1

Group A
TOUR DEBRIEFING

VISIT OF
‘HIGH VOLTAGE & SHORT
CUIRCUIT TESTING LABORATORY,
NTDC, RAWAT’
28TH of DECEMBER 2018

2
 Group A
TOUR DEBRIEFING

Group Composition
1. Shakeel Ahmed Awan (Group Leader)
2. Faisal Mehmood
3. Muhammad Naeem Aziz
4. Samreen Akbar
5. Syed Hayat Hussain
6. Ashfaque Ahmed Soomro
7. Muhammad Tahir Jadoon
8. Muhammad Omer Khan 3
 Sequence of Presentation
1. Shakeel Ahmed Awan Introduction to the Visit
(Group Leader)
2. Faisal Mehmood- High Power Testing Section
3. Muhammad Naeem Aziz- High Voltage Testing Section
4. Samreen Akbar- High Voltage Testing Section (Continued)
5. Syed Hayat Hussain- Client Profile & Budget
6. Ashfaque Ahmed Soomro Establishment & Modernization of HV & SC Lab.
7. Muhammad Tahir Jadoon: Properties / Tests of Oil
8. Muhammad Omer Khan: Oil Testing Facilities & Future Plan

4
High Voltage & Short Circuit Testing Laboratory, Rawat 5
High Voltage & Short Circuit Testing Laboratory, Rawat 6
High Voltage & Short Circuit Testing Laboratory, Rawat 7
 INTRODUCTION

HISTORY
In the establishment of this laboratory,
Government of Japan provided over 1.4 Billion
rupees in 1986 in foreign exchange under its
Grant-in-aid program.

There were many proposals as to which shall be

the controlling agency this laboratory but in the
8
end it was put under Wapda.
 Introduction
HISTORY
However, contrary to the apprehensions of many
people, by the Grace of God and untiring efforts of the
Management, the Lab became a viable self-reliant
organization and it was declared by Chairman WAPDA
as a self-financing unit in April, 2004 and since then it is
running into profit
9
 INTRODUCTION
OBJECTIVES

1.National self reliance (Testing of Electrical Power

Equipment)
2.Quality enhancement of new equipment
3.Enhancing reliability of repaired equipment
4.To encourage manufacturing of equipment of
10
higher ratings
 INTRODUCTION

OBJECTIVES

5.Save & earn foreign exchange

6.Serve as qualified inspection resource center for
foreign procurements
7.To have international recognition and competency
levels through relevant ISO certifications 11
 INTRODUCTION

ORGANIZATIONAL SETUP

 HV&SC Lab Rawat works under the control of

GM TSG, NTDC, Lahore.

 HV&SC Lab is headed by a Chief Engineer

who is supported by Managers (Tech), DM, AM
and other allied staff.

12
 INTRODUCTION

MAIN TESTING SECTIONS

 High Power Testing Section Rawat

 High Voltage Testing Section in Rawat

13
 INTRODUCTION

STANDARDIZATION

 HV&SC Lab Rawat has got the certification of

ISO 9001:2008, expired on

 High Voltage Testing Section in Rawat

14
FAISAL MAHMOOD
DY. MANAGER(QA&A)
NTDC LAHORE
 Description of High Power testing Section of
HVSCL Rawat, Islamabad
HVSCL Rawat is laced with most state of the art
equipment. The high power section has got the
most vital testing facilities in Pakistan i.e. short
circuit testing which is not available anywhere in
Pakistan except Rawat Lab. The heart of this
testing facility is “Short Circuit Generator”.
Brief description of components used in short
circuit testing facility.
Description of High Power testing Section of
HVSCL Rawat, Islamabad

High Power Section has the following main Installed

equipment:
Short Circuit Generator: Short circuit rating: 650
MVA (3 cycles), 500 kVA continuous-rated
alternator, split coil Y-connected, 16 kV, Excitation
voltage: 500 V, 50 Hz, 4 Poles, 1500 rpm, 37.5 kA L-L
symmetrical & 3-Ø 23.438 kA symmetrical short
circuit currents (60 ms), Class F insulation.
Description of High Power testing Section of HVSCL
Rawat, Islamabad
IN High Power Section has the following main Installed equipment
Short Circuit Generator: Short circuit rating: 650 MVA (3 cycles), 500
kVA continuous-rated alternator, split coil Y-connected, 16 kV,
Excitation voltage: 500 V, 50 Hz, 4 Poles, 1500 rpm, 37.5 kA L-L
symmetrical & 3-Ø 23.438 kA symmetrical short circuit currents (60
ms), Class F insulation
11 kV Induction Motor: Prime mover of SCG, 3-Ø, 2500 kW, 1500 rpm
Back-up Circuit Breakers: 02 numbers, 3 Phase, Indoor type VCB, 24
kV, 50 Hz, 2 kA with a breaking capacity of 40 kA
Making Switch: Specially designed, Indoor type, 3 x single pole, Air
blast type (20 Kg/cm 2), 16 kV, 3 kA, 50 Hz
 Description of High Power testing Section of
HVSCL Rawat, Islamabad

Short Circuit Transformers:

16/30 x √3 kV, 3-Ø ,50 Hz, 150 MVA step-up transformer, 16/90 kV, 1- Ø; Step-up
transformer
Low-voltage High-current Transformer: Single phase, Indoor type, 16 kV/250 Vx2,
3 MVA for
3 seconds
Current Transformer Test Bench (6000 A): For Accuracy test on Current
Transformers
 Description of High Power testing Section of
HVSCL Rawat, Islamabad

Following different tests can be performed in HP Section:

Short Circuit Tests:
Direct Short Circuit Tests: 16 kV, 25 kA max
Low Voltage, High Current Tests: Up to 500/250 V, 100 kA
Temperature rise test on Distribution Transformers, LV Bus Duct
& Switchgear Panels
Mechanical endurance test on Switchgear Panels
Description of High Power testing Section of
HVSCL Rawat, Islamabad

Following are the under test equipment which are frequently tested in HP Section:
Load and Fault Interrupting Current Test on 11 kV Dropout Cutouts
Power Arc Test on Disc Insulators
Short-time withstand current Test on Current Transformers, LV Bus Duct, 11 kV VCB panel, 11 kV termination kits/joints,
3-Ø grounding sets, Knife Switches, 3 Way & 4 Way Switch, 132 kV Line/Bus Isolator
Short-Circuit Test on:
All types of 11 kV Distribution Transformers
11 kV Potential Transformers
132 kV Power Transformers (Up to 31.5/40 MVA)
3-phase distrubtion transfarmor
SINGLE INSULATOR DROP OUT CUT OUT 11Kv
Mohammad Naeem Aziz

DY. MANAGER
NTDC, Multan
 High Voltage Testing Section

• These facilities comply with IEC insulation standards of High Voltage

testing
• Provides a wide range of possibilities in the field of short and long-term insulation testing.
• In parallel with the voltage tests:
• Mineral insulating oil testing,
• Radio interference voltage,
• Measurements of Capacitance and Dissipation Factor and
• Rain tests.
 SYSTEM DESCRIPTION
(HIGH VOLTAGE TESTING SECTION )

• Impulse Generator:
• Indoor static type, Maximum voltage: 1800 kV, 180 kJ, 9 µF

• High Voltage Transformer:

• Single phase, outdoor type, 2000 kVA, 11 kV x 2/500 kV, 50 Hz
• Motor Generator Set:
• Driving Motor:
• Squirrel cage induction motor, 3 phase, 720 kW, 11 kV, 50 Hz

• High Frequency Generator:

• 11 kV, 1000 kVA, 91A, Single phase, 200 Hz, PF leading with damper winding

• Step-up Transformer:
• Single phase, outdoor type, 200 Hz, 1000 kVA, 11 kV/75-150 kV,
250 kVA: 11 kV/18.75-37.5 kV
 SYSTEM DESCRIPTION
(HIGH VOLTAGE TESTING SECTION)

• Artificial Rain Facility:

• Needle nozzle frame, spray nozzle frame, water pump (0.3m3/min)
• Artificial Fog Generation Facility:
• Steam boiler, water storage tanks, oil storage tanks
• Wall Bushing:
• 500 kV, 4A Max, Partial Discharge level: less than 10 at 500 kV
• Coupling Capacitor:
• Single phase, outdoor type, 50 Hz, 500 kV, 1000 pF
 HIGH VOLTAGE TESTING SECTION
CAPABILITIES
• 50 Hz dry & wet voltage withstand test
• 50 Hz dry & wet voltage flashover test
• Lightning impulse voltage withstand test up to 1800 kV
• Lightning impulse voltage flashover test
• Switching impulse voltage withstand test up to 1300 kV
• Switching impulse voltage flashover test
• Single-phase power frequency voltage withstands test up to a maximum of 500
kV, 2000 kVA
• Induced over-voltage withstand test up to 150 kV, 1000 kVA at 200 Hz (1-Ø)
• DC (direct current) voltage withstand test
• DC (direct current) voltage flashover test
 Voltage Withstand Test

• Dry withstand test :

• Most common routine test for all types of electrical equipment especially insulators, bushing, rod
gaps etc.
• Applied voltage between two to three times of the normal working voltage
• Wet withstand test :
• To simulate the effect of natural rain on external insulation.
• Recommended for tests on apparatus which are designed for outdoor used.
• Use artificial rain.
• Applied for 30-60 seconds.
 Voltage Flashover Test
• The flash-over is due to a breakdown of air at the insulator surface, and is independent of the
material of the insulator. As the flash-over under wet conditions and dry conditions differ , tests
such as the one minute dry flash-over test and the one minute wet flash-over test are
performance
• Dry flash-over voltage test
• In this the test voltage is applied . The voltage is raised to this test value in
approximately 10 seconds and shall be maintained for one minute. The voltage
shall then be increased gradually until flash- over occurs
• Wet flash over voltage test
• In this the insulator is sprayed throughout the test with artificial rain drawn from
source of supply at a temperature within 10 degrees of centigrade of the ambient
temperature in the neighborhood of the insulator. The resistivity of the water is to
be between 9,000 and 11,000 ohm cm.
 Lightening Impulse Voltage
• Is designed to investigate the insulation performance due to the lightning stroke or
Lightning impulse chopped on the front switching operation.
• The standard lightning-impulse voltage is a smooth full lightning-impulse
voltage having a front time of 1.2 µs and a time to half-value of 50 µs and
described as a 1.2/50 impulse
• In impulse tests it is required to apply to the circuit or apparatus under test, a high
direct voltage whose value rises from zero to maximum in a very short time and dies
away again comparatively slowly

• 3 types of impulse voltages.

• 1) Full wave
• 2) Chopped wave
• 3) Switching wave
 Switching Impulse Voltage Test

• The purpose of switching impulse voltage test is to secure the transformer

insulation withstand the lightening overvoltage which may occur in service
• The switching over voltage or switching impulse may have front time of several
hundred microseconds and this voltage may be periodically
damped out
• The IEC 600060 has adopted For their switching impulse test, a long wave having
front time 250 microsecond and time to
half value 2500 microsecond with tolerances.
 Induced Over Voltage Test
• This test is basically used to check the inter turn insulation of the transformer
windings.
• Apply the double voltage and double frequency to the LV side by keeping the HV
side open circuited.
• In lab single phase generator with 200 HZ frequency is available
• The applied voltage is calculated as

• Time required for this test is calculated as

 High Voltage Direct Current tests
• These tests are done on apparatus expected to operate under direct voltage conditions,
and also where, due to the inconvenience of the use of high capacity transformers
required for extra high tension alternating voltage tests and due to transport
difficulties, alternating voltage tests cannot be performed after installation.
• A special feature of importance of the d.c test is the testing of cables which are
expected to operate under a.c. conditions.
• If the tests are done under a.c. conditions, a high charging current would be drawn and
the transformer used would have to have a current rating.
• Normal to subject the cable to carry out a high voltage test under d.c conditions.
• The test voltage would be about 2 working voltage ) and the voltage is maintained
from 15 min to 1.5 hrs.
• This d.c test is not complete equivalent to the corresponding a.c. conditions , it is the
leakage resistance which would determine the voltage distribution
• Although the electric field differs in the 2 cases, it is likely that the cable will stand up to
the required a.c. voltage.
Ms. Samreen Akbar

DY. MANAGER(TECH)
O/O GM (AM) SOUTH, NTDC
JAMSHORO
High Voltage Testing Section
(Continued)

This section further divided in two

sections namely

i. General High voltage

ii. Mineral Oil testing 37
 High Power Testing Section Capabilities

 Pollution Testing Heating Cycle Test

 Radio Interference Voltage Test
 Capacitance and tan delta measurement test
 Measurement of internal and external charge
and internal resistive current of metal oxide
surge arrestors

38
 High Power Testing Section Capabilities

 Artificial pollution Test up to 500kv for

single suspension insulator String
 Rain test
 Insulation AC/DC Watts loss test
 Heating cycle test
 Mineral insulating oil testing
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 High Power Testing Section Capabilities

Artificial pollution Test up to 500kv for single

suspension insulator String 40
 Services
XLPE power cables (Medium Voltage)
Power cable accessories (Termination Kits and
Straight through Joints)
Distribution transformer, LI/SI test on power &
Auto transformer
Testing of instrument transformers (MV)
41
 Services
Transformers panel ( MV)
Dropout Cutout Test (MV)
Industrial Panel ( MV), Bulk Metering Panel (
MV)
Disc/Pin Insulators
11 kV Grounding Stick, Shunt Capacitors, Knife
Switches
3 Ways & 4 Ways Switch
Line/Bus Isolator (132 kV, 2000A) 42
SYED HAYAT HUSSAIN

Client Profile & Budget

43
 LANDMARKS (1/2)
Type Testing of Following Equipment:
 Power T/F : 132/11.5 kV, 10/13, 20/26 & 31.5/40 MVA.

 Dist. T/F : 10-1500 kVA (Whole Range).

 OCB : 11 kV, 12.5 kA

 MCCB : 400 A & 800 A

 HT CT(11 kV) : 200/5,400/5,800/5 & 1600/5/5A

 LV CT(415V) : 800/400/5A

 Dropout Cutouts : 11 kV, 10 kA Asymmetrical

 Power cables : 15 kV ( 1-  and 3- )

 Termination kits : 11 kV

 Cable joints : 11 kV
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 LANDMARKS (2/2)

 Routine testing of Auto T/F: : 220/132/11 kV,160 MVA

 Routine testing of capacitors : 11 kV,100 kVAR & 500 kVAR


 Routine testing of Bushings : 32 kV and 220 kV

 Power arc performance of porcelain insulators : up to 220 kV

 Thermo-mechanical test of porcelain insulators : up to 220 kV

 Corona performance of Spacers / Dampers

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CLIENT’S PROFILE

 NATIONAL MANUFACTURERS

 NATIONAL ELECTRIC UTILITIES

 FOREIGN CLIENTS

 MISCELLANEOUS USERS

46
 NATIONAL CLIENTS
PRODUCT MANUFACTURER

1. HEC
POWER TRANSFORMERS 2. SIEMENS/VALIDUS
3. PEL
1. PEL
2. SIEMENS/VALIDUS
3. TRANSFO POWER
4. ELMETEC
DISTRIBUTION 5. TRANSFAB
TRANSFORMERS 6. JF INDUSTRIES
7. AB AMPERE
8. PAN POWER
9. SKY POWER
10. HAMMAD ENGG.
11. SYNERGY ELECTRIC
12. ACE Indigo
13. M-Tech
14. World Over
15. Power Tech

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 NATIONAL MANUFACTURERS
PRODUCT MANUFACTURER

1. PEL
CIRCUIT BREAKERS & 2. ALSTOM
PANEL, 11 kV 3. SIEMENS
4. FICO, GUJRANWALA
5. SIDDIQUE SONS
6. TARIQ ELECTRIC
1. FICO
2. WORLD OVER
3. NAEEM & CO.
DROPOUT / CUTOUTS 4. UPPAL BROTHERS
5. EAC
6. CREATIVE ENGG. CO.
7. ACE INDIGO INDUSTRIES
8. MALIK & SONS
9. SARA INDUSTRIES
10. UMAIR INDUSTRIES
11. UNITED ENGG.
12. AJMER ENGG.
13. CLIMATE ENGG.
1. EMCO
INSULATOR 2. HIGH LAND CERAMICS
3. PICO
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 NATIONAL MANUFACTURERS
PRODUCT MANUFACTURER

1. PEL
CT / PT 2. ELMETEC
3. FICO
4. METELX TECHNOLOGIES
5. BAIG ELECTRIC
TERMINATION KIT/ 1. SGWI, LAHORE
JOINTS 2. MI-TECH
3. ACA (ELASTI MOLD)
1. PAK CABLES
2. POINEER CABLES
XPLE POWER CABLES 3. NEWAGE CABLES
4. ATLAS CABELS
5. FAST CABLE
BULK METERING 1. BAIG ELECTRIC
PANEL/ 2. MK ENGG.
INDUSTRIAL PANEL 3. SIDDIQUE SONS
4. ZGL, FAISALABAD
5. PEL, LAHORE
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 NATIONAL UTILITIES

CLIENT PRODUCT

- DISTRIBUTION.T/F (Whole Range)

- POWER TRANSFORMERS
- POWER CABLES
K-Electric
- 11 kV VCB PANELS
- 11 kV CT
- 0.415 kV CT

- D.T/Fs (Whole Range)

- CABLES, JOINTS, CABLE TERMINATIONS
DISCOS
- DROPOUT/CUTOUTS

- P.T/Fs 132/11.5 kV(10/13 MVA,20/26 MVA)

- P.T/F 220/132/11.5 kV 160 MVA
NTDCL
- BUSHINGS, INSULATORS,CAPACITORS
- 500 kV DISCONNECTING SWITCH

ELECTRICITY, AJK - D.T/Fs, P.T/Fs

50
 FOREIGN CLIENTS

MANUFACTURER PRODUCT

AEG, GERMANY DISCONNECTING SWITCH (500 kV)

TRANSFO, IRAN POWER T/F (20 / 26 MVA)

XIAN ELECTRIC MACHINERY

CABLE (11 kV)
IMPORT EXPORT, CHINA

IRAN ELECT. EQUIP. ENGG. (IREEE) SPACER/DAMPER (220 kV)

EMCO, SAUDI ARABIA INSULATORS (132 kV)

AL-AMIN ENERCOM, BULGARIA POWER T/F (20/26 MVA)

ELPRAM ENGRO, BULGARIA

DIST. T/F 100 kVA

ELASTIMOLD, EYGPT CABLE TERMINATION (11 kV)

51
 BUDGET VERSES INCOME (FY July 2004-2010)

Financial Budget Expenditure Income

Year Grant (Rs Million)
2004-2005 71 79 73
(Self Financing)

2005-2006 67 52 86
2006-2007 71 115 102
2007-2008 78 91 103
2008-2009 98 43 106
2009-2010 98 55 112
2010-2011 54 57 109

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 BUDGET VERSES INCOME (FY July 2011-2018)

Financial Budget Expenditure Income

Year Grant (Rs Million)
2011-2012 67 49 112
2012-2013 84 68 157
2013-2014 91 74 120
2014-2015 95 56 184
2015-2016 130 92 198
2016-2017 155 127 213
7/2017 to 05/2018 316 160 197
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ESTABLISHMENT & MODERNIZATION OF
HV & SC LAB.

ASHFAQUE SOOMRO
 MODERNIZATION OF HV&SC LAB.

• HV&SC Lab. Rawat was established in 1992.

• Transformer Oil lab was established in 2006.

• The facilities of testing of Electrical Equipment along with

Transformer Oil lab. was upgraded in 2017.

55
 MODERNIZATION OF HV&SC LAB.

• Up-gradation of Digital Impulse Measurement (DIM) System of Lightening &

Switching Impulse Test.

• Replacement of in-coming cubicle for 500 kV High Voltage Transformer.

• Replacement of Lubrication Oil (11000 liters) of Short Circuit Generator.

• Replacement of Battery Bank (110 VDC, 1000 AH) for Short Circuit
Generator.

• Up-gradation of Transformer Oil Lab.

56
 OIL TESTING FACILITIES IN 2006
Relevant
S.# Equipment Name Make Test Name
Standard

1. AVO Megger Megger-UK Breakdown voltage IEC-60156

2. DTL measuring system Baur GmbH-Germany DDF at 90 0C IEC-60247

3. Temperature bath Stanhope seta-UK Corrosive sulphur IEC-62535

Potentially Corrosive
4. Temperature bath -do- DIN-51353
sulphur

5. 702 SM Titrino Metrohm- Switzerland Acidity IEC-62021-2

6. Density meter Zeal-UK Density at 20 0C ISO-3675

57
 CONTD…
Relevant
S.# Equipment Name Make Test Name
Standard

Pensky Martin close cup

7. Tanaka-Japan Flash point ISO-2719
test unit
Tanaka-Japan
8. Mini pour point tester Pour point IS0-3016

9. DTL measuring system Baur GmbH-Germany Resistivity at 90 0C IEC-60247

Kinematic viscosity bath

10. Tanaka-Japan Viscosity at 40 0C ASTM D-445
(KV-6)

11. Karl fisher test set Megger-UK Water content IEC-60814

12. DP-Petrotest set Petrotest GmbH- Oxidation Stability IEC-61125

Germany 58
 OIL TESTING
EQUIPMENT
INSTALLED IN 2006.

UNIT-1

59
OBJECTIVE OF UP-GRADATION OF OIL TESTING LAB.

• To enhance available testing facility.

• To include type testing facility.
• To make testing more convenient.
• To save time.
• To make the testing economical.

60
 OIL TESTING FACILITIES IN 2017

Relevant
S.# Equipment Name Make Test Name
Standard

1. Gas Chromatograph Scion-UK Total PCB Content IEC- 61619

2-Furfural & Related IEC-61198

High Performance Liquid
2. Sykam-Germany compounds &
Chromatograph IEC-60666
Inhibitor Content

3. Refrigerated Viscosity Bath Koehler-USA Viscosity at -20 0C ASTM D 445

4. Tensiometer Kruss-Germany Interfacial Tension ASTM D 971

61
 CONTD…
Relevant
S.# Equipment Name Make Test Name
Standard

5. Rotary Evaporator Heidolph-Germany PCA Content IP-346

Transformer Oil Gas

6. Shimadzu-Japan DGA ASTM D 3612
Analyzer

Sediment and
7. Filtration assembly Sartorius-Germany IEC-60422
sludge

8. Colorimeter Lovibond-UK Color ASTM D 1500

62
 OIL TESTING
EQUIPMENT
INSTALLED IN 2017.

UNIT - 2

63
 FEATURES OF NEW OIL LAB.

• The Equipment is European / Japanese.

• High accuracy class and robust.
• The Only Public Sector Oil lab having complete type testing
facility.
• Increased Revenue generation.
• Addition of DGA Test to analyze T/F oil.

64
PROPERTIES / TESTS OF OIL

M. TAHIR JADOON
 TRANSFORMER OIL
• Oil used in transformer for insulation is mineral oil, obtained by refining crude
petroleum

• It serves to:

 Provide dielectric strength

 Act as a coolant
 Preserve core & windings
 Protect the paper
 Act as diagnostic tool
 FUNDAMENTAL PROPERTIES OF TRANSFORMER OIL

• As per IEC-60296 Transformer Oil must have:

 Excellent dielectric properties resulting in minimum power loss.

 High resistivity leading to better insulation values.

 High flash point and thermal stability to reduce evaporation losses.

 Excellent ageing characteristics & heat transferability.

 Wide operating temperature range (higher Flash point & lower Pour point).
 CLASSIFICATION OF TRANSFORMER OIL

• Virgin/ Unused Oil:

Mineral oil as delivered by the supplier, that has not been used in, nor been in contact with the
electrical equipment or any other equipment not required for manufacturing, storage or
transportation.

• Prior to Energization Oil:

Mineral insulating oil that has already come into contact with the electrical equipment which
may not have been energized itself i.e. after filling in new electrical equipment before energizing.

• Used Oil:
Mineral insulating oil in an in-service electrical equipment that might be subjected to heat,
oxidation & moisture.
 IMPORTANCE OF OIL TESTING

• Oil properties changes gradually due to:

 Electrical and mechanical stresses.
 Contaminations by chemical interactions with windings and solid insulations at high
temp.

• Making it less-effective for its intended purpose.

• Must be periodically tested to ascertain its basic properties, and make sure it is suitable
for further use.
 PROPERTIES OF OIL & SIGNIFICANCE
• As per IEC-60296 oil properties are divided in to 4 different categories:

 FUNCTIONAL: properties having impact on its function as insulating & cooling liquid i.e. breakdown, water
content, viscosity, DDF, density & pour point.

 REFINING & STABILITY: properties that are influenced by quality & type of refining and additives i.e.
appearance, color, IFT, acidity, furan content & corrosive sulphur.

 PERFORMANCE: properties that are related to long term-behaviour of oil in service & its reaction to high
temp. and electrical stress i.e. oxidation stability.

 HEALTH, SAFETY & ENVIRONMENT: properties related to safe handling & environment protection i.e.
Flash point, PCB, PCA.
 PROPERTIES /TESTS OF OIL
S.No PROPERTIES/ TEST S.No PROPERTIES/ TEST

1 Color & Appearance 11 Corrosive sulphur

2 Water content 12 Potentially Corrosive sulphur

3 Breakdown voltage 13 Oxidation stability

4 DDF at 90 0C 14 Sediment and sludge

5 Acidity 15 2-Furfural & related compounds

6 Kinematic Viscosity at 40 & -20 0C 16 Inhibitor content

7 Resistivity at 90 0C 17 PCA Content

8 Density at 20 0C 18 PCB Content

9 Flash point 19 Interfacial Tension

10 Pour point 20 Dissolved Gas Analysis

OIL TESTING FACILITIES

M. OMER KHAN
 COLOR
(ASTM D-1500)
•The color and clarity of transformer oil can tell a great deal about the oil’s age and quality.
•As the oil ages, it slowly changes from a pale yellow, transparent color to a deep brown, more opaque shade.

•Darkened coloration is the first sign of ageing

& reduced efficiency and that the oil needs to
be changed or filtered.
Max. Limit: 2.0 (color Scale)
(for oil prior to energization)
COLOR TEST SET
 WATER CONTENT
(IEC-60814)
• This test detects moisture content in parts per million of the oil.
• Water content dramatically affect the
electrical characteristics of an insulating liquid.
• A high water content may make oil
unsuitable for some applications because
it lowers the dielectric strength/BDV.

Max. Value : 30 PPM (for virgin oil)

Note: the max. limits for prior to energization & used

oil are different.
KARL FISCHER TEST SET
 DIELECTRIC STRENGTH
(IEC-60156)

•The maximum voltage at which oil insulation breaks down.

• Significant reduction in the DES may indicate that oil is no longer
capable of performing its vital function.
• Reduction in dielectric strength may be due to
polar contaminants, such as water, oil & paper
degradation by-products.

Min. Values:
Un filtered: 30kV
Filtered: 70kV
BDV TEST SET
 DISSIPATION FACTOR
(IEC-60247)

• It measures the dielectric losses in the liquid & hence the amount of
energy dissipated as heat.
• A high power factor is an indication of significant power loss in the
insulating oil.
• A result of polar contaminants such
as water, oxidized oil and cellulose
paper degradation.

Max. Value : 0.005

DISSIPATION FACTOR TEST SET
 RESISTIVITY
(IEC-60247)
• Determination of specific resistance.
• It is a measure of the electrical insulating properties of oil
• High resistivity indicates a low concentration
of conductive contaminants.

Min. Value : 60 GΩ-m

RESISTIVITY MEASURING TEST SET

 KINEMATIC VISCOSITY @ -20 & 40 ◦C
(ASTM D-445)
• An important controlling factor in the dissipation of heat (circulation).
• Ageing & oxidation of the oil tend to increase viscosity.
• Also affected by temperature, In a cold climate it is
important that the viscosity is
sufficiently low to enable sufficient
oil circulation.

Max. Value
At -20 ◦C: 1800mm2/s
At 40 ◦C: 12mm2/s
KINEMATIC VISCOSITY TEST SETS
 DENSITY (SPECIFIC GRAVITY) @ 20◦C
(ASTM D-445)

•The ratio of the weights of equal volumes of oil and water.

•Oil density increases with decrease in temperature
•In extremely cold climates this can be used to
determine whether ice will float on the oil,
potentially resulting in flashovers.

Max. Value : 0.895 g/ml

DENSITY HYDROMETERS
 ACIDITY/ NUETRALIZATION NO.
(IEC 62021-1)

•Oil is oxidized under the influence of excessive temperature and

oxygen, resulting in an increase in Acid Number.
• Can result in sludge, oil canals may become blocked and the
transformer is not cooled well, which further
intensify oil breakdown.
• Increase in the acidity has a damaging effect on
the cellulose paper & insulating properties
of the oil.

Max. Value : 0.01 mg KOH/g

ACIDITY TEST SET
 POUR POINT
(ISO-3016)

• The minimum temperature at which oil just start to flow.

• An important property mainly at the places where climate is extremely
cold.
• If the oil temperature falls below the pour
point, transformer oil stops flowing and block
cooling in transformer.

Max. Value : -30.0 ◦C

POUR POINT TEST SET
 FLASH POINT
(ISO-2719)

• The temperature at which oil gives enough vapors to produce a

flammable mixture with air.
• Flash point is important because it specifies the chances of fire hazard
in the transformer.
• It is desirable to have very high flash point
of transformer oil.

Min. Value : 135.0 ◦C

FLASH POINT TEST SET

 OXIDATION STABILITY
(IEC-61125)
•Measured by the tendency of oils to form sludge and acid products.
•One of the most important properties of mineral insulating oil.
• Primarily affects the stability of oil during extended use.
•oxidation yields products that may compromise
oil properties, impair oil quality and
equipment performance.

Oxidation stability:
acidity: max. 1.2 mgKOH/g
sludge: max. 0.8%
DDF: max. 0.500
OXIDATION STABILITY TEST SET
 SEDIMENT & SLUDGE
(IEC-60422)
• Measurement of Sediment & Sludge in oil.
• Sediment is the insoluble oxidation or degradation product of solid & liquid
insulation.
•Sludge is a polymerized degradation product of solid & liquid insulation,
soluble in oil up to a certain limit.
•Presence of sediment or sludge may change the electrical properties of oil,
hindering heat-exchange and leading to thermal degradation of insulating
material.
 CORROSIVE SULFUR
(DIN-51353)

• Detection of unacceptable quantities of corrosive sulfur compounds that can

result in deterioration of metals.

• Oil is constantly in contact with metals that

are subject to corrosion.

• Free sulfur present in mineral insulating oil

can cause corrosion to the metals.

Min. limit: Non-corrosive

Note: this test is carried out using a silver strip and the
temperature is maintained at 100◦C for 18hrs.
CORROSIVE SULFUR TEST SET
 POTENTIALLY CORROSIVE SULFUR
(IEC-62535)

•Detection of unacceptable quantities of organosulfur compounds

• Oil is constantly in contact with the solid
Insulation of transformer
• As some organosulfur compounds present in
oil can cause copper sulfide formation which
is deposited on paper reducing its insulation
properties.

Min. limit: Non-corrosive

Note: this test is carried out using a copper strip and the
temperature is maintained at 150◦C for 72hrs.
POTENTIALLY CORROSIVE SULFUR TEST SET
 INTERFACIAL TENSION
(ASTM-D971)
• IFT is surface tension at the interface between two liquids.
• An indicator of presence of polar compounds & oxidation products in oil.
• Transformer oil is a non-polar hydrocarbon, when oil undergoes
degradation, some species are formed which are polar in
nature.
• In this test the surface tension of oil is measured against that of
water, which is highly polar. The more nearly the two liquids are
alike in their polarity the lower the value of the surface tension
between them.
• Thus the higher the concentration of polar materials
(contamination) in the oil, the lower will be the interfacial
tension of the oil measured against water.
Min. limit: 35 mN/m

INTERFACIAL TENSION TEST SET

 POLYCHLORINATED BIPHENYLS (PCB)
(IEC-61619)
•

• Detects the concentration level of polychlorinated biphenyls in transformer

oil by gas chromatography.
• PCBs were widely used as a fire retardant and insulator
in the manufacture of transformers and capacitors, due
to their ability to withstand exceptionally high temp.
• Because of their classification as a human carcinogen
& pollutant, the Environmental Protection Agency
(EPA) banned their use in 1979.

Min. limit: Not detectable (<2 mg/Kg)

PCB TEST SET

 FURFURAL CONTENT / FURAN CONTENT
(IEC-61198)
•

• Measurement of Furan content in oil.

• Furan derivatives are a measure of the degradation of paper insulation.
• When the paper ages, its degree of polymerization reduces so its mechanical
strength decreases.
• The degree of polymerization of the paper can be directly
related to the concentration of furan derivatives in the oil
as they are formed as a direct result of the breakdown of
the polymeric structure of cellulose paper.

Min. limit: Not detectable (<0.05 mg/Kg )

(for each compound)

FURAN CONTENT TEST SET

 INHIBITOR CONTENT
(IEC-60666)
•

• Measurement of inhibitor/ additive in oil

• Most mineral oil/ dielectric fluids contain an added oxidation inhibitor which is
a chemical additive that act as a preservative.

• Used to prevent oxygen from reacting with oil

thus slowing the aging rate of oil & solid insulation.

• Concentration of additives should be known in order

to monitor its depletion during service.

Min. limit:
Uninhibited oil: Not detectable
Trace-inhibited oil: <0.08%
Inhibited oil: 0.08% - 0.40%
INHIBITOR TEST SET
 POLYCYCLIC AROMATICS (PCA)
(IP-346)
•

• Measurement of PCA content in oil.

• Polycyclic aromatic hydrocarbons (PCA/PAHs) are a group of different
chemicals that are released from burning coal, oil,
gasoline or other organic substances.
• Some PCAs are known to be carcinogenic,
environmental pollutants and need to be controlled
to acceptable limits in oil.

Max. limit: 3%

PCA CONTENT TEST SET

 DISSOLVED GAS IN-OIL ANALYSIS
(ASTM D-3612)
•

• DGA is by far the most frequently requested diagnostic test performed on transformer oil.
• During the natural aging process of the oil and insulating parts, especially in the case of
thermal or electrical failures, gases form, and are dissolved in the oil e.g. Nitrogen,
oxygen, carbon monoxide & dioxide, hydrogen, methane, ethane, ethylene and acetylene.
•DGA is used to determine the concentrations of these gases in the oil
•Useful maintenance tool to evaluate transformer health.
• The concentrations and relative ratios of these gases
can be used to diagnose certain operational
problems with the transformer.
•Example: High levels of carbon monoxide relative to
the other gases may indicate thermal breakdown
of cellulose paper, while high hydrogen along
with methane may indicate a corona discharge
within the transformer.

DGA TEST SET

FUTURE PLAN OF HV&SC LAB
 FUTURE PLAN
• Rawat Lab is the only testing laboratory for the entire power sector in the country
and has acquired ISO 9001:2008 Certification in 2005.

• The laboratory intends to continue its capacity-building to match the growing

demands of Power Sector by achieving Laboratory Management System (LMS) ISO-
17025.

• Skill enhancement of technical personnel to serve as R&D Centre / Centre-of-

excellence in the field of Electrical Power Engineering.
 FUTURE PLAN

• Acquire international accreditation / recognition to test Local made electrical

equipment, hardware and to attract Foreign Manufacturers for testing to save
foreign exchange and to earn for organization.

• Role model organization to attract qualified personnel for long-term

employment.

• To Play the key role in setting up Engineering standards of Highest Quality.