E402 Electrical System Design and

Estimation

Module-4
Industrial Power and Lighting
Installations
Module 4
• Industrial installations –classifications
• Design of electrical distribution systems with main switch board, sub
switch boards and distribution boards with ACBs, MCCBs and MCBs as
the case may be, for feeding power (mainly motors) and lighting loads of
small and medium industries.
• Selection of armoured power cables (AYFY, A2XFY, YWY) – calculation
of ampacity, voltage drop, short circuit withstand capacity etc.
• Design of MSB & SSB including Motor Control Centre (MCC) for motor
controls – selection of bus bars and switchgears.
• Selection of 11kV indoor and outdoor transformer substations upto 630kVA
- selection of switchgears and protective devices –Preparation of schedule
of works and bill of quantities (cost estimation excluded).
• Short circuit calculations and earthing design for the HV and LV sides of
an 11 kV substation of capacity up to 630 kVA.
• Pre-commissioning tests of 11kV indoor/outdoor substation of an HT
consumer.
 Industrial Installations

1. More sophisticated installation

2. Take care of diverse load requirement in economic
manner
3.Preserving safety and reliability with electrical
installations
4.Easiness of maintenance and fault location features
5.Energy conservation
 Classification of Industrial Buildings

(A) Fire hazard

(B) Power Consumption

(C) Pollution hazard

 (A) Classification based on fire hazard
(i) Group G1- Building used for low fire hazard
industries

Operation/process conducted in those

buildings, there are no possibilities of self
propagation of fire to occur. Only effect of fire
from external sources.

E:g; Cement factories, Glass factory, Rice mill,

Soap and detergent factory etc.
(ii) Group G2- Building of moderate fire hazard
In this type, operation/process are liable
to give rise to fire that will burn with
moderate rapidity, produce considerable
volume of smoke or non-toxic fumes and
will not result in an explosion

E:g; Ship repairing docks, coir industry,

chemical manufacturing, flour mill etc
(iii) Group G3- Buildings with high fire hazard
In this type, operations/ process are
liable to give rise to a fire which will burn
with extreme rapidity, generate poisonous
fumes, lead to explosions.

E:g; Alcohol distilleries, explosive

manufacturing, fire work industries, oil
mill, petrochemical
 (B) Classification based on power consumption

(i) Light industries(Small)

(ii) Average industries (medium)

(iii) Heavy industries

Description Average power requirement Examples

Light industry Up to 50 kVA Hosiery, garment making,

ornament making etc

Average Industry above 50 up to 2000kVA Furniture pottery, glass,

tobaco, electrical gadgets,
textiles, engine fitting, light
processing etc.

Heavy industry above 2000kVA Heavy electrical quipment,

steel mills, foundaries, ship
building, chemical plants,
fertilizer plants, metal
extraction, petrochemicals,
paper mills etc.
 (C ) Classification based on pollution level
(i) Pollution degree 1
No pollution or only dry, non conductive
pollution occurs. The pollution has no
influence

(ii) Pollution degree 2

Only non-conductive pollution occurs
except that occasionally a tempory
conductivity caused by condensation is to be
expected.
(iii) Pollution degree 3
Conductive pollution occurs or dry non-
conductive pollution occurs which becomes
conductive due to condensation

(iv) Pollution degree 4

Continuous conductivity occurs due to
conductive dust, rain or other wet conditions.
 Power distribution architecture of Industrial
Installation-Factors considering
1. Activity
2. Site topology
3. Layout latitude
4. Service reliability
5. Maintainability
6. Installation flexibility
7. Power interruption sensitivity
8. Disturbance sensitivity
1.Activity- The type of activity carried out
in the building. i.e; whether manufacturing,
food processing, logistics etc.
2. Site topology- Here consider the number
of buildings, number of floors in each
building, floor area. E.g; single storey or
multistorey or highrise buildings
3. Layout Latitude-Consider constraints in
terms of the layout of electrical equipment in
the buildings
Some parameters
 Aesthetics
 Presence of dedicated location
 Use of technical corridor(horizontal service
duct) per floor
 Use of technical service duct(vertical)

Three layout categories

Low- The layout latitude is low when the positions

of the electrical equipments are virtually imposed
on the building and cannot be changed to achieve
above said parameters
Medium- There is some flexibility in positioning the
electrical equipments.

High- Layout latitude is high if there is no constraints

in positioning the electrical equipment in the building
to satisfy the parameter mentioned above.

(4) Service reliability-

It is defined as the ability of the power supply
system to meet the supply function under stated
conditions for a specified period of time.
There are 3 categories of service reliability
(a) Minimum service reliability
(b) standard
(c) Enhanced service reliability

Service reliability will be minimum if the

installation is subjected to interruption related to
geographical(positioning of buildings with reference
to power production centre), technical(Power supply
through OH or UG or Ring system),
economic(Maintenance aspects)
Service reliability can be enhanced by taking
measures to reduce the power consumption
(5) Maintainability-During design stages
to limit the impact of maintenance on the
operation of the whole or part of the
installation.
Maintenance activity can be carried out
without disturbing the operation of the
production
(6) Installation flexibility
This is the possibility of easily moving of
power delivery points within the installation or
the facility to increase the power availability at
certain points.
• Non-flexible
• Design flexibility
• Implementation flexibility
• Operation flexibility
(7)Power interruption sensitivity
This is the capability of the process or system
to accept interruptions.
Sheddable loads-Possible to shut down a portion
of the load at any time
Long interruption acceptable loads-Accepting
interruption for more than 3 minutes
Short interruption acceptable-Accepting
interruption less than 3 minutes
No interruption acceptable- Power interruption
cannot be accepted
(8) Disturbance sensitivity- It is the ability of an
industry to work properly in the presence of
disturbance(over voltage, voltage distortion due to
harmonics, voltage fluctuations, voltage
unbalance).
It is classified as
Low sensitivity-very little effect on the
operation(e;g; heating devices
Medium sensitivity- a notable deterioration in the
operation (e;g; induction motors, lighting loads)
High sensitivity- stoppage of operation(e;g; IT
equipment, sensitive instrument)
 Selection of Transformer Substation
 Consider economy of operation
 Technical suitability
 Cost
 Long term gains
 Transportation constraints
 Handling facilities
 Availability of supporting switchgear
Factors deciding selection of transformers
• Maximum demand

• Future expansion

• Spare capacity

• Statutory requirements

• Site condition
Standard rating of Distribution Transformers
(11/0.433kV)-
50,63,80,100,160,200,250,315,400,500,630,800,1000,1250,
1600 and 2000kVA
Cooling- Oil Natural Air Natural(ONAN), Oil Natural Air
Forced(ONAF),
Parallel operation of transformers- A pair of transformer
is said to be parallel if they are connected in parallel on at
least two sides for meeting higher loads
Condition for parallel operation
• Same vector group
• Turns ratios should be similar
• Same % impedance voltage
• Ratio of the rated capacities of the transformers shall not
be more than 3:1
Typical single line layout of Transformer Substation and Main
Switch Board(MSB)
Types of 11kV Substations

Consider distribution

1.Outdoor Substation
(i) Pole mounted outdoor substation
(ii) Floor mounted outdoor substation

2.Indoor type-Floor mounted

(i) With Oil filled transformer
(ii) With dry type transformer
Outdoor Substation
2 Pole Substation with Transformer
• H-pole structure, base channel of
100mmx50mm size
• Erected at a height of 2.44m from ground level
• 11kV Lightning arrestors(3 numbers) are
erected at the top
• Earth terminals of all 3 LAs are joined together
and connected to earth
• The 11kV gang operated switch( Air Break
switch) installed below the 11kV conductor
taps the 11kV supply to the transformer
• Operating handle located on one pole of the
structure 1.25m from ground
• 11kV horn gap(HG) fuses, installed below the
gang operating switch
• On LT side 3.5 core LT cables are used, LT
cables are selected according to capacity of
transformer
• Connecting jumpers from the 11kV line to the
G O switch, from the G O to HG fuse , and
from the fuse unit to transformer bushing,
covered with empire tape or polythene pipe for
safety
• Lightning protection
11 kV LA
• One side of three of the
LAs earthed for surge
bypassing
11kV Air Break
Switch
AB Switch
HORN GAP FUSE is a protective device used to protect the
equipment from higher voltage, horn gap fuse is a thin wire
element compared to load line when a high current is drawn
from the line, fuse wire melts and protects the equipment
•
11kV
Protection fuse
Drop Out (DO) Fuse
• Fuse breakage easily
detected
• Easy refusing from ground
Indoor Substation
 11 kV/415V are frequently used
 HT and LT switchgear and cable trench for
incoming and outgoing cables
 Adequate clearance between walls and
equipment to ensure safety
 Adequate ventilation
 The supply from the OH line is brought inside
the substation through UG cable using an
outdoor cable box
 The secondary terminal is to be connected to an
LT CB or switch fuse unit using 3.5 core LT
cable
 For current upto 300A switch fuse unit are used
 For metering PTs & CTs are installed at HT side
and measure Maximum demand, PF etc
 Two separate distinct earth electrode shall be
provided for neutral earthing, body earthing and
lightning arrester earthing.
•
Tutorial
Design a Pole Mounted 11kV/415V substation with a 100KVA
Transformer used for Consumer Power Distribution
• No need of Energy Meter
• TRF will be mounted on the 2 Pole Structure
• No need of Power Cables, as bare conductors are used for
interconnections
• Currents: 5.25A(11KV), 133.3A (415V)
100KVA Distribution Transformer on a Two
Pole Structure
 Selection of Cables

• Copper conductor cable only will be used for submain/ circuit/ point
wiring.
• Minimum
• Lightsize of wiring:
Wiring (Lamp, Fan, 6A Socket) : 1.5 sq. mm.
• Power Wiring(16A or 20A Socket) : 2.5 or 4.0 sq. mm.
• Power circuit rated more than 1 KW : Size as per calculation based on Voltage drop
* (Refer Tutorial for more details)

• Insulation : Copper conductor cable shall be PVC insulated conforming to BIS

Specification.

The permitted voltage drop for any given equipment from the control switch is
3% for LT-AC system. The conductor size need to be increased if the voltage drop
exceeds this value. Voltage drop along a conductor mainly depends on current
flowing through it and the length and cross sectional area of the conductor
 High Current Cables used for LT System

• Used to transfer power between

• KSEB supply (11kV) to step-down Transformer
• Transformer to Main Switch Board (MSB)

• Usually aluminium (Al) conductor used

• lower cost, here conductor area is much higher due to high current flow
• Insulation materials
• Conductor insulation - PVC or XLPE (Cross Linked Poly Ethylene) - Seen in Red, Yellow or Blue Color
• Outer Insulation – PVC for water proofing

• Size selection based on current flowing and manufacturer derating charts

Cable Coding System (IS 7098)

• Components listed from inner

core to outer sheath

• AYFY – Al cable, PVC

insulated, Steel strip armour,
PVC outer sheath
• A2XFY - Aluminum cable,
XLPE insulated, , Steel strip
armour and having PVC outer
Sheath
• YWY - Copper cable, PVC
insulated, Steel round wire
armour, PVC outer Sheath
Cable Coding System
• Calculation of
• Ampacity: Current rating and deration based from cable data sheet
• Voltage drop: Based on cable impedance/km and load current based
– from cable data sheet
• SC rating: From fault current calculation and cable data sheet
Material Load Current Fault Current
Density Permitted Density
(A) Permitted (A)

Copper 1.2 A/mm2 120

Aluminium 0.8 A/mm2 80
GI 0.48 A/mm2 48
 Armoured Power Cable - Parts
• Conductor material – Copper or Aluminum
• Cu cable is smaller in thickness
• Al cable is cheaper

• Inner insulation material – Paper, PVC or XLPE

• XLPE is a better insulator than PVC and Paper
• Higher current rating
• Higher SC rating
• Higher operating temp
• Higher insulation rating and life

• Mechanical Protection Sheath – GI strip

• always grounded

• PVC is water and chemical resistant, hence used for outer protection
• Black color used
Earth wire sizes - Standard Wire Gauge (SWG)
• Uninsulated Copper conductor is
used as the earth wire Each number
• Higher current will heat the represents a size of
cable and damage the insulation wire
and may result in short circuit
• Design 500KVA, 11kV/415V transformer substation used for
power supply to a medium industry
• Assume the Transformer as Indoor Oil Filled Type
1. TRF Current Ratings: 26.2A/666.5A (Ref. Table 31 of DB)
2. DO Fuse: 50A (Refer Table-34 of DB)
3. HT Cable: 3 Core, 150mm3, XLPE (From NEC)
4. HT CB: Load Break Switch (LBS) with Trip at 26A
5. LT Cable: 3 Runs of 3.5Core 400mm2 AYFY Cable(Refer Table-34, 54 of
DB)
6. LT ACB: 800A with Over Current Trip set at 666A (Refer Table-108 or
109 for MCB or 110 for ACB)
7. Busbar Sizing
• Permitted Current Density of Aluminium = 0.8A/mm2
• Busbar Area = 666A/(0.8A/mm2) = 833mm2
• Busbar Size: Single Bar of 76mm X 6mm Aluminium (Refer Table 38A of DB)
• Design 100KVA to 630KVA , 11kV/415V transformer substation
used for power supply to a medium industry
• Assume the Transformer as Indoor Oil Filled Type
1. TRF Current Ratings: (Ref. Table 31 of DB)
2. DO FuseRating: (Refer Table-34 of DB)
3. HT Cable: 3 Core, 150mm3, XLPE (From NEC)
4. HT CB: Load Break Switch (LBS) with Trip at ---A
5. LT Cable: 3 Runs of 3.5Core ----mm2 AYFY Cable(Refer Table-34, 54 of
DB)
6. LT MCCB or ACB: ----A with Over Current Trip set at ---A (Refer Table-
108 or 109 for MCB or 110 for ACB)
7. Busbar Sizing
• Permitted Current Density of Aluminium = 0.8A/mm2
• Busbar Area = ---A/(0.8A/mm2) = ---mm2
• Busbar Size: Single Bar of --mm X --mm Aluminium (Refer Table 38A of DB)
 Installation of transformer substation
Outdoor type
 Minimum clearance between suppliers and
consumers 11kV structure shall be 3m
 Phase to phase clearance 915mm and phase to
earth 610mm
 Minimum safety clearance of 2.6m between bare
conductor and live parts
 Lightning arrestors –between AB(Air Break)
Switch and D.O(drop out) Fuse
 AB switch operating handle- 1m to 1.25m from
ground level
 11kV AB switches shall be three insulators types
Indoor Type
Recommended for rating above 630kVA
 Only dry type
 In case of oil indoor type
 free access for fire engines to the transformer
stations
 Minimum clearance of 1.5m from building
 substation building shall be weatherproof and
fireproof, walls of 355mm thick brick or
230mm thick RCC
 AB switch fuse unit/ VCB shall be provided on
the primary side
 Minimum size of cable on 11kV side -150 sq.mm
XLPE
 Fire separation walls shall be provided in between oil
filled transformers
 Oil drainage facility/soak pits shall be insisted for oil
type
 All round clearance shall be provided- minimum
1.25m if wall are provided at four sides
 Adequate ventilation easy access
 Doors and windows of transformer room –non
flammable material
 Minimum 50cm headroom clearance
 Minimum phase to phase 130mm and phase to ground
80mm clearance of busbars in 11kV panel
 Selection of Switchgears
Basic Functions
• Electrical protection( Overload, short
circuits, insulation failure)
• Electrical isolation of a section of the
installation( a gap interposed insulating
barrier between the open contacts)
• Local or remote switching( functional,
emergency switching, emergency stopping,
switching off for maintenance)
Electrical Protection
Protection of circuit elements( against overloading,
provided by fuse or CB)
Protection of persons and livestock( due to insulation
failure, protection through fuses, CBs, ELCB or
RCCB)
Protection of equipment (against overheating , single
phasing, protection through thermal relay)
Electrical isolation- Separate a circuit or equipment
from other installation to carry out work. In the
isolation neutral pole must be opened, provided with
mechanical locking, comply with national standards,
visual indication complete opening of contacts
Switching control
Functional control-Includes all switching operations
during normal conditions for energizing and de-
energizing of a part of a system or installation or
equipment
Emergency control- It is a built in facility to de-energise
a live circuit which could be dangerous to person and
property. Provide large red mushroom headed emergency
stop button, single action guarantee complete switching
off.
Maintenance operation-To enable maintenance work,
stopping or disconnect a piece of equipment or circuit
 Switching Devices
1. Isolators-Manually operated ON/OFF switch with
provision for locking and provides safe operation.
Cannot operated under loaded condition
2. Load break switch-Design for operation on loaded
circuit, under normal operating condition. Non-
automatic ON/OFF switching device
3. Contactors-It is a solenoid operated switch which is
held closed by a current through a solenoid coil.
4. Discontactors-A contactor equipped with a thermal
relay for protection against over current is defined as
a discontactors. It is not a CB
5.Changeover switches-Wide application in
situations when the reliability of electrical supply
from utility is low and are used in lighting/industrial
applications wherever continuity of supply is
necessary. ON load as well as OFF load available
6.Automatic transfer switch (ATS)-Automatic
transfer of power. By using Automatic Main
Failure(AMF) system. It is self acting equipment
containing the transfer switching devices and other
accessories for monitoring the supply sources and
for transferring load circuit from one supply to
another.
Material Load Current Fault Current
Density Permitted Density
(A) Permitted (A)

Copper 1.2 A/mm2 120

Aluminium 0.8 A/mm2 80
GI 0.48 A/mm2 48
 INDUCTION MOTOR
IM Feeder Components
FEEDER DESIGN
1. MCCB in MSB or PDB (Power Distribution Board)
2. 3.5 Core Cable form MSB to Motor Location
3. Starter near the IM (DOL, SD, VFD Drive)
1. Up to 5HP: DOL Starting
2. 5HP to 15HP: Star Delta Starting
3. Above 15HP: Soft Starting using Power Electronic drive
4. Induction Motor
5. Body Earthing of IM at 2 points
 Electrical Installation for Small
Industries
Motor Circuit Wiring
• Every motor must be controlled by a main switch
• A three phase motor would need triple pole switch with fuse in each
phase
• A starter may be required for starting and stopping the motor
• Size of the switch fuse unit and that of starter will depend upon the
rating of the motor
• Depending up on the rating of motor, PVC cables of suitable size are to
be used for wiring
• For large capacity motors, three phase underground cables used
• Each motor has to be controlled separately from the mains through DBs
• Connecting two or more motors in one circuit should be avoided as far
as possible
Design Considerations of Electrical Installation in
small Industries
1.Motor Current
• Starting current of the motor will be much more than its rated
current till the motor comes upto speed
• As the motor reaches full speed delivering its rated HP, motor
carries its rated current
• If the motor is overloaded, the current increases and it will
overheat, may even burn out
• Current rating of cable may be based upon the normal full load
current of motor
• Rating of fuse should be based upon the starting current
• Rating of fuse should not be greater than twice the rating of
cable
2.Deciding cable size
• Current carrying capacity of cable should be 1.5 times the full
load current
• Minimum cross-sectional area of conductors that can be used
for power wiring is 1.50mm2 for Cu conductor cable and 2.50
mm2 for for aluminum conductor cables.
3.Determination of size of conduit
4.Deciding the fuse rating
5.Deciding the starters,DB, MS
Problem 1
Q. Design a feeder for
installing a 40HP induction
motor in an industry
From the data book (Refer Table 28 on Page
21)

• Full load current of 40HP motor = 55A

• Cable size = 35mm2
• CB rating = 100A approx.
• Earthing conductor = 6SWG Copper

SOLUTION
• MCB or MCCB
• Use 100A MCCB with 100A setting
• Cable: 3.5 Core 35mm2 AYFY Cable
• Starter: Soft Starter with VFD operation
type as the motor is 40HP
• Safety earthing from two points on motor
body using 6 SWG Copper strip.
• An industrial electrical installation has a demand of
50 kW at a power factor of 0.75 lagging. Determine
the rating of the capacitor bank required to improve
the power factor to 0.95 lagging
• Basic idea (1 Mark) Expression (1 Mark) Reactive
power rating of the capacitor bank calculation =
27.66kVAR (3 Marks)
Selective Coordination: Page 194 – 195
MSB: 100A, 63A, 40A, 26A, 16A

SSB: 63A, 40A, 26A, 16A

DB: 26A, Lowest Tripping Time

(Fault)
• MV Switch Boards Page: 214
• Diesel Generator Set, Change over Switch: Page 185-186
• Automatic Transfer Switch
(ATS)
 Cable Voltage Drop Calculation
• Single Phase Loads
• Max V Drop: 3% from DB to Load
• PF=0.8 assumed

• VD = 2(i*R*l) Volts R- resistane/m of Cable

• % VD = V*100/VD %
 Cable Voltage Drop Calculation
• 3 Phase System
• Assume Balanced, PF = 0.8, Calculate I, r

• VD = (i*r*l) Volts
• % VD = (V*100)/ VD %

• ‘r’ Values?? (DBook, AYFY Al: Page- 49, 50)

 COMMISSIONING OF POWER
TRANSFORMER

• After, installation of power transformer, several

pre-commissioning tests to be done before putting
the transformer in service.
• Along with different pre-commissioning tests,
different instruments associated to the transformer
also to be checked.
 Common Pre-commissioning
Tests of Transformer
• The following are the pre commissioning test conducted on a transformer
1. Insulation Resistance Test
2. Dielectric Absorption and polarization index Test
3. Measurement of winding resistance at all taps
4. Turns ratio (Voltage ratio) Test
5. Polarity and vector group Test
6. Magnetic balance test
7. Measurement of magnetizing current and no load losses (3-phase 415V to be
supplied on low voltage side of the transformer)
8. 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)
 Common Pre-commissioning Tests of Transformer

1.Insulation Resistance Test:

• Insulation resistance values of various winding should be checked.

• For 33/11 KV Power Transformer 2500 V megger is to be need.

• During measurement of insulation resistance, the transformer must not be connected with any
external lines or lightning arrestor etc.

• Power Transformer neutral Earthing is to be disconnected

• Line terminal of the megger is to be connected to one of the HV Bushings of Power transformer
and Earth terminal of megger is to be connected to Power transformer Body Earth Point.
 Insulation Resistance Test (contd…)
• IR Values are to be read on the megger by meggering the Power transformer
• i) The above Value is to be noted as HV to Body

• ii) Then IR Value between LV terminal and body of Power transformer is to be measured & noted.

• ii) IR Values between HV & LV terminals are to be measured & noted.

• iv) The temperature of transformer oil at which the IR Values are measured is also to be noted.

• v) Particulars of megger is also to be noted.

• The maximum value shall be 60MΩ at 60°C temperature for transformer which are in
service.

• For new transformer the value obtained shall be tallied with manufactures test
results.

• When insulation resistance falls below specified value, it can often be brought back to
the required value by cleaning and drying.
2. Dielectric Absorption and polarization index Test:
• 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

• Oil sample from the top and the bottom of the tank, selector switch and diverter switch ,tank of the
tap changer and radiator tank etc should be tested.

• The dielectric strength of the transformer oil should be more than 50 KV.

• The polarization index (PI) is defined as the ratio of IR values measured at the intervals of 600 and
60 seconds respectively.

• Whereas, the dielectric absorption is the ratio of IR values measured after 60 sec and 15 sec.
• The Dielectric strength of transformer oil is also known as the breakdown voltage of the transformer

oil. “Breakdown Voltage” (BDV) is measured by observing the voltage that is required to jump a

spark between two electrodes immersed in the oil separated by a specific gap or

• Also known as the sparking strength, the higher the voltage required to jump the spark, the higher the

BDV will be in the oil. The lower the voltage required to jump the spark, the BDV will be lower

indicating the presence of moisture content and other conducting substances in the oil distance.

• A rating of 30 kV is the minimum breakdown voltage at which transformer oil can be safely used in a

power transformer.

• Dielectric strength of oils is also determined by the dielectric loss tangent or “Tan Delta.”

• Oil samples from top oil & bottom oil of Power transformer main tank as well as OLTC tank are to be

collected and tested. Across 2.5 mm gap test Kit, The oil shall stand for KV For/ minute.
3. Measurement of winding resistance at all taps

• To check for any abnormalities due to loose connections, broken strands and high contact resistance in tap
changers.

• Resistance measurement of winding should be done at all tap positions.

• The Resistance of HV winding LV winding between their terminals are to be measured with precision milli
ohm meter/ micro ohm meter.

• HV side RY= YB= BR=

• LV side ry = yb = br = rn = yn= bn =

• Winding resistance is always defined as the DC‐resistance (active or actual resistance) of a winding in Ohms
(Ω).

• The values shall be compared with original test results.

• There are basically two different methods for resistance measurement:”“voltmeter‐ammeter method” and
The bridge method. (using a Kelvin (Thomson) Bridge)
4. Turns ratio (Voltage ratio) test :

• To determine the turns ratio of transformers to identify any abnormality in tap changers/ shorted or
open turns etc.

• Measurement of turn ratio is based on, applying a phase voltage to one of the windings using a
bridge (equipment) and measuring the ratio of the induced voltage at the bridge.

• The measurements are repeated in all phases and at all tap positions, sequentially.

• The ratio test between the HV and LV at all tap positions should also be performed.

• For three winding transformers ratio between other pair of windings should also be taken.

• Theoretical turn ratio = HV winding voltage / LV winding voltage

• % Deviation = 100 x ((Measured TR) ‐ (Designed TR)) / (Designed TR)

• Where TR is turn ratio. The % deviation of the turn ratios should be ≤ 0.5 %.
• With turns Ratio meter, turns Ratio between HV & LV windings at various
taps to be measured & recorded. At normal tap for 33/11 KV Delta/Star
transformer the turns ratio is 5.196. At other taps values will be as per the
percentage raise or lower at the respective tap positions.

• When “Turns Ratio meter” is not available, Voltage Ratio Test is done at
Various tap position by applying 3 phase LT(415V) supply on 33 KV side of
Power transformer. At Various taps applied voltage and Resultant voltages
LV side between various Phases and phases& neutral measured with
precision voltmeter & noted.
• The tap changer should be undergone the following tests

• Manual operation

• Local electrical operation

• Remote electrical operation

• Parallel operation

• The operation should be checked from one end of the range to the other to
check for the limit switch operation also.

• IR values of the motor and control wiring should be checked by 500 V

Megger.
5. Polarity and vector group Test

• This test is used to determine the phase relationship and polarity of transformers.

• . Polarity test
Polarity test
 Vector Group Test

• Determining the connection group is valid only in

three phase transformers.

• The phase angle between the high voltage and the

low voltage windings varies between 0⁰ and 360 ⁰.

• Connect HV side ‘R’ Phase terminal to LV side ‘R

Phase terminal of Power transformer.

• Apply 3Phase 415 V supply to HV side of Power

transformer. Measure Voltages between various
terminals as follows.
 6. Short Circuit Test
• The four terminals on LV side of Power transformer are shorted with 50 sq. mm.
copper cable.

• Three phase LT supply is applied on HV side of power transformer at normal tap

and currents measured in all the phases on HV side and phases & neutral on LV
side values noted.

• The Resultant HV & LV currents areas follows:

7. Magnetic Balance test

• Magnetic balance test is conducted only on three-phase transformers to check the imbalance in the magnetic circuit.

• Result of this test indicates uniform distribution of flux insulation.

• 415V, Two phase supply is to be applied to any two phases terminals on HV side of Power transformer and voltages in
other two phase combination are to be measured.

• Sum of the Resultant two values shall be equal to the voltage applied.

• In this test, no winding terminal should be grounded. Otherwise results would be erratic and confusing.

• The test shall be performed before winding resistance measurement.

8. Exciting / Magnetizing current measurement

• This test should be done before DC measurements of winding resistance to reduce the effect of residual
magnetism.

• Magnetizing current readings may be effected by residual magnetism in the core.

• Therefore, transformer under test may be demagnetized before commencement of magnetizing current test.

• The magnetizing current can be measured with milli ammeter by feeding 415 V, three phase 50 Hz supply
from HV side keeping the LV side open circuited and the value in different phases could be compared.
 PRE COMMISSIONING CHECKS ON POWER TRANSFORMERS

Check that
1) Top & Bottom valves of radiators are in open position
2) All drain valves are in closed position with dummy plates in position duly fitted with bolts & nuts
3) All filler valves in closed position with dummy plates in position duly fitted with bolts & nuts
4) No oil leakages from radiators, valves, dummies, top cover, inspection covers, oil level gauges etc.
5) Silica gel breather is in position with silica gel filled & oil in oil cup
6) The air path of silica gel breather is free with out any seals to holes of the oil cup
7) Equalizing valve of the interconnecting pipe of vent pipe to conservator tank is in open position
8) Top oil filling point of conservator tank is in closed position with cover duly bolted.
9) The valves on either side of Bucholtz relay are in open position.
10)Thermometer pockets on main tank top cover are having oil inside & Thermometer sensing bulbs are in position duly nuts fixed properly.
11)The double earthing of neutral of Power transformer is done as per standards.
12) The double earthing of body of Power transformer is done as per standards.
13)The oil levels in conservator tank, OLTC Conservator tank.
14)The operation of main Bucholtz relay & OLTC Bucholtz relay ( Trips &alarms to be checked)
15)Operation of Transformer alarms.
16) The operation of PRV to trip the breakers or operation of alarms
17) The vent pipe diaphragm is intact.
18) The lock pieces are provided, duly welded to base channels, for the support wheels of transformers (If wheels are provided)
19)Tightness of all bolts, nuts, clamps, jumpers etc.
• Buchholz Relay Test

• Buchholz relay operation for alarm and trip should also be checked by injecting air to the test pocket provided
in the relay.

• Low Oil Level Alarm Test

• The low oil level alarm of the magnetic oil gauge should be checked.

• Temperature Indicator Test

• The contacts of the Oil Temperature Indicator and Winding Temperature Indicator for alarm trip and control
should be checked and set at required temperature.

• Cooling Gear Test

• The IR values and setting for operation of oil pumps and fans motor should be checked.

• Alarm trip contact settings of differential pressure gauge, oil and water flow indicators, where provided should
be checked.
• Marshalling Box

• The Marshalling box is the master control panel for protection devices. This panel comes
with a see-through glass door to allow easy visibility of the instruments and their readings.
The panel is situated next to the transformer.

• The wiring from various accessories to the Marshalling kiosk should be checked

• Protective Relay Test

• Tripping of associated circuit breakers is to be provided by actual operation of

differential relay, over current relay, earth fault relay and other protective relays as applicable.
Additional checks during commissioning of power
transformer
1. All oil valves are in correct position closed or opened as required.
2. All air pockets are cleared.
3. Thermometer pockets are filled with oil.
4. Oil is at correct level in the bushing, conservator tank, diverter
switch tank etc.
5. Arcing horn of the bushing is set correctly
6. CT polarity is correct when bushing mounted CTs are provided.
• If all the above tests/checks are found satisfactory, a settling time of at least 24 hours, should be
allowed for the oil and air released from all points at six hourly intervals, before commissioning
the transformer.

• Whenever possible, while commissioning, the voltage should be build up slowly and brought to
the full level in about 4 to 6 hours.

• If the circuit breaker is tripped on differential, Buchholz or any other devices, the cause must be
investigated before re-energizing the transformer. Sometimes tripping occurs maybe because of
magnetic inrush current which depends upon the switching at a particular moment in the cycle.

• After commissioning magnetising current should be measured by connecting clip on meter in

current transformer circuits and the reading should be compared with the test report value.
• Tests on Breakers

• A) I) Status of Breaker “Open” Measure IR values between “IN” & “Out” terminals Each limb of breaker shall be more than 3000 MΩ

• II) Status of Breaker “Close” Measure resistant of each limb by connecting “IN” & “Out” terminals to a precision Micro ohm meter. The values shall tally with manufacturer’s test
report.

• III) Status of Breaker “Close” Measure IR values between phase & Body ground terminal of breaker for all limbs the values shall be more than 3000 MΩ

• B) Opening time & closing time tests to be done on all limbs. The values shall tally with test results of the Manufacturer.

• C) As follows:

• a) IR values of current Transformers are to be measured.

• b) Polarity check on current transformers is to be made.

• c) Primary injection test on current transformer is to be done to check operation of relays functioning of meters.

• d) Secondary Injection test on relays is to be done.

• e) DC tests on breakers panel are to be done.

• f) Calibration of meters is to be done.

• g) D.C. interlock are to be tested.

• h) Check that all Jumpers, clamps etc. are in to CT

• i) Clean all the bushings.

• j) Ensure no leakages from the CTs.

• Tests on Potential Transformers

• A) IR value are to be checked with megger.

• B) Ratio test is to be done.

• C) Polarity check is to be done.

• D) Check that there are no oil leakages

• E) Clamps & Jumpers properly tightened.

• Tests on Lightening Arrestors

• a) IR value are to be checked. b) Jumper connection to be checked

• Other tests in a Sub Station

• a) Battery charger & Battery to be checked for proper operation

• b) Earth Resistance is to be measured & noted.

• c) Meggering of Bus Bars is to be done.

• d) Check the entire earthing system in the Sub Station is as per standards.
 A Few more tests are mentioned below:
• Operational Checks on protection System: Checks whether the protection devices are working good. It checks

on the cooler bank (pumps & Fans), Breathers (silica gel or drycol), MOG, temperature gauges (WTI/OTI),

gas actuated relays (Buchholz, PRD, SPR etc.) and simulation test of the protection system.

• Capacitance measurement of bushings: Measurement of C1 & C2 Capacitance, Changes in the normal

capacitance of an insulator indicate abnormal conditions such as the presence of moisture layer, short ‐ circuits

or open circuits in the capacitance network.

• Vibration measurement: The measurement of vibration is an important control procedure that must be

performed periodically, which can be the result of the movement of the core-spiral assembly and the shielding

structure caused by the variable magnetic forces in time that results in the vibration of the tank and auxiliary

equipment. These vibrations have detrimental effects, such as excessive tension in the core-coil assembly.
• Frequency Response Analysis (FRA) measurement: To evaluate the mechanical integrity of the transformer. Transformers while experiencing the

severity of the short-circuit current lose their mechanical properties by means of deformation of the winding or core. During the precommission, this

test is required to determine that the active part of the Transformer has not suffered any severe impact / shake during transport.

• Floating Neutral point measurement: This test is conducted to ascertain the possibility of the short circuit in a winding.

• Measurement of Short Circuit Impedance: This test is used to detect the winding movement that usually occurs due to a heavy fault current or

mechanical damage during transportation or installation from shipment from the factory.

• Magnetising current measurement: To locate the defect in magnetic core structure, shifting of windings, failures, in turn, to turn insulation or

problems in tap changers. These conditions change the effective reluctance of the magnetic circuit thus affecting the current required to establish the

flux in the core.

• Operational check on OLTCs: To ensure smooth & trouble free operation of OLTC during operation.

• Stability of Differential, REF of Transformer/ Reactor: This test is performed to verify the proper functioning of the differential protection and REF

of the transformer and the reactor simulating the actual conditions. Any problem in the CT connection, incorrect wiring, retransmission adjustment

can be detected by this test.

• Tests/ Checks on Bushing Current Transformers (BCTs): To ascertain the healthiness of bushing current transformer at the time of erection
Thank You