel gen-set).
Capacitive load bank
• combination of several capacitors are connected in series or parallel connection with the same rating then it is called a
capacitor bank.
• There are three types of capacitor banks which are discussed below Internally Fused,Externally Fused,Fuse Less.
Resistive Reactive (Combined) load bank
• A combined load bank usually consists of both resistive elements and inductors that can be used to
provide load testing at non-unity PF (lagging) including the capability to test the generator set fully at
100% nameplate kVA rating
Electronic load bank
• An electronic load bank tends to be a fully programmable, air- or water-cooled design used to simulate a solid state
load and to provide constant power and current loading on circuits for precision testing.
APPLICATION
• Factory testing of turbines and engine diesel generator sets
• Battery and UPS system testing
• Ground power testing
• Load optimization in prime power applications
• Removal of carbon build-up on generator piston rings
MANUFACTURERS:

High Voltage Discharge Rods

HVD RODS
• High Voltage Discharge Rod.
• The rod can eliminate a post charging effect by almost instantly removing the cable charge.
The discharge rods are made of GFK (fiber glass strengthened plastic), come with a
handle, and have a conservatively rated clearance against physical contact with high
voltage.
PRINCIPLE:
• It's tip houses a live conductor, and the rod features a discharge resistor that limits the
discharge current and ensures a damped discharge. The rod can eliminate a post charging
effect by almost instantly removing the cable charge. After 5 - 10 τ (max. 5 s) the voltage
has dropped.
APPLICATION:
• safe discharging
• earthing/grounding of high voltage cables
• perfect for damped discharge and direct
• visible earthing/grounding.

MANUFACTURERS

Micro Ohmmeter
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Micro Ohmmeter
DLRO:
• DLRO stands for Digital Low resistance Ohm Meters. It works based on four
wire, kelvin probe system.
Working Principle:
When an ohmmeter applies current to the circuit or component, it measures the resulting voltage and calculates the
resistance value using ohms law.
This instrument is used to measure resistance across a resistor and we can identify the type of winding in the
component we measure from.
• We can also measure whether the winding is open winding or short
winding.
• Open winding will be displayed as OL in ohmmeter.
• Short winding will be displayed as 0 ohms , or as lower winding
resistance than the normal winding resistance value in the ohmmeter.

• This device can measure resistances of 0.1 micro ohms- upto 2000 ohms
• The handspikes can be made as per the requirement of the consumer i.e the no.of leads, length of
wire etc.
• The fuse voltage varies across 600V.
• The device can measure continuity of potential and current connections.
• Nowadays the device is made in order to easily wear around the neck and measure req.
parameters.
• It has a Li-Ion or Ni-Mh battery which is interchangeable.
Top Manufacturers

CB Analyzer

CB Analyzer(Circuit Breaker Tester)
Function :
• It evaluates the mechanical integrity of the circuit breaker under various
parameters. It operates the circuit breaker under fault current conditions.
Working Principle:
• After the finishing of testing of the breaker, it measures all the parameters of the
breaker and using a set algorithm. It diagnoses the condition of the device under
various conditions.
The CB Analyzer measures the following values:
Timing Measurements
• Timing tests are used to determine the time taken for open (trip), close, close-open,
and reclosing operations.
Motion Measurements
• It is used to reveal the performance by evaluating the velocity of the main contacts
when traveling through the arcing zone .
Vibration Analysis
• It is done using accelerometers which work like microphones to record the sound
when contact gets open and closed.
• Generally, a reference signature is used to analyze the vibrations in the CB. If a reference signature isn’t
available, we get a reference signature from another CB analyzer of the same type. If the curve diverges
above 10 db., and the time shift is above 8 ms the CB is no longer in optimal working condition.
Static Resistance Measurement (SRM)
• Static resistance measurement (SRM) of circuit breaker contacts was developed to assess the resistance of
the main contacts since during this condition the arcing contacts are bypassed.
• The minimum level of DC current that we will be using will be 50A (set by IEC).
• Static contact resistance is measured by injecting a DC current through the breaker and measuring the milli-
voltage drop. A four-wire measurement method is used. The breaker must be in the closed position. It is
recommended to test the contacts at a higher current (80-100A). A higher current will have the ability to
overcome connection issues and oxidation on terminals, whereas a lower current (~50A) may not produce
accurate readings under these conditions
Dynamic Resistance Measurement (DRM)
• Dynamic resistance measurement (DRM) of circuit breaker contacts was developed to assess the condition
i.e., resistance of the arcing contacts without dismantling a breaker.
• This method is a better solution for the limitations faced in static resistance measurement.
• Here 100A DC current is injected through the breaker. We cannot measure the dynamic resistance during
the open-close operation of the contacts since there will be sudden variation in arcing contacts resistance
which is impractical.
• The contact movement is recorded by a linear contact travel sensor where the resistance at each point of
contact can be calculated if the movement is recorded.
• Generally, a sampling frequency e.g., 10kHz is used to measure the dynamic resistance in each time
period. The resistance measurement and the current transfer from arcing to main contacts are recorded
once in 100 microseconds.
• This method is also is used to measure the length of the arcing contacts.
Structural diagram of
Contactor
Connection Diagram

This diagram represents the complete DRM and
SRM in graphical form which includes various
instances and parameters which this method
measures.
Coil Current
Here we have 2 tests in general i.e., Trip Coil Test and Close Coil Test. We need to analyze the coil currents flowing
through the coils which will be responsible for the opening and closing of the contactor coils.
• Trip Coil Test
The analyzer will measure the time taken by the circuit breaker to trip after applying certain amount of current to the trip
coil (open coil).
• Close Coil Test
The analyzer will measure the time taken by the circuit breaker to close after applying certain amount of current to the
close coil.
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Top Manufacturers

VLF Test Instrument (69 KV)

VLF Test Instrument (69 KV)
Function:
• This instrument is used to measure the insulation integrity of the medium and high
voltage cables.
Working Principle:
Applying a sinusoidal waveform with a frequency typically ranging from 0.01 Hz to 0.1
Hz to the insulation of medium and high voltage cables.
The main purpose of the instrument is to detect any insulation weakness, stress
uniformity, provide preventive maintenance
• The VLF Testing Instrument involves applying a sinusoidal waveform along with very
low frequency which enables testing without causing any excessive stress on the
cable.
• This device can also be used to provide voltage boost, over-voltage protection
and under-voltage protection, step down, measurement (operates like CB) to an
electrical device
• The device is used to evaluate the insulation integrity mainly for Power Cable,
Rotating Machinery such as Generators, Motors etc

Example connection diagram of VLF testing instrument from Megger

Applications:
The VLF Testing Instruments are used in various areas
such as,
• Utility based Industries,
• Telecommunications and
• Industrial manufacturing for Cable system maintenance
and Diagnosis.
Top Manufacturers:

Comparison of CPC 100 and VLF Testing Instrument
Feature CPC 100 VLF test set
Voltage range Up to 100 kV Up to 69 kV
Frequency range 15 Hz to 400 Hz 0.1 Hz to 0.01 Hz
Current transformer (CT), voltage
transformer (VT), power transformer,
Test types Power cable, rotating machinery
grounding system, lines and cables, circuit
breaker
Power plants, substations,

Power plants, substations, distribution
Applications distribution networks, electrical
networks, testing laboratories
equipment manufacturing facilities
Portable and easy to use, can be

Versatile and powerful test system, can be used to test long cables and large
used to perform a wide variety of tests on generators, can be used to
Advantages
electrical equipment, portable and easy to perform off-line partial discharge
use and tan delta cable diagnostic
testing
Not as versatile as CPC 100, can
More expensive than VLF test set, not as
Disadvantages only be used to test power cables
specialized as VLF test set
and rotating machinery

CT Analyzer

CT Analyzer:
What is CURRENT TRANSFORMER:

• The current transformer is an electrical instrument where it is used
to measure current in electrical circuit.
• It consist of iron core which has a coil of wire wrapped in both
primary and secondary side.
• Current passes through primary winding and magnetic flux induces
electrical current and taken as output in secondary side

What is CT Analyzer:
• It is the power system device and used to test and assess the
performance of current transformer.
• It measure excitation curve and knee point.
• The CT Analyzer automatically determines all relevant current
transformer values and compares the results with the selected
standard.
Where it is used:
• The CT Analyzer are used by manufacturer of current transformer

• It also used in place were high voltage current transformer

PURPOSE OF CT ANALYZER:
• The purpose of CT Analyzer is to check the knee point, saturation
curve, CT ratio and CT phase angle.
• It include in providing overload protection for equipment which are
operating at hight current.
• It reduce the testing time and increase productivity.
Companies Producing CT Analyzer:
• According to the need and uses there are some companies
manufacturing CT analyzer
1.Megger
2.OMICRON Energy
3.METREL
4.HIOKI
5.Chroma ATE

Megger

MEGGER
• MEGGER (INSULATION RESISTANCE Measurement Device).
• Megger works on the principle of electromagnetic attraction.
• A megger is an insulation resistance tester.
• Insulation Resistance of an electrical equipment should be high
enough to prevent the flow of current through the insulation.
Why Megger Testing is Done?

• An electrical system degrades with time, environment condition i.e.
temperature, humidity, moisture and dust particles.
• It is very necessary to check the IR (Insulation resistance) of
equipment at a constant regular interval to avoid any measure fatal
or electrical shock.

Types of Megger Test:
1. Electronic type
2. Magnetic type
Companies manufacturing Megger(IR):

3. Megger
4. HIOKI
5. METREL

HVHI-Pot

HV HI-pot:
• HV and Hi-pot are (high voltage and high potential tester)
Working principle:
• HV-HIGH VOLTAGE
• HIPOT- high potential or high voltage test
• The HVHI-pot works under the principle of dielectric breakdown, the
point at which an insulator fails to prevent the flow of electricity.
• Hi-pot testing is an important part of electrical safety testing.
• The insulation of the equipment being tested resists the flow of
current, and the amount of current flow is measured.

DIFFERENCE BETWEEN HIPOT AND MEGGER
Feature Hipot test Megger test

Definition High-voltage test Low-voltage test
Check for insulation Measure insulation

Purpose defects resistance
High voltage, typically Low voltage, typically 500

Voltage 1,000 to 10,000 volts to 10,000 volts
High current if insulation

Current is damaged Low current
Application Electrical safety testing Quality control testing

Companies manufacturing HVHI-POT:
1. Pot-Tech electronic
2. Vishay Intertechnology
3. Bourns
4. ALPS Alpine

Conclusion
All the instruments have been studied based on their functions, working principle,
applications and manufacturers.

Instrumental Analysis 27-08-2023

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Internship Report

Restricted | © Siemens 2023 | Author | EL TPS AC |

 Traction Power Supply

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 COBRA stands for Competitive Operation Business for Rail Automation.

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Rail electrification team in siemens design the complete electrification,

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• 45 degree of the response trace is a indicating of good instrument condition

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Power plants, substations,

Portable and easy to use, can be

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What is CURRENT TRANSFORMER:

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• The CT Analyzer are used by manufacturer of current transformer

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Why Megger Testing is Done?

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Companies manufacturing Megger(IR):

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• HV and Hi-pot are (high voltage and high potential tester)

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Feature Hipot test Megger test

Check for insulation Measure insulation

High voltage, typically Low voltage, typically 500

High current if insulation

Application Electrical safety testing Quality control testing

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