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DC&ACVoltageTestingof ElectricalEquipments

Vivek Jha
1

Presentationoutline
y Introduction y DCtestingofInsulation: y DCTestingMethods y DCTestingApplications y ACTesting: y PowerFactorandDissipationFactorTest y ACTestingApplications y Conclusion

Introduction

NeedofMaintenance&Testing
y Tolengthenthemeantimebetweenfailures(MTBF)of theelectricalequipment. y Reducedcostofrepairs y Reduceddowntimeofequipment y Improvedsafetyofpersonnelandproperty.

ROLEOFMAINTENANCEMANAGEMENT
TO BALANCE BETWEEN
COST OF MAINTENANCE PLANT AVAILABILITY

MAINTENANCE MANAGEMENT
22 November 2010 5

Differentapproachesto maintenance
y y y y y

RuntofailureorReactivemaintenance: Inspectandserviceasnecessary TimeBasedScheduledpreventivemaintenance ConditionBasedPreventiveMaintenance Reliabilitycenteredmaintenance(RCM)

22 November 2010

22 November 2010

Rulesofmaintenance
y y y y

Keepitdry Keepitcool Keepitclean Keepittight

22 November 2010

CausesofInsulationDegradationandFailureModes ofElectricalEquipment
y y y y

Mechanicalstress Thermalstress,hotspots Environmental(moisture,chemicals,dirt,andoils) Electricalstresses(corona,surges,andpartialdischarges)

TEAM Stresses
Temperature Electrical Ambient Mechanical

10

Insulation Strength noTEAMtransients


Insulation Strength
Good design, manufacture & O&M: significant margin

Poorer design & manufacture- faster rate of decline Insulation Spare Margin

Insulation Stress
New Increasing Age Old

Insulation Strength withTEAMtransients


Insulation Strength Insulation Spare Margin Reducing Strength with time and after incidents

Failure Insulation Stress


New

Incidents

Increasing Age

Old

Typesoftests
y y y y

FactoryTests Acceptancetests Routinemaintenancetests Specialmaintenancetests

InsulationasaCapacitor

14

InsulationasaCapacitor
Thedielectricconstantofaninsulatorisanindicationofhowmuchdielectric fluxtheinsulationwillallowthroughit.Underidenticalconditionsinsulation withahigherdielectricconstantwillpassmoredielectricflux throughitthan anotherinsulationhavingalowerdielectricconstant

15

InsulationasaCapacitor

PerfectInsulator

16

InsulationasaCapacitor

PracticalInsulator

17

InsulationTest:ACorDC?

18

InsulationTest:ACorDC?

19

InsulationTest:ACorDC?

20

InsulationTest:ACorDC?

21

DCtestingofInsulation

22

Introduction:DCtests
InformationprovidedbyDCTestswillbebasisfor:
y Decisionmakingaboutcorrectivemaintenance/replacement needed y Decisionmakingaboutenergizingthenewequipment y Recordingtrendofgradualdeteriorationovertime

23

DCvoltageApplicationtoInsulation
WhenDCvoltageisappliedtoinsulation,currentdrawnby insulationcanbeanalyzed3components: y Capacitancechargingcurrent y Dielectricabsorptioncurrent y Leakagecurrent

24

DCvoltageApplicationtoInsulation

Capacitancechargingcurrent
Charging current
E ic= --e-t/RC R

E=VoltageinKV R=ResistanceinM C=capacitanceinF t=Timeinsec.

Itisinitialchargingcurrentwhenvoltageisapplied Itisafunctionoftime,anddecreasesastimeofapplication increases Testreadingsshouldnotbetakenuntilthischargingcurrentdecreases toquitelowvalue

DielectricAbsorptioncurrent
Absorption current ia= K ECt-n
E=VoltageinKV K=proportionalityconstant C=capacitanceinF t=Timeinsec. n=constant

Initiallyhigh(notashighascapacitancechargingcurrent) Decreaseswithtime(ataslowerratethancapacitancechargingcurrent) chargingcurrentwhenvoltageisapplied Itisafunctionoftime,anddecreasesastimeofapplication increases Testreadingsshouldnotbetakenuntilthisabsorptioncurrentdecreasesto quitelowvalue

Leakagecurrent
Itisthecurrentwhichflowsthroughvolumeof insulation thisisthecurrentthatisusedtoevaluatethe statusofinsulationsystem. chargingcurrentwhenvoltageisapplied Testreadingsshouldbetakenonlyafter stabilizationofthisleakagecurrent.

AdvantagesofDCVoltageTesting
y Preferredforequipmentshavinghighchargingcurrent, suchascables y DCvoltagestressismuchlessdamagingascomparedto ACvoltages y TimeofvoltageapplicationisnotascriticalasACvoltage y Historicaldatacanbecompiledaccuratelyfor comparison y SizeandweightofDCtestequipmentissignificantly reducedascomparedtoACtestequipment
29

DisadvantagesofDCVoltageTesting
y Stressdistributionforelectricalequipmentsisdifferent underACvoltage y Defects,untraceablewithDC,cansometimescause failureunderAC y DCTestresultsareaffectedbytemperatureand humidity. y ResidualchargeafterDCtestshouldbecarefully discharged

30

DCTestingMethods

DCTestingMethods
TwotypesoftestsaredonewithDCvoltageapplication:
Insulationresistancetesting(IR) Highpotentialtesting(HiPot)

32

DCTestingMethods InsulationResistanceTesting
Testvoltageapplication:100 15000v Instrumentused:Megohmmeter

(hand/motor/electronic) Allreadingstobecorrectedtostandard temp,bycorrectionfactortable M valueisinverselyproportionalto volumeofinsulationundertest IRvaluebythemselvesdonotindicate weaknessorstrength,theycanindicate troubleifdownwardtrendcontinues further

DCTestingMethods InsulationResistanceTesting
FourcommonIRtestmethods: y ShortTimeReadingsorSpotchecking y DielectricAbsorptionRatiotest y PolarizationIndexTest y StepVoltageReadings

34

ShortTimeReadings
y Thistestsimplymeasurestheinsulationresistancevalueforashort

durationoftime,throughaspotreading. y Thereadingonlyallowsaroughcheckoftheinsulationcondition. y Readingscanbeusedforcomparisonofthisvaluewithpreviousvalues.A continueddownwardtrendisindicativeofinsulationdeteriorationahead. y Forinterpretingtheresults,thevaluesusedforcomparisonshouldallbe normalizedto20C.

35

DCTestingMethods TimeResistanceReadings: DielectricAbsorptionRatiotest


y Agoodinsulationsystemshowsacontinuedincreaseinitsresistancevalueover

theperiodoftime.Ontheotherhand,aninsulationsystemthat iscontaminated withmoisture,dirt,etcwillshowalowresistancevalue. y Ingoodinsulation,theeffectsofabsorptioncurrentdecreasesastimeincreases.In badinsulation,theabsorptioneffectisshownbypersistinghighleakagecurrent. y Thetimeresistancemethodisindependentoftemperatureandequipmentsize. Theratiooftimeresistancereadingscanbeusedtoindicatetheconditionofthe insulationsystem. y Theratioofa60sreadingtoa30sreadingiscalledtheDAR(DielectricAbsorption Ratio)
DAR Resistancereadingat60s Resistancereadingat30s:

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DCTestingMethods PI(PolarizationIndex)Test
y ThePItestisaspecializedapplicationofthedielectric absorptiontest.Thistestisusedfordryinsulation.

PI =

insulation resistance at 10 min insulation resistance at 1 min

37

DCTestingMethods StepVoltageTest

LEAKAGECURRENTinA

Breakdown of insulation system

VOLTAGEINKV

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DCTestingMethods Highpotentialtesting(HiPot)
y DCvoltageappliedacrosstheinsulationatoraboveDC equivalentofpowerfrequencyACvoltage y Testcanbeappliedasgradual testorstepvoltagetest y Ingradualtest,maxvoltageisappliedslowly,gradually andmaxvoltageisheldforaperiod.Leakagecurrent readingsarerecorded. y Instepvoltagemethod,maxvoltageisappliedinsteps andreadingstakenateachstep.

39

DCTestingApplications

DCTestingApplications:Transformers
Testprocedure y Donotdisconnectgroundconnectiontotank y DisconnectallHV,LV,neutralconnections,cooling system,meters,LAandotherLVcontrolsystem y HV/LVjumpersshouldnottouchmetalorgroundedparts

41

Testconnectionsfor3phtransformer HVtoLV&Earth

42

Testconnectionsfor3phtransformer HVtoLV&Earth
Megohmmeter

Guard

Line

Transformer

Earth

H1

X1 H2 X2 H3 X3 X0

Testconnectionsfor3phtransformer HVtoEarth,LVGuarded
Megohmmeter

Guard

Line

Transformer

Earth

H1

X1 H2 X2 H3 X3 X0

Testconnectionsfor3phtransformer LVtoEarth,HVGuarded
Megohmmeter

Guard

Line

Transformer

Earth

H1

X1 H2 X2 H3 X3 X0

Megohmmeter

Guard

Line

Earth

46

Megohmmeter

Guard

Line

Earth

47

Megohmmeter

Guard

Line

Earth

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InterpretationofDCtestreadings

InterpretationofDCtestreadings
Dctestresultscanserveasguidetodecideoneofthe followingactions:
Puttheequipmentintoservicetillnextscheduled inspection y Puttheequipmentintoservicenow,butplanto repair/replaceassoonaspossible y Puttheequipmentoutofservice
y

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InterpretationofDCtestreadings
Howtodeterminewhetherinsulationisgoodorbad:
y Manufacturersinformation y Comparisonwithvaluesobtainedduringinstallation y Comparisonwithvaluesfrompreviousroutinetests y Comparisonwithvaluesofsimilarequipment y Ruleofthumb:
y Min1M /ratedKV+1M y Never<1M inanycase

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InterpretationofDCtestreadings
Morerulesofthumb:
y Fortransformers,MinIR=(CE)/ kVA
IR=wdg toEarthM,E=voltagerating,kVA =ratedkVA C=constant
valueofC Trafo type valueofCat20 degC oilfilled 1.5 Drytype 30

y Forcables,MinIR=Klog10 (D/d)
IR=cond.to EarthM per100ftofcable D=outsidedia ofcond insulation k=constantforinsulatingmaterial,d=dia ofconductor

MinvalueofK Impreg paper polyethylene Syntheticrubber XLPE 2640 2000 2000 20000

52

Acceptancecriteriaforjudginginsulation
Nominalvoltageclass 600v 7.2kv 15kv 33kv 72kv 242kv 550kv Typicalsystemvoltage MinacceptableIRvalueat 200 C(M) 120/240/440v 6.9kv 11kv /138kv 33kv 69kv 220kv 500kv 1.5 8.2 14.8 35 70 231 501

Resistancesabovedonotnecessarilyindicatesoundinsulationcondition,butonlythatthe equipmentmaybeenergizedwithoutsignificantriskoffailure

53

InterpretationofDCtestreadings
y Aclean,dryinsulationinexcellentconditionshouldhave resistanceseveraltimesthemin.value y IRvaluehaslittlesignificanceononetime,absolutevalue basis.Longtermtrend indicatesprogressivedeterioration y Toallowmeaningfultrending,influenceoftemp, humidityshouldbeminimized

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ACVoltageTestingof ElectricalEquipments:PFTest

Vivek Jha
55

Introduction
y Powerfactor(PF)anddissipationfactor(DF)testsare conductedinthefieldforacceptanceandfieldmaintenance testingofinsulationofelectricalequipments. y PurposeofACTests:
y Identifyiftheequipmenthasbeeninstalledcorrectly y Determineneedforcorrectivemaint/repair y Trackthegradualdeteriorationoftheequipment

y WhyACtests:Givesbestinfoaboutequipmentcondition

(neartrueoperatingconditions)

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Introduction
y VarioustypesofACvoltagetests:

PowerFactor(PF)andDissipationFactor(DF)Test y ACHighPotentialTest y 0.1HzVoltageTest PowerFactor(PF)andDissipationFactor(DF)Testisthemost widelyusedtest.Itisconsiderednondestructivetestbecause testvoltagesnormallydonotexceeddesignedvoltageof equipment. ACHipotisconsidereddestructivetestandshouldnotbe repeatedfrequently


y
57

58

PowerFactorandDissipationFactorTest
y Usedsinceearly1900s y BasedonScheringBridge y ThetestusesACandpursuestoknowlossangleofthetestedequipment,to y y y y y y

knowtheconditionofinsulation. Thetestprovidesinformationonoverallconditionofinsulation intheformofa ratio(PForDF)whichisindependentofthevolumeofinsulationbeingtested. Provideassessmentofinsulationundernormalfrequencyworking condition, whicharenottimedependentlikeDCtests Thetestdoesnotoverstresstheinsulation Providehandytoolforcomparisonwithsimilarequipments Itisimportanttotakenoteoftransformertemperatureandenvironmental moisture(surfaceleakage). ThistestissometimesreferredasDoble Test becauseofhistoricalsignificance ofDoble testkit.
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PowerFactorandDissipationFactorTest: PrincipleofPF/DFTest
PFandDF y ThePF ofinsulationisdefinedastheratioofwattloss tototalchargingvoltamperes,orthecosine ofthe angle betweentotalcurrentvector(IT)and the impressedvoltagevector.Itisameasureoftheenergy component(resistivecomponent)ofthecharging current. y TheDF isdefinedastheratioofthewattlossto chargingamperes,orthetangentoftheangle betweenthetotalcurrentvectorandthecapacitive currentvector.Theangle isthecomplementaryangle ofthePFangle.

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PowerFactorandDissipationFactorTest
y Ic =V/Xc
=VC

y PF=cos ,DF=tan
Forverysmall,PF=DF

y Changesincapacitivecurrentindicate insulationdegradationduetomoisture, shortedlayers,changedgeometryetc y Changesinresistivecurrentindicatescarbon tracking,volumetricleakage,surface conduction,coronaetc

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Example
y insulationofPF=1.0%.

y PFisapproximatelyequaltoDFwhenPFandDF<10.0%,thatis y Cos=tan=cotan y cos(89.43)=tan(0.57)=0.01(1%)

62

FactorsthatinfluencePFmeasurement
y Changesininsulationqualityresultinmeasurablechangesinsomeofthe

basicelectricalcharacteristicsoftheinsulation,suchascapacitance, dielectricloss,orPF.Therefore,bymeasuringtheseelectrical characteristicsovertime,changesintheintegrityoftheinsulationcanbe assessed,ThemainfactorsinfluencingPFmeasurementare:


Temperature y Humidity y Surfaceleakage
y

y Itisnecessarytonormalizetheresultstoacommonbasetemperature y Equipmentshouldberetestedifambienttempistoohighortoolow y PFtestsshouldnotbeperformedfordetectionofpresenceofmoisturein

theinsulationwhenthetemperaturesaremuchbelowfreezing,

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PFTestEquipment
Cs = standard reference capacitor Cx = insulation under test A voltage is applied to both CS and CX. The ratio arms, Ns and Nx are adjusted to balance capacitive current, and the variable resistor Rs is adjusted to balance resistive current. The null indicator is used to determine when the bridge circuit is balanced. The values of Ns and Nx are used to determine capacitance and the value of RS correlates to power ( dissipation) factor of the test insulation. Safety features, self diagnostic and calibration check facility is provided in the kit
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GeneralprocedurefortheOperationofthePFTestSet
1.Assemblethetestsetinaccordancewiththeoperatinginstructionmanual. 2.Connectgroundleadfromthetestsettoastationground. Caution:PFtestsareperformedonlyondeenergizedandisolatedapparatus.Verifythe equipmentisclearedbeforeattemptingtoconnectleads. 3.Preparethespecimenfortesting.Thismayincluderemovingexternalconnections,shorting windingterminals,etc. 4.Connecttestleads:firsttothetestset,thentotheapparatustobetestedfollowingthe instructionsintheoperatingmanual. 5.Checkoperationofsafetyandgroundinterlocksifsuppliedonthetestset. 6.Selectthepropertestconfigurationfortheinsulationtobe measured. 7.Initiatevoltageoutputfromthetestset.Raiseoutputvoltagetothedesiredlevel. 8.Continueoperationofthetestsettoobtaintestreadings,followingthespecificinstructionsin theoperatingmanual.BalancethebridgeforcapacitanceandPF. 9.Reducevoltagetozero,orlowestsettingandcutoffvoltage output. 10.Recordallvaluesasprovidedbythetestset:testvoltage, current,wattsloss,capacitance, andPF.

65

BasicTestConnections(TestModes)forPFTesting
y GroundedSpecimenTestMode(GST) y GSTModewithGuard(GSTG) y UngroundedSpecimenTestMode(UST)

66

BasicTestConnections(TestModes)forPFTesting
GroundedSpecimenTestMode(GST)

67

BasicTestConnections(TestModes)forPFTesting
GSTModewithGuard(GSTG)

68

BasicTestConnections(TestModes)forPFTesting
UngroundedSpecimenTestMode(UST)

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SafetyPrecautionswithPFTesting
y AllPFtestsareperformedwiththeapparatustobetestedcompletelyde

energized andisolatedfromthepowersystem.Inaddition,theapparatus housingortankmustbeproperlygrounded.Thereisnosubstitutefora visualchecktoensurethattheapparatusterminalsareisolatedfromthe powersource y Safetygroundsshouldbeappliedtoallapparatusterminalsbeforedoingany workonthem,andbeforeconnectinganddisconnectingthePFtestleads y operatorshouldhaveanunobstructedviewoftheapparatusundertestand ofvariouspersonnelassistinginthetests. y properclearanceshouldbemaintainedbetweenthetestsetandapparatus; itshouldberecognizedthatdamagedordefectiveapparatusmayfailduring test.

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SafetyPrecautionswithPFTesting..
y Testsetsshouldhavegroundrelay thatpreventstestvoltagebeingapplied

until:
1.Aheavydutysafety(stationground)hasbeenappliedtothegroundreceptacleof thetestset. 2.Thetestcasehasbeengroundedthroughthepowersupplycord. 3.Thevoltagecontrolisatthefullycounterclockwise zerovoltageposition

y Donotconnecttestleadstotheapparatusterminalsunlesstheleadsare

alreadyconnectedtothePFtestset. y Beforemakingthefirsttest,bothsafetyswitchoperationshouldbechecked y Nevershortcircuitsafetyswitch y Theheavydutytestsetgroundisthelastleadtoberemovedfromthetest set.

71

ApplicationsofPFTest

ApplicationsofPFTest
y PFtestingisnormallyusedforacceptancetesting,preventing maintenance,andpostmaintenanceinsulationassessment,and forconditiontrending. y ThetestvoltageusedforPFtestingshouldbesufficientto detectanylatentweaknessesintheinsulation,butsincethe testisintendedtobenondestructive,thevoltageshouldnot exceednormallinetoneutralorlinetogroundoperating voltageoftheapparatusundertest.

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ApplicationsofPFTest:Transformers

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ApplicationsofPFTest:Transformers

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ApplicationsofPFTest:Transformers
Calculationofresults: Test1minustest2
1.Subtractchargingcurrentoftest2fromtest1 2.Subtractwattlossoftest2fromtest1 3.ThencalculatetheCHLandPF,thatis[CH+CHL][CH]=CHL

Test3minustest4
1.Subtractchargingcurrentoftest4fromtest3 2.Subtractwattlossoftest4fromtest3 3.ThencalculatetheCHLandPF,thatis[CL+CHL][CL]=CHL

y ThecalculatedvalueofCHLfromtheabovecalculationshouldbesame.Ifit

isnotthenthereiseitheranerrorinthetestresultsorthecalculations

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ApplicationsofPFTest Bushings

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ApplicationsofPFTest:Bushings

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ApplicationsofPFTest RotatingMachinery:PFmeasurementofPhaseto groundinsulation.

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ApplicationsofPFTest RotatingMachinery:PFmeasurementofInterphase (Endturn)insulation.

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PFtest:Shieldedcables

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EvaluationofPFandDFTestResults
y Fourcategories:

1 GoodInsulation :conditionisgoodandsuitableforcontinuedservice 2 DeterioratedInsulation :conditionissatisfactoryforservicebutshouldbe checkedwithinsixmonthstoseeiftheconditionhasfurtherdegraded 3 MarginalInsulation :conditionisnotsatisfactoryforserviceimmediate investigationofthedegradedconditionsshouldbebegunandifthisisnot possiblethenitshouldbebegunassoonaspossible 4 BadInsulation:Removefromserviceandreconditiontorestoreinsulation togoodcondition,ifnotpossible,thenreplaceThe

86

EvaluationofPFandDFTestResults
y Referencesforevaluatingtestresults:
Manufacturersrecommendations y yeartoyeartestresults y Resultsofsimilarequipments
y

y Wheneverthetestresultsarequestionableormarginal,itisgenerally

recommendedtoperformtestsonmorefrequentbasis
y AgradualandconsistentincreaseinPFmaybeduetocontamination,

deterioration,ornormalaging,whereasasuddenincreaseinthePFisa causeofimmediateconcernevenwhentheabsolutePFvalueisnot consideredexcessive


87

TypicalofmaximumallowablePFvalues*
Equipment TypicalmaxallowablePF valuesat20DegC 0.5% maybeupto1%forold transformers upto2% maybeupto5%forold transformers 0.05% 0.50% 1% 0.50% 0.05 1.0% 0.5 1.0% 3to5% 4to8%

OilFilledPowerandDistributionTransformers

DryTypePowerandDistributionTransformers TransformerOil Bushings RotatingMachines Cableinsulation: Paper XLPE Ethylene/propylenerubber Rubber(oldertype) Varnishedcambric

These are general guidelines. Please Refer Manufacturers recommendations and equipment history

88

ACHighPotentialTest
ACHipotisusedasacceptancetest(go/nogotype) Thumbrule: Acceptance:75%offactorytestvoltage,ascertifiedby manufacturer Maintenance:60%offactorytestvoltage,ascertifiedby manufacturer

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Conclusion

Conclusion
Foroptimumbenefit: y Essentialtorecordalltestdatainproperformatsforfuture reference y TestEquipment
y Properselection y Regularmaintenanceand y Regularcalibration

y Trainedpersonswithknowledge,experienceandcoolmind

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TestingInformation
Theinformationontestingcanbeobtainedfromseveraldifferentsources suchas
Powerequipmentmanufacturersmanuals(BHELetc), y Testequipmentmanufacturersmanualssuchas
y
y
y y

AVO,International:http://www.avointl.com
Doble Engineering:http://www.doble.com AEMC:http://www.aemc.com

industrystandardssuchas y IndianStandards(IS) y InstituteofElectricalandElectronicEngineers(IEEE), y AmericanNationalStandardInstitute(ANSI), y NationalElectricalManufacturersAssociation(NEMA), y NationalFireProtectionAssociation(NFPA) y InternationalElectricalTestingAssociation(NETA), y InsulatedCableEngineeringAssociation(ICEA), y Andofcourseourbestfriend,INTERNET

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THANKYOU

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Temp Correction factors


Rotating Equipment Deg C 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 Class B 0.4 0.5 0.63 0.81 1 1.25 1.58 2 2.5 3.15 3.98 5 6.3 7.9 10 12.6 Transformer oil filled 0.25 0.36 0.5 0.74 1 1.4 1.98 2.8 3.95 5.6 7.85 11.2 15.85 22.4 31.75 44.7

Tempcorrectionfactorof2for

Approxevery10degincrease inTempforoilfilled Transformers

Approxevery15degincrease inTempforRotating equipmentshavingclassB insulation

Reproduced from NETA MTS 1997 Table 10.14

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