Testing and commissioning of HV power transformers,

circuit breakers, CTs and VTs

electrical-engineering-portal.com/testing-commissioning-hv-power-transformers-circuit-breakers-cts-vts

By Edvard Csanyi September 11, 2019

Testing and commissioning procedures

As you already know, substations are the points for controlling the supply of power on
different routes by means of various equipment such as power transformers, circuit
breakers, CTs/VTs, compensating equipment, isolators, etc. The various circuits are
joined together through these components to busbar systems at the substations.

Testing and commissioning of HV power transformers, circuit breakers, CTs and VTs

This technical article provides guidance to substation personnel in carrying out testing
and commissioning oF high voltage power transformers, circuit breakers, current and
voltage instrument transformers.

One of the prime requirements of a good substation is that it MUST have regular
maintenance. Testing and commissioning procedures are crucial and ensure safety of
the operation and maintenance personnel.

Table of content:

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1. Power transformers

After installation of transformer on the plinth, accessories viz. radiators, headers,

bushings, air blowers, oil pumps with connecting pipes, OLTC drive mechanism and the
connecting pipes to diverter switch compartments, marshalling box, etc. have to be
mounted on the transformer as per the manufacturers’ drawings.

Oil should be admitted into the transformer from its bottom valve and suction side to be
connected to the top valve to evacuate nitrogen/dry air inside the transformer as the
oil fills from the bottom.
It is preferable to fill the oil received from the works (in barrels) into an oil tanker of
sufficient capacity and filter this oil separately. This helps in removing moisture absorbed
in the oil during transport and storage. Fairly moisture free filtered oil now can be
admitted from the oil tanker to the transformer.

The following check list provides various checks to be conducted for transformer
assembly.

No. Description Done

1 Availability of erection drawings and literature at site. Yes/No

2 Whether all components available at site in good condition. Yes/No

3 Rinsed all the piping, radiators, conservator etc. with 60kV tested oil Yes/No
and blocked with dummy plates.

4 Filtered the oil for 60kV BDV and recorded in the erection register. Yes/No

5 Measured the IR values of HV, MV condenser type bushings(with a Yes/No

5kV Megger testing device) and observed more than 5000 MΩ after
removing coverings, wrappers etc and cleaning.

6 Washed with hot oil (in case of other bushings of plain porcelain type). Yes/No

7 Assembled the bushing after fixing corona shield and removing links Yes/No
and bends in pull through leads, on the turret at proper incline.

8 Complete assembly of HV, LV, Ter. & Neutral bushings done correctly. Yes/No

9 Completed all piping work, conservator, explosion vent, equalizer pipes Yes/No
etc. as per the drawing and filled with oil , Bucholz relay checked.

10 Filled radiator after washing individually and ensuring removal of Yes/No

blanking plates and free movement of butterfly valves both top and
bottom.

11 Measured IR values with temperature after filling of oil and compared Yes/No
with factory test value and recorded in the register.

12 For drying out of Transformer:

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 Applied proper lagging around the transformer. Fire fighting equipment Yes/No
kept at site.

Filter machine cleaned and filled with transformer oil. Yes/No

Filter connected with outlet into the conservator and inlet from the Yes/No
bottom tank.

Filter heaters switched on and the filter temperature maintained less Yes/No
than 60°C and filter vacuum maintained at 755 mm of mercury.

Dehydration process for 7 days maintained oil temperature 60°C in the Yes/No
transformer (thermometer pockets filled with oil).

13 Filled the radiators with 60kV BDV tested oil. Opened the bottom Yes/No
butterfly valve provided between main tank and radiators after opening
top air release valve to communicate with main tank.

14 All gases released from different release points in the order of Yes/No
ascending heights.

15 HV, LV, Tertiary Neutral earthing provided. Body earthing at two sides, Yes/No
earthing of DM and FCC provided.

16 Petroleum jelly applied in clamps and connectors in the transformer Yes/No

bushing studs and checked the tightness.

17 Blue silica gel crystals of 2.5 to 4mm size filled in the breather. Breather Yes/No
filled with oil after removing bottom cup, transit protection cover, cork
packing etc.

18 Removed blanking plates on explosion vent pipe and fixed diaphragm. Yes/No

19 In case of transformers provided with thermo-siphon filter and air-cell Yes/No

(pronol bag) breathing arrangement checked up as per manufacturers
recommendations.

20 All air release points and other points thoroughly checked to ensure Yes/No
that there is no oil leakage.

21 Connecting test taps of all 132,220,400kV condenser bushings. Yes/No

22 Oil level in main& OLTC conservators upto the mark. Yes/No

23 Filling of oil in oil packets of OTI and WTI. Yes/No

24 Welding of wheel stoppers to the rails. Yes/No

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1.1 Pre-commissioning Tests On Transformer

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After installation and assembly at site, the following pre-commissioning tests on
transformer should be conducted. These are basically low voltage tests.

1. Ratio
2. Polarity and vector group
3. Measurement of magnetizing current and no load losses (3-phase 415V to be
supplied on low voltage side of the transformer)
4. Measurement of short circuit current, load losses and impedance at all taps (3-
phase 415V supply to be given on the high voltage side and the other side shorted)
5. Magnetic balance test
6. Measurement of winding resistance at all taps
7. Insulation Resistance and polarization index

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1.2 Testing of Auxiliary Protective devices

Checking of operation of alarms and trips of following auxiliary relays:

1. High temperature settings for oil and winding temperatures

2. Bucholz relay and OLTC oil surge relay
3. Pressure relief device
4. Magnetic oil gause (MOG) of conservator

Checking for running /stopping of cooler fans and/or oil circulating pumps in groups
at the set temperatures/pressures. Conduct all checks and tests on turret mounted CTs
as indicated under CTs.
You might find interesting reading an article about the most important alarms coming from
a substation.

6 alarms coming from a substation transformer you MUST take very seriously

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1.3 Testing OLTC (On Load Tap Changer)

The following checks should be performed for OLTC:

1. Checking for manual and electrical operation (both local & remote and lower &
raise) of On Load Tap Changer and for continuity between the operations.
2. Check for operation of limit switches at the extreme tap positions and mechanical
interlock between manual and electrical operation.
3. Check for Master/Follower and out of step relay operation of transformers if parallel
operation is intended.

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1.4 Tests for reference (Signature)

The following tests should be done before commissioning and the results compared
with the factory test results. These results should be kept as reference values for
comparison with the future test results of these tests while conducting, as a part of O&M
later.

1. Measurement of Capacitance and tanδ of windings, Condenser Bushings

2. Dissolved Gas analysis
3. Furan Analysis (to measure degree of polymerization)
4. Frequency Response Analysis
5. Transient Recovery Voltage (TRV) Measurement
6. Oil sample test for Dielectric strength, acidity, specific resistance, moisture content
and tanδ

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1.5 Tests on main protective relays

The following protective relays connected to the transformer HV/LV/Tertiary sides shall be
tested for proper operation duly adopting the settings communicated by the power
systems:

1. Over current / Earth fault relays (directional/non-directional).

2. Operation of the instantaneous elements for the set current value.
3. Differential relays with bias and restraint features including through current stability.
4. Restricted Earth fault relays.
5. Local Breaker Backup (LBB) relays.
6. Over flux relay.
7. Under and Over voltage relays.

Testing procedures for protective relays are not described in this article, but you can read
about this subject in details here.

Commissioning tests of protection relays at site (before set to work)

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2. Circuit breakers

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Physical checks for any damages to components of the circuit breaker should be
made. Tightness of connections at all jumpers, flanges, joints in pipes, valves etc. should
be checked. Check for oil/ gas/ air leakages at concerned valves/pipes and all oil seals,
gaskets should be made. Checking and tightening of all foundation bolts should be done.

The following pre-commissioning tests/checks shall be conducted:

1. Measurement of insulation resistance – Phase to earth, Between phases, across

contacts with breaker open.
2. Measurement of capacitance and tanδ of voltage grading capacitors. The grading
capacitors are oil filled paper capacitor type.
3. Purity and dew point measurement of SF6 gas at rated pressure of the breaker and
at atmospheric pressure.
4. In ABCBs Dew point of air to be measured. Air serves as insulation as well as arc
quenching medium.
5. Measurement of CB close, open, close-open, timings with CB Operation analyzer.
6. Measurement of Dynamic contact Resistance and contact travel.
7. Operation of Pole Discrepancy relay:
To measure the difference in closing and opening times of different poles of CB
where the poles are individually operated (220kV and above). Simultaneous closing
of all the three poles in case of a three pole/ gang operated breaker (132kV and
below).
8. Check for proper working of carrier inter trip and auto-reclose features (for feeder
breakers).
9. Check for capacitor tripping device where provided.
10. Measurement of resistance and current drawn by close coil and trip coils I and II.
11. Checking of interconnecting cables to bay marshalling box.
12. Checking of operating mechanism.
13. Checking of operation counter and all mechanical indications.
14. Checking of all Non-return valves/ Safety valves.
15. Checking of local/remote breaker operations.

Check for correct operation of following operational lockouts at set pressures:

1. SF6 gas pressure- alarm and lockout at different set pressures.

2. Pneumatic operating system – Automatic start/stop of air compressor at set
pressures.
3. CB closing lockout.
4. CB operational lockout.
5. CB auto-reclose lockout.

HV Circuit Breaker Testing (VIDEO)

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Circuit breakers allow the flow of energy to be controlled by safely switching currents on
and off at all voltage levels of the energy grid. The interrupter and the mechanical drive
are the main components that are subject to wear and aging.

In order to ensure the proper operation of a circuit breaker throughout its lifetime,
diagnostic tests are performed, such as resistance, timing, minimum pick-up, travel,
and power factor.

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3. Current transformers (CTs)

Physical observation of the CTs for proper installation with respect to the drawings and
substation layout should be made. Tightness of bolts of support structures to the
foundation and CT base mounting to the support structure shall be ensured.

Oil leakages in case of oil filled CTs and SF6 gas leakages/rated pressure of gas in case
of SF6 gas filled CTs to be observed. Bellows provided for taking care of oil expansion
shall be checked for proper functioning.
The following checks and electrical tests shall be conducted:

1.
1. Checking of tightness of all electrical connections including connections made
in the marshalling box.
2. Checking for tightness of CT secondary terminals and checking healthiness of
secondary terminal bushings.
3. Checking for short circuiting the secondary terminals of such CT secondary
windings which are not required. Shorting should be done at secondary
terminals in the CT secondary terminal box.
4. Checking for earthing of common point of three phases of each secondary
winding at one point only, preferably at the marshalling box.
5. Measurement of IR values including Di-electric absorption ratio and
Polarization index of primary to body and primary to secondary with a 5 kV
Megger testing device.
6. Measurement of IR values between secondary winding of each core to body
and between different secondary windings of the CT with a 0.5 kV Megger
testing device.

1. Measurement of capacitance and tan∂ of the CT.

2. Measurement of secondary winding resistance of each secondary winding.
3. Testing for Magnetization characteristics (knee point voltage) of CT cores.
4. Ratio test for approved CT ratios in all the cores including complete wiring in the
secondary side to ensure correct ratio and continuity of the wiring.
5. Check for polarity of CTs, to ensure correct directional sensitivity of metering and
protection system.

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Each CT should be individually tested to verify the polarity markings on primary and
secondary windings. Test circuit is given below.

Figure 1 – CT polarity test

Ammeter “A” is a robust moving coil permanent magnet center zero type instrument.
Primary winding is given DC supply momentarily from a low voltage battery through a
push button. When push button is pressed with the above markings on CT and ammeter,
the ammeter should give a +ve flick, indicating correct polarity.

Multi meters and Digital ammeters can also be used. CT secondary connections to
transformers, busbars, and feeders:

3.1 Busbar CT’s secondary connections

Busbar CTs secondary connections

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3.2 Transformer CT’s secondary connections

Transformer CT’s secondary connections

3.3 Line CT’s secondary connections

Line CT’s secondary connections

Where CT secondary connections are to be made in star, the star point should be made
as follows.

Irrespective of the polarity on the primary side, star point on secondary side shall be on
line side for feeders and on the equipment side for the bus bars, and transformers as
shown in the figures above. In case of a feeder protection, if P1 is towards the bus, then
S2s’ are to be shorted and if P2 is towards bus then S1s’ are to be shorted.

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Testing protection current transformers with CT Analyzer (VIDEO)

Important parameters of a protection current transformer are its ratio, its excitation
curve, the knee point, its winding resistance, and the burden.

CT Analyzer determines all relevant current transformer data during a test duration of
approximately one minute: it measures the burden of the secondary circuit, the winding
resistance and the excitation curve, calculates the accuracy limiting factor for rated and
actual burden, determines its ratio, amplitude and phase angle accuracy, and verifies the
polarity.

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4. Voltage transformers (CVTs / IVTs)

Visual observation for any cracks/breakages must be made. Mounting of capacitor
stacks, electromagnetic units, and terminal box shall be checked for correctness as per
the drawing.

Tightness of foundation bolts connecting the support structures to the foundation and
the bolts connecting base of the VTs/CVTs to the supporting structures should be
ensured.
The following checks shall be made:

1. Check for tightness of all electrical connections on primary and secondary sides of
CVTS/VTs including connections in the marshalling box.
2. Check for oil leakages and oil level.
3. Ratio test –voltage in all the secondary windings should be measured.
4. Insulation resistance of primary to body and primary to secondary windings to be
measured by a 5 kV Megger testing device.
5. Insulation resistance of secondary to body and between secondary windings to be
measure by a0.5 kV Megger testing device.
6. Measurement of capacitance and tan ∂ of CVTs.
7. Checking of HF point in case of CVTs. Caution given on the name plate by the
manufacturer should be followed.
8. Check for adopting the approved ratios and connections for different secondary
windings.

Testing voltage transformers (VIDEO)

Voltage transformers (VTs) are used around the clock throughout the energy grid, and
their life span can reach up to 40 years. During that time, the effects of aging, regular
operation, network faults, or external influences may affect the integrity of a voltage
transformer.

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 Utilities perform various tests during commissioning and maintenance to find any
irregularities that have been caused by transportation, installation or daily
operation.

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Source: Technical reference guide by APTRANSCO

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