Inspection of Electric Equipment

-K P Kalyan Reddy
Visakh New LPG Terminal
Scope

• This standard specifies the minimum inspection requirements for

the installed electrical systems in the Oil Industry, during their
operation and maintenance with special reference to the safety
aspects.
• i) Permit-to-work (Electrical) or Electrical Line Clearances
covering special safety requirements for jobs requiring Electrical
Isolation/ Lockout.
• ii) Pre-commissioning check items for new installations as well as
for repaired equipment.
Hazards due to failure of Electrical
Equipment
• Failures of electrical equipment gives rise to any or all the following hazards:
• i) Fatal accidents due to electric shock.
• ii) Fire accidents and burn injuries due to electric arcs/sparks/hot surfaces
• iii) Abrupt interruption in plant operation.
• iv) Environmental hazards such as leakage of insulating oil / SF6 gas etc.
• v) Burn injuries due to leakage of hot lube oil/ transformer oil.
• vi) Injuries to the personnel due to due to improper handling of charged springs of various
circuit breakers.
• vii) Fire/ spark/ burn/ explosions due to wrong operations of battery bank and capacitor
bank.
• viii) Flashover due to failure of shrouds between phases in a cubicle.
Probable Reasons for failure

• i) Imposed external conditions such as deterioration of enclosure, insulation and operating

mechanism by environment conditions like heat, moisture, dust, chemical attack, dirt, drop object,
cable damage due to vehicle/ crane entry etc.
• ii) Quality of power supply (like undervoltage, overvoltage, frequency variation, asynchronous
operation, improper wave form e.g. main supply to inverter supply, overheating, power dips,
unbalanced voltage, frequently failures of power supply etc.
• iii) Overloading due to any reason.
• iv) Internal faults in the equipment itself mainly due to manufacturing defects, or those crept in
during installation, maintenance and repairs.
• v) Inferior quality of work due to factors like poor workmanship by unqualified/unskilled and
untrained workers, inadequate or incompetent supervision, non-compliance of safety and statutory
requirements, adoption of incorrect procedures, and usage of poor quality of tools and tackles.
• vi) Usage of substandard materials and equipment not in conformity with original design
specifications.
Probable reasons of Failure

• vii) Design deficiencies in the technical specifications, improper

sizing and layout of installations and lack of total system concept.
• viii) Bypassing of protective and interlocking devices/circuits
during operation though originally designed for the system.
• ix) Inability for carrying out shutdown inspection/tests on the
equipment in time, as required by maintenance inspection
schedules, due to difficulties in taking the equipment out of
service.
Procedures for Electric tests and
Recommended Values

• Insulation Resistance Test.

• Insulation tests are used to determine the quality or condition of the insulation
systems of electrical equipment or circuits. Insulation resistance is measured to
ensure absence of leakage current and humidity.
• For a given insulation condition, the acceptable value of resistance depends on
the size and type of the equipment, and voltage rating. The insulation resistance
is directly measured with the help of Insulation Resistance Tester which applies
constant test voltage (d.c) on the insulation. This test voltage has to be applied
for the time required for the absorption current to die down, (normally 1
minute). Electrical installations shall be tested for insulation resistance between
all conductors and earth and between the conductors themselves.
Insulation Resistance Test

• As per the CEA Regulations 33:

• (i) all equipment shall have the insulation resistance (IR) value as stipulated in the
relevant Indian Standards;
• (ii) on application of 500 V DC between each live conductor and earth for a period of one
minute the insulation resistance of installation and equipment of voltage not exceeding
650 V shall be at least 1 MEGA OHM or as specified in the relevant Indian Standard;
• (iii) on application of 2.5 kV-DC between each live conductor and earth for a period of
one minute, the insulation resistance, of installation and equipment of voltage exceeding
650 V but not exceeding 33 kV shall be at least 5 MEGA OHM or as specified in the
relevant Indian Standard. If the insulation resistance values obtained are less than
required value, the approved method of drying out/ repairs shall be applied until the
required steady insulation resistance value is obtained
Measurment of Earth Resistance

• Earth resistance can be directly read through an

earth resistance tester which has associated Test,
auxiliary Current and Potential electrodes. This
instrument which is a combination of ohmmeter
and generator works on ‘fall of potential’
principle. Test voltage is derived from the
generator of the earth resistance tester
• Two auxiliary earth electrodes, besides the test
electrode, are placed at suitable distance from
the test electrode as shown in figure below. A
measured current is passed between the
electrode ‘A’ to be tested and an auxiliary
current electrode ‘C’, and the potential
difference between the electrode ‘A’ and
auxiliary potential electrode ‘B’ is measured. The
resistance of the test electrode ‘A’ is then given
by: V R = -- I Where, R = Resistance of the test
electrode in ohms V = Reading of the voltmeter in
volts I = Reading of the ammeter in amps.
Allowable Earth Resistance Values

• For the electrical system and equipment, a value that ensures the
operation of the protective device in the electrical circuit but not in
excess of 4 ohms. However, for generating stations and large sub-
stations this value shall not be more than 1 ohm.
• For lightning protection, the value of 4 ohms as earth resistance shall be
desirable, but in no case it shall be more than 10 ohms.
•  7 Ohms for storage tanks
•  1 Ohm for main earth grid, and bonding connections between joints in
pipelines & associated facilities.
•  2 Ohms for each electrode to the general mass of the earth
Earth Continuity Test

All protective and bonding conductors

must be tested to ensure that they are
Click icon to add picture
electrically safe and correctly connected.
Method for measuring resistance of
protective conductor by using the neutral
conductor as return lead is as follows: A
temporary link is made at the distribution
board between neutral and protective
conductor systems (Don't forget to remove
the link after testing). The low resistance
tester is then connected to the earth and
neutral of the point from which the
measurement is taken (see {Fig below}).
This gives the combined resistance of the
protective and neutral conductors back to
the distribution board.
Polarisation Index Test

• The polarization index is a specialized application of the dielectric-absorption test.

• This test is used to determine the insulation resistance level of cable, transformers,
motors and similar electrical equipment. Using a power driven insulation tester, the
test voltage is applied to the equipment for a period of 10 minutes.
• The insulation resistance values at the end of 1 minute and 10 minutes period are
recorded.
• The ratio of the final resistance to initial resistance is called the Polarisation index.
A fair index is greater than 2.0; a poor to questionable index is 2.0 to 1. When index
level starts at 2.5 to 4 base level and begins to fall one or two years later to 1.5 or 2
it is apparent that either the insulation/ cable has absorbed moisture, or the
insulation has become weak to an unsafe level.
Polarisation Index Values.

• Thermal Class Rating (Insulation Class as per IEC 60085-01 :1984)

Minimum PI
• Class A 1.5
• Class B 2.0
• Class F 2.0
• Class H 2.0
Dielectric Absorption Test

• Moisture absorption is usually evaluated from the ratio of two

values of insulation resistance measured with Insulation tester
after 60 seconds and 30 seconds respectively.
• This ratio is called the Coefficient of moisture (dielectric)
absorption, denoted by ‘K’. R60 K = ----- R30
• Damp installation will have a coefficient value close to 1.
• As the insulation dries out, the coefficient rises and when it
becomes 1.3 or greater the insulation is considered to be dry.
DAR 1.4 or more 1.25 - 1.0 1.0 or less
Criteria Best Good Bad
Cathodic Protection

• The underground or submerged structures such as pipelines, mounded bullets shall be

protected against electrolytic corrosion by cathodic protection, either by the “impressed
current” or the “sacrificial anode” methods.
• Periodic testing of cathodic protection system such as structure to soil voltage, anode
current, soil resistivity, performance of transformer and rectifier shall be carried out to
ensure continued protection.
• Current output and voltages shall be adjusted to maintain the degree of cathodic
protection. Allowable values of structure to soil voltage shall not be less than (-) 0.85
volts with respect to copper /copper sulphate half cell. Current density requirement
depends on the condition of coating and soil resistivity. Better the quality of coating,
lower will be the requirement of current.
• The upper limit for the PSP shall not exceed (-) 1.2 V to avoid disbonding of insulation
wrap coating.
Tests On Lightening Protection

• Building and Structures: The ohmic resistance of lightning protective system complete with
air terminations but excluding earth electrode connections should not exceed 1 ohm.
• The continuity of lightning conductors and bonding connections of structures shall be tested
to ensure that there are no open circuits. Also, checks shall be made to ensure that the
clearances from other structures are maintained to prevent flashover to the structure during
lightning.
• b) Lightning arrestor: On Line Measurement of Third Harmonic Resistive Leakage Current.
The total current (IT) through the Surge Arrester having Capacitive component (IC) and
Resistive Current (IR) flows through the Leakage Current monitor.
• The IR component has 3rd, 5th and other harmonics present in it.
• When degradation of the metal oxide discs occur, the variation of 3rd harmonic Resistive
currents is more pronounced than other harmonics currents, total current ( IT) and total
Capacitive current ( IC).
Lightening Protection Test Method.

• A clamp type CT probe is connected to the ground wire which allows the leakage current to be
detected.
• The probe output passes through a shielded cable to the detector unit. A band pass filter is
built into the initial stage to pass the 3rd harmonic and to cut off the 5th & higher harmonics.
• After the 3rd harmonic is selected, it is amplified and then displayed. A compensating
antenna is also provided, output of which is fed to the test kit to compensate for the
harmonics present in the system voltage.
• The harmonics present in the EHV system are compensated and filter circuits are provided for
bypassing undesired currents and only 3rd harmonic resistive current is measured. The
following parameters are measured: •
• True RMS value of total current, flowing through ground circuit.
• • Peak value of total current • True RMS value of third harmonic leakage current. • Ambient
Temperature.
Interpretation of Results.

• The non-linear voltage-current characteristic of a metal-oxide arrester gives rise to harmonics

in the leakage current when the arrester is energized with a sinusoidal voltage.
• The harmonic content depends on the magnitude of the resistive current and the degree of
non-linearity, which is a function of voltage and temperature.
• The third harmonic content of the resistive current is typically 10 % to 40 % of the Total
Resistive current.
• An increase in the third harmonic resistive component of leakage current brings the arrester to
thermal overloading and finally causes breakdown.
• If the increase in the 3rd harmonic current is monitored and detected earlier, then arrester
can be repaired or replaced, thus preventing damage.
• The parameters of currents recorded are compared with previous measured values on the
same arrester. The values are also compared with arrester of similar make and type, operating
under similar conditions.
Acceptable Values of third harmonic.

• Acceptable limits of Third Harmonic Resistive Current as per CBIP

Manual on EHV Substation Equipment Maintenance (Publication No.
294) (Refer Annexure -1, Table 11.9)
Transformer Testing.
Tan Delta Testing
• The dielectric loss in an insulation system is the power dissipated by the insulation
when subjected to an applied alternating voltage.
• Good insulation usually has a very low loss, while a high loss may indicate problems
in the insulation structure.
• A dielectric loss testing program provides several important benefits. Periodic tests
performed during the service life of the equipment can indicate that the insulation is
either aging normally or deteriorating rapidly.
• The dielectric loss is usually determined by a bridge measuring instrument, such as
the Schering Bridge.
• The test can be performed at any voltage within the normal operating range of the
equipment under test, however usually performed at rated voltage or a maximum of
10kV.
Transformer Oil Testing

• Proper care shall be taken for taking oil samples for testing. It
should be ensured that the sample bottle is clean and dry. The
bottle shall be properly rinsed with the same oil which has to be
tested, before filling up the sample.
• The Oil Testing shall be carried out as per IS 1866. The various
tests and the recommended limits for the characteristics of Oil
based on IS 1866 are as follow
Transformer Oil Testing
Transformer Oil Testing
Dissolved Gas Analysis

• This test is used to determine the amount of specific gases generated in Transformer oil during
service.
• The amount of gases and certain combinations of those is the first indication of a possible
malfunction that may eventually lead to failure if not corrected.
• Some of the mechanisms which lead to generation of gases due to the chemical decomposition of
oil are arcing, partial discharges, low-energy sparking, severe overloading, overheating of the
insulation etc. Certain empirical values are provided to give an indication of the impending failure.
• For DGA testing the sample should be obtained using a clean, moisture free, gas tight container.
Care should be taken to purge the container of all free gas at the time of taking the sample.
• The first step in evaluating DGA results is to consider the concentration levels (in ppm) of each key
gas. It is recommended that values for each of the key gases be trended over time so that the
rate-of-change of the various gas concentrations can be evaluated. Basically, any sharp increase in
key gas concentration is indicative of a potential problem within the transformer
Dissolved Gas Analysis
Thermography

• Heat is often an early symptom of equipment damage or malfunction for

electrical equipment.
• Checking the temperature of electrical equipment on a regular basis helps
in quickly identifying unusual temperature conditions and reduces the
likelihood of unplanned downtime due to equipment failure.
• In thermography the thermal image of the equipment is taken, the infrared
image captures the equipment temperature profile.
• Thermography can be used to measure bearing temperatures in large
motors, hot spots in electrical switchgear, identify faulty terminations, and
identify electrical equipment like transformers, LA, circuit breakers
operating at high temperatures.