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DOC NO.

: D-2-01-03-01-04

PRE-COMMISSIONING FORMATS FOR REACTOR


I.

GENERAL DETAILS

Region: ESTERN REGION-II


LOANo.:CC-CS/393-ER-2/SS2266/3/G6/CA-l/4991, dtd. 14/O7/2016

DETAILS
Sub-Station: DURGAPUR
Make:BHEL

Sr. No.:6007529
Equipment identification
No.:406 BR-2
Year of Manufacture: 2016
Voltage Class :420KV
Type of Neutral Grounding:
Solid
Oil type: UNINHIBITED
Quantity of Radiator: 10

Type: 3-PHASE
Rating:125MVAR BUS REACTOR
Cooling Type: ONAN
Oil Make: RAJ PETRO
Oil quantity:54.45KL
Date of Receipt at
site:22.06.2016
Date of Completion of Erection
and Oil filling:11/10/2016

Date of Starting of
Erection:31.08.16
II.

SEQUENCE OF TESTS TO BE CARRIED OUT FOR REACTOR

SL.
NO.

NAME OF TEST

Core Insulation Measurement


upon arrival of equipment at site
Insulation Resistance
Measurements Of Bushing Cts
Continuity Test Of Bushing Cts
Secondary Winding Resistance Of
Bushing Cts
Polarity Test Of Bushing Cts

2
3
4
5
6
7
8
9
10

TESTING KIT DETAILS


RATING/
MEASURI
NG
RANGE

DATE OF
LAST
CALIBRATI
ON

MEGGER

1KV

2016

OK

FLUKE

0-

2015

OK

FLUKE
FLUKE

0-
0-

2015
2015

OK

GMETER

0-50
micro
A

2015

OK

MAKE

Current Ratio Test


Magnetizing Curves Performance
Measurement of Resistance of
Earth Pit and Main Grid
Frequency Response Analysis

OK

OK
OK

MEGGER
DOUBLE
FLUKE

Magnetization Current of

TEST
RESULTS
Ok/Not Ok

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 1 of 16

OK

01MHz
0-

2015

OK

2015

OK

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

11
12
13
14
15
16
17
18
19
20
21
22

Windings
C & Tan Measurement Of
Bushing
C & Tan Measurement Of
Windings
C & Tan Measurement Of NGR
Windings( If any)
Insulation Resistance
Measurement of Winding
Insulation Resistance
Measurement of Cable
Core Insulation Measurement
after oil filling
Measurement of Winding
Resistance
Measurement of Winding
Resistance of NGR
Protection And Alarm Tests
Stability Test Of Differential And
Ref Protection
Contact Resistance Measurement
Vibration Measurement

MEGGER

OK

MEGGER

OK

NA

NA

MEGGER

1KV

2016

OK

FLUKE

0-

2015

OK

MEGGER

1KV

2016

SCOPE

2015

NA

FLUKE
FLUKE

NA

0-
0-

SCOPE

OK

2015

OK

Comments of Corporate-OS on test Results (To be attached separately)


Manufacturer Recommendation on test Results (To be attached separately)

Signature:

Signature:

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 2 of 16

OK

2015
2015

Comments of Commissioning Team on test Results: ALL RESULTS ARE IN ORDER

Signature:

OK

Signature:

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

Name:

Name:

Name:

Name:

Desgn.:

Desgn.:

Desgn.:

Desgn.:

Organization:
(Erection Agency)(POWERGRID Site(POWERGRID
(Supplier
I/C)
Commg. Team)
Representative)
Members:
(Wherever
1.
Applicable)
2.
3.
4.
III.

CHECKS AFTER RECEIPT OF REACTOR AT SITE:

A) N2/ Dry Air Pressure & Dew Point Record


Inspection Action

During dispatch at
factory
After receipt at site
Storage at site before
commissioning

Date
Of
Meas.

N2/ Dry
Air
Pressure

Dew
Point

Ambient
Temperatur
e

Remark
s

0.15kg/cm2
13/06/16

0.15kg/cm2

22/06/16

35

0.15kg/cm2

33.5

Note:
1.
2.
3.

Refer graph 2.1.3 fig.1 in POWERGRID doc no d-2-03-xx-01-01 rev-01 for maintaining N2/ Dry air pressure
and dew point during storage(To be maintained in a separate sheet/ Register)
Any noticeable drop in N2 during storage at site is observed, then matter to be referred to Manufacturer and
CC-OS).
If Reactor is received with zero N2 pressure then matter to be referred to Manufacturer and Corporate-OS
prior to erection

B) Impact Recorder Analysis

No of Impact Recorder
installed:
Make of Impact Recorder(s)
Type of Impact Recorder(s)
Date of removal of impact
recorder from equipment
Sl.No.
1
2

01
Minilog
Digital
15.09.2016

Check Points
Functionality of Impact recorder at the time of
dismantling from main unit
Joint data downloading carried out at site
immediately after receipt

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 3 of 16

Status

Remarks

On

Of

On

Yes

No

No

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

Analysis of joint report received from


manufacturer before charging

3
Note:
1.

Yes

No

Yes

Manufacturer to provide necessary software and downloading tools to respective sites so that data
downloading can be carried out at site jointly by POWERGRID & Manufacturer
Regarding permissible limit for maximum shock please refer procedure
Impact Recorder should be switched off and detached from the Reactor when the main unit has been placed
on its foundation.

2.

3.

C) Core Insulation Test (Immediately after Receipt at Site)


Shorting link between CC, CL & G to be removed and IR value to be taken between CC-G, CL-G & CC-CL by
applying 1 kV DC

Terminals
CC-G
CL-G

Insulation
Value
3.37 GOHM
3.98 GOHM

Insulation
Value

Terminals
CC-CL
Semi-shield G (if provided) at 1 kV

8.67 GOHM
NA

Note:

i. Permissible value > 500 M


ii. In case core insulation values are less than the permissible limit matter to be referred to OEM for
corrective measures and same to be checked during internal inspection for any abnormality
iii. Ensure shorting of CC-CL & G after the completion of the testing

Internal Inspection

D)

SL.
No.
1
2
3

Status
Yes No

Internal Inspection
Details photographs of all visible parts /components are taken during internal
inspection.(refer procedure2.1.6)
Any abnormality observed during internal inspection
Matter referred to manufacturing, CC-QA & I , CC-ENGG and CC-OS

YES
NO

Details of abnormality observed during internal inspection (if noticed) ______________


_______________________________________________________________________________
_______________________________________________________________________
IV.

REACTOR ERECTION

A)

Checks / Precautions During Erection :

Sl.
No.
1
2

Description

Remarks

Total Exposure of Active part of Reactor to atmosphere in hours


( To be kept minimum)
Dew point of dry air generator / dry air cylinders, during exposure of active part

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 4 of 16

SHUNT REACTOR

3 HRS
-65 deg C

DOC NO.: D-2-01-03-01-04

5
6

of Reactor
Available of Oxygen in % before entering in Reactor tank
N2/ Dry air pressure in PSI while Reactor is kept sealed in between different
erection activities
Ensure Leakage test of Air cell / bellow carried out
Check Hermitically sealing is intact in all Bushings by OEM / Expert

B)

Evacuating And Oil Filling

3
4

a) Before filling oil, each drum has been physically checked for
free moisture and appearance

Yes

4.3 PSI
YES
YES

No

b) Details of oil filter machine (As per latest TS of Reactors)


Make ______VPI_______________
Sl.No
1
2
3
4

Capacity____6KL____________________

Description Of Works
Changing of Lubricating oil of vacuum pump
Cleaning of Filter packs
Flushing of whole filter machine with fresh oil
Vacuum obtained without load (milli bar)

Remarks / Reading
YES
YES
YES
0.0 mbar

c) Vacuum pump for evacuation of Reactor


Sl.No
1
2
3
4

Description of Works
Changing of Lubricating oil of vacuum pump
Vacuum obtained without load (milli bar)
Diameter of vacuum hose (50 mm)
Employ of Dry ice chamber

Remarks / Reading
YES
YES
80MM
--

d) Oil storage tank


Capacity________30KL_____________
Sl.No
1
2
3
4

Quantity______28KL_________________

Description of Works
Silica gel breather provided in the tank
Any opening left uncovered
Inside painted or not
Cleanliness of inside of pipes/ hoses to the storage tank

Remarks / Reading
YES
NO
YES
YES

e) Exposure during erection


Format No.: CF/SR/02/ R-4,DATED 01/01/2013
Page 5 of 16

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

Sl.No
1
2
3
4
5
6
7

Description of Works
First day exposure ( in hrs)
Second day exposure ( in hrs)
Third Day exposure ( in hrs)
N2 pressure applied after each days erection work ( in PSI)
Ambient Temperature (in degC)
Average Relative Humidity
Weather Condition(Rainy / Stormy / Cloudy / Sunny)

Remarks / Reading
02hrs
06hrs
nil
4.3PSI
35
sunny

Note:
i.
Erection activities to be carried out in sunny weather and RH<60%
f) N2/ Dry Air sealing in case of delay in oil filling-NA
Sl.No
1
2
3
4

Description of Works
No. of Cylinders used for displacing the air inside the tank
N2 admitted from bottom valve
Valve at diametrically opposite end at top kept open
No. of Cylinders used for building up to 4- 5 psi( .3kg/cm2 )

Remarks / Reading

g) Leakage Test through pressure


Sl.No
1

Inspection Actions
Fill dry N2/ dry air till pressure of 4- 5psi (.3 kg/cm2 )
achieved

Date

Time

01/10/16

11:45

02/10/16

18:00

2
3
4
5

To be kept for 24 Hrs


In case pressure remain same, check for dew point
If dew point is achieved, proceed for evacuation
In case of drop in pressure, attend the leakages and
repeat the pressure test

Remarks /
Reading
1st cycle dew
point
-26.2,@33.8 C
achieved on
02/10/2016

NA
2 nd cycle
dew point
-39.3,@32.6de
g C achieved
on 04/10/2016

6
If dew point is not OK, dry air/ N2 cycle to be carried
out till desired dew point is achieved
h) Schedule for Vacuum & Tightness Test

Sl.No

Inspection Actions

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 6 of 16

Date

Time

SHUNT REACTOR

Remarks /
Reading

DOC NO.: D-2-01-03-01-04

1
2
3
4
5
6
7

Starting of evacuation on complete unit


Stopping of evacuation below the pressure of 5 kPa
(50 mbar)
Pressure P1 in kPa after 1 hour of stopping evacuation
Pressure P2 in kPa after half an hour of reading
pressure P1
Leakage = (P2-P1) x V , V= Oil quantity in Cu mtr
*If leakage<3.6, continue evacuating
If leakage > 3.6, attend leakage and repeat process
as
per Sr. No. 1 to 4.
Start of Vacuum reaching below 0.13kPa(1 Torr)
Break of vacuum
* Vacuum process to be continued for 24 hrs Up to
145 KV, 48 hrs for 145 to 220kV and 72 hrs for 420
kV and above

27/09/16

16:30

0.3 Kg/Cm2

27/09/16
27/09/16

20:30
21:30

50 mbar
50mbar

27/09/16

22:00

50mbar

28/09/16

20:00

0
0.65T

01/10/16

20:00

0.15kg/cm2
maintained

i) Record of drying out process (if carried out)


Sl.No
1

Activity
First Nitrogen purging cycle
Pressure of Nitrogen 0.15 kg/cm2
Dew Point after 48 Hrs
Temperature with heaters on condition around the Reactor
Tank(Refer procedure)
First Vacuum cycle
Vacuum achieved
Rate of condensate collection(Hourly basis)
Duration of vacuum after achieving 1 to 5 torr
Second Nitrogen purging cycle
Pressure of Nitrogen 0.15 kg/cm2
Temperature with heaters on condition around the Reactor
Tank(Refer procedure)
Dew Point after 24 Hrs

Note:
i.

Date

Time

01/10/16
02/10/16

11:45
18:15

Remarks /
Reading
Dew
point
-26.2, Temp33.8

NA

760mmHg
1Torr
04/10/16
NA

17:00

05/10/16

16:00

Dew
point
-35.5, Temp28.1

If dew point is within the permissible limit oil filling under vacuum may be started otherwise vacuum/
Nitrogen purging with heating cycle to be continued till desired dew point is achieved.

j) Schedule for Oil filling and Settling

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 7 of 16

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

Sl.No
1

INSPECTION ACTIONS

DATE

TIME

06/10/16

13:15

07/10/16

16:00

REMARKS /
READING

Ensure measurement of Particle counts during oil


filtration in oil tanks(If specified in the contracts)
Oil Filling in Main Tank
Oil filling in Conservator tank

3
4

Oil filling in diverter switch


Hot oil circulation (minimum 2 cycles or depending on
oil parameters) at oil temperature 55-60 deg C.
08/10/16
Start of oil settling
11/10/16
End of oil settling
* Minimum settling time to be given 12 hrs for 145
KV , 48 hrs for 145 to 420kV and 72 hrs for 765 kV &
above
13/10/16

5
6

V.

na
18:30
11:00

11:00

PRE-COMMISSIONING CHECKS:

Sl.
No.
1

Description Of Activity

Status
N
Yes
o
YES

REACTOR and its Auxiliaries are free from visible defects


on physical Inspection
All fittings as per out line General Arrangement Drawing

Check Main Tank has been provided with double earthing

YES

YES

Check neutral is grounded through separate connections.


Ensure metallic requirements as per specification (e.g. Cu)
in earthing strips used
Check that Marshalling Box, , Radiator Bank & Fan(if any)
etc. has been earthed
All nuts and bolts are tightened correctly as per specified
torque (as per manufacturers recommendation)
Check tightness of Terminal Connectors

Check leveling of Reactor and its accessories

YES

Erection Completion Certificate along with list of


outstanding activities reviewed
Any Paint removed / scratched in transit has been touched

YES

5
6

10

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 8 of 16

Deficien
cies, If
Any

YES

YES
YES
YES

YES

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

up
11

Bushings are clean and free from physical damages

YES

12

Oil level is correct on all Bushings

YES

13

Check brazing of all Bushings Leads

YES

14

Check oil leakage through any Joints / Valves etc.

YES

15

Check oil drain valves are properly closed and locked

YES

16

Check oil level in Main Conservator tank

YES

17

YES

19

Check oil level at conservator matches with oil temperature


of Reactor
Check OTI and WTI pockets and replenish the oil, if
required
Check all valves for their opening & closing sequence

20

Check the colour of the breather silica gel

YES

21

Check availability of oil in the breather cup

YES

22

Check tightness of bolt of main unit after placed on


foundation
Check busing test tap is grounded

YES

Check the operation of flow sensitive shut off valve between


main tank & conservator, if any
Check the functioning of SPR (Sudden pressure relay) ,if
any
Check no debris, loose T & P and oil strains on and around
the Reactor
Check door seals of Marshalling Box is intact and all cable
gland plates unused holes are sealed
Check that pressure relief valve is correctly mounted

YES

Ensure unused secondary cores of Bushing CTs, if any, has


been shorted
Check CT star point has been formed properly and grounded
at one end only as per scheme
Check that permanent and adequate lighting arrangements
are ready
Check that labeling and identification is permanent and
satisfactory
Check that Buchholz Relay is correctly mounted with arrow
pointing towards conservator
Check cables are properly fixed and ensure cable entry at the
bottom

YES

18

23
24
25
26
27
28
29
30
31
32
33
34

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 9 of 16

Crimping
checked

YES
YES
blue

YES

NA
YES
YES
YES

YES
YES
YES
YES
YES

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

35

Ensure all Power and Control cable Terminals are tightened

YES

36

Check all cables and Ferrules are provided with Number as


per Cable Schedule (Cross Ferruling to be checked)
Check that all cables are correctly glanded

YES

37
38
39
40
41
42

YES

Check external cabling from Junction Box to Relay / Control YES


Panel completed
Check that air has been released from the Radiators and their YES
headers/ Buchholz relay/Main tank/tank/Bushing turrets etc
Check Fire Protection System & Emulsifier systems is
adequate & ready
Check that CC-CL & G are shorted
YES
NA

45

Check that neutral connection has twin conductor in case of


single phase unit
Check that all radiator bank valves on top and bottom
headers are open
Change over operation of ac supply from source- I to sourceII checked
C heck the flanges of bushing for any crack after fixing

46

Calibration of OTI & WTI performed as per procedure

YES

47

Ensure Remote OTI and WTI data transfer to control room


is taking place
Ensure On-Line DGA is commissioned and kept ON

YES

Ensure On-Line Dry out system is commissioned and kept


ON
Check various interlocks provided with Fire Fighting
as per the schematic Ref. Drg.
No.___________________

YES

43
44

48
49
50

VI.

YES
NA
YES

Descriptio
n of
Interlocks

Checked

MEASUREMENT OF EARTH RESISTANCE OF ELECTRODE

Location

Value

With Grid (Earth Pit -1)


Without Grid (Earth Pit -1) (Neutral Earth )
With Grid (Earth Pit -2)
Without Grid (Earth Pit -2) (Neutral Earth)

0.12 ohm
1.47 ohm
0.24 ohm
1.40 ohm

*Permissible limit with grid < 1 ohm


VII. PRECOMMISSIONING TESTS AFTER READINESS OF THE REACTOR

A) Frequency Response Analysis (FRA)


Format No.: CF/SR/02/ R-4,DATED 01/01/2013
Page 10 of 16

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

Sl.No
1
2
3
4

Description

Yes

No

Remarks

Carried out after completion of all commissioning YES


activities
Factory FRA test report in soft form available at site
Interpretation of test results carried out
Test results matching with the factory results

Hard copy
Matching

Note:a)

Measurement to be carried out at Minimum, Maximum and Nominal Tap for all combination of HV & IV and
Nomenclature to be made similar as mentioned in the procedure documents

B) Magnetization Current Test


Ambient temperature ______________________
oil______________________
Voltage Applied
( Volts)
R-N
Y- N
B-N
NGR

240
240
240
NA

Current Measured (mAmp)


179
178
179
NA

R - PH
Y - PH
B - PH
NA

Temperature of

Remark
OK
OK
OK
OK

Note:
a. Excitation current < 50 milli-Amperes, then difference between two higher currents should be
less than 10%.
b. Excitation current > 50 milli-Amperes, then difference between two higher currents should be
less than 15 %.
c. Value of centre leg should not be more than either outside for a three phase reactor.
d. Results between similar single phase units should not vary more than 10%.

C) Tan And Capacitance Measurement


a) Tan Delta And Capacitance Measurement Of Bushing
BUSHING DETAILS
.

Make
Type
Sl. No.
STYLE
NO
DRAWING NO

R-

Y-

B-

Neutral

ALSTOM

ALSTOM

ALSTOM

CGL

OIP
37997008301

OIP
37997007191

OIP
37997008295

OIP
S-1451004057

NGR
NA

Ambient temperature in C_____30 C ________

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 11 of 16

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

i.

Capacitance & Tan of bushing


Capacitance

Voltage
Applied

2 KV
10 KV
1 KV
Voltage
Applied
2 KV
10 KV
1 KV

R-
Factory

Y-
Site
Site
Factory
Measurement of C1
474.4
477.9
474.8
477.37
478.1
479.48
Measurement of C2
3317
3502
Tan
R-
Y-
Site
Factory
Site
Factory
Measurement of C1 Tan
0.00347
0.00344
0.00348
0.00323
0.00346
0.00343
Measurement of C2 Tan
0.00158
0.00166

Remarks

B-
Factory

Site
474.5
474.8

475.60

3509
Remarks

B-
Factory

Site

0.00307
0.00306

0.00155

0.00299

b) Capacitance & Tan of Neutral bushing


Voltage Applied
2 KV
10 KV

Site
261.6
261.7

Capacitance
Factory
NA

Tan
Site
0.00267
0.00267

Factory

c) Tan Delta And Capacitance Measurement Of Winding


Ambient temperature in C ______30 C _______________________
Winding
Test
Capacitance
Combination Mode
Site
Factory
2 KV
10890
HV/Tank+Ear
GST
h
10 KV
10890 11140
Capacitance & Tan of NGR NA
Winding
Capacitance
Voltage
Test Mode
Combination
Site Factory
NA NA
2 KV
HV/Tank+Earh
GST
NA NA
10 KV
Voltage

Note:
i.

Tan *
Site
0.00257
0.00251

Remark

Factory
0.0031

Tan *
Site
Factory
NA
NA
NA
NA

Remark
NA
NA

C2 values shall be only for record purpose.

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 12 of 16

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

ii.

For bushing acceptable Limit for Tan 1 should be comparable (+/- 0.001) with factory value subjected to
max of 0.005 & Tan 2:-0.01
For winding acceptable Limit for Tan 1 should be comparable (+/- 0.001) with factory value subjected to
max of 0.005 & Tan 2:-0.01
Acceptable Limit for Capacitance -5% to + 10%

iii.
iv.

Insulation Resistance Measurement

VIII.

a)

Insulation Resistance Measurement of Cable and others (Using 500 Volt Megger)
Ambient temp in C

SL. NO.

A
B

_____________________
STATUS

DESCRIPTION

YES

NO

REMARKS, IF ANY

OK

Control wiring
Cooling System
a) Motor Fan
b) Motor Pump
c) Control wiring

NA
NA
NA

* Permissible limit of IR value should be > 50 M

b)

Insulation Resistance Measurement in M (Using 5000 V Megger)


Ambient temp in C
_______________________

Main Winding
a) HV / E
b)NGR WINDING

Ir Value
Dielectric Absorption
Polarisation
Coefficient(DAI
)
=
Index(PI
) = 600 Remarks
15
60
600
60
Sec
/
15
Sec
Sec
/
60
Sec
Sec Sec Sec
9.76
G
NA

13.89
G
NA

32.2
G
NA

1.423

2.32

NA

NA

*Permissible limit of IR value should be > 500 M for 66kV & above at 30C,
should be >1.3 and PI should be >1.25 To 2
IX.

NA

DAI

Measurement Of Winding Resistance (In Ohm)

Ambient temperature in C______


reading __32____

OTI Reading

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 13 of 16

_32_____

SHUNT REACTOR

WTI

DOC NO.: D-2-01-03-01-04

i.

WINDING RESISTANCE OF REACTOR WINDING

Winding
Resistance(HVN)
R
Y
B

Resistance At
75 C
R

0.9335

1.083

1.0911

1.085

1.1123

1.1120

1.1104

2.63

1.88

2.29

0.9328

ii.

0.9275

% Deviation

WINDING RESISTANCE OF NGR WINDING

Winding
Resistance(HVN)
NA

Factory Value
At 75 C

NA

*Resistance At
75 C

NA

NA

*Factory Value
At 75 C

NA

NA

NA

NA

% Deviation

NA

NA

NA

NA

NOTE:
i.
Formula for calculating the resistance at 75C: R 75 = RT (235+75)/ (235+T), where RT =
Resistance Measured At Winding Temperature T.
ii.
Permissible limit: 5% variation between phases or from Factory test results
X.

Core Insulation Test

Shorting link between CC, CL & G to be removed and IR value to be taken between CC-G, CL-G & CC-CL by
applying 2 kV DC

Insulation
Value

Terminals

10.5 G

CC-G
CL-G
Note:
i.
ii.

XI.

Insulation
Value

Terminals
CC-CL
Semi-shield G (if provided) at 1 kV

12.0 G

3.0 G
NA

Permissible value > 500 M

Ensure shorting of CC-CL & G after the completion of the testing


Oil Characteristics

(Sample to be taken prior to charging to Reactor and it should fulfill the recommendations as per
IS 1865 /IEC 60422)
DATE OF OIL
SAMPLING

Permissibl
e Limit

MOISTURE

TAN DELTA

RESISTIVITY

70KV(min)

5
PPM(Max)

0.01 at 90 C
(Max)

6x 10 ^12
-CM at 90 C
(Min)

70.6

B.D.V.

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 14 of 16

INTERFACIAL
TENSION

0.0 35 N/m at
27C (Min)

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

DISSOLVE GAS ANALYSIS

Dissolve
Gasses

H2

CH4

C2H4

C2H6

C2H2

CO

CO2

O2

N2

TCG

Note:i.
TCG should be below 1%
ii.
One fresh oil sample per lot (from drum) shall be sent to Lab for carrying out Oxidation
Stability test
Operational Test Of Other Equipments

XII.
i.

Checking of cooling Equipments

SL.NO

XIII.

HV

Neutral

STATUS

DESCRIPTION

Rotation direction of Fans

OK

NOT OK

NA

NA

NA

Checks on Bushing CTs


a) Rated Data And Duty
Core

Ratio

Core-I
Core II
Core III
Core IV
Core-I

200/1
200/1
200/1
200/1
200/1
50010002000/1
50010002000/1
-

Core II
Core III
Core IV

Class
PS
PS
PS
1
PS

Burden

Kvp

Protection / Metering

200
200
200
200
2505001000
2505001000

Differential Protection
REF Protection
Backup Impedance
Metering
Differential Protection

10

PS
PS
5

Differential
Spare
WTI

b) Insulation Resistance Measurement Of Bushing Cts(Using 500v Megger)

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 15 of 16

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

Line side
MEASUREMENT
UNIT
BETWEEN
MEASUREMENT BETWEEN

Earth - Core I
Earth - Core II
Core
CoreIIIII
Earth I-Core
Core
I

CoreIV
III
Earth - Core
Core I Core IV
Core II Core III
Core II Core IV
Core III Core IV

i.

HV
R
UNIT

Y-

M
333
M
540
M
M
365
M M 215
M
M
M
M

HV

194.5
R
170.0
620
168.0
620
125.0
585

B-

210
245
222 278
228 333
220

Y-

870
750
540

B-

316
350
395

221
212
233

477
550
590

Neutral side
MEASUREMENT
UNIT
BETWEEN
MEASUREMENT BETWEEN

i.

HV
R
UNIT

Y-

Earth - Core I
M
14.93
Earth - Core II
M
29.53
Core
CoreIIIII M M 14.61
Earth I-Core
Core I Core III
M
Core II Core III
M

HV

28.2
R
24.9
32.0
21.5
111.2

B-

56.3
12.83
52.618.48
34.2

Y-

77.5

B-

37.1
37.6

91.2

38.2

c) Continuity Test Of Bushing Cts (In )


Continuity, Check between Terminals OK / NOT OK
CORE

Core I
Core II
Core III
Core IV

BETWEEN
TERMINAL

R-

HV
Y-

B-

1S11S2
2S12S2
3S13S2
4S14S2

OK
OK
OK
OK

OK
OK
OK
OK

OK
OK
OK
OK

d) Secondary Winding Resistance Of Bushing CTs (In )


i.
CORE

Core I
Core II
Core III
Core IV

HV side
BETWEEN
TERMINAL

UNIT

1S1 1S2
2S1 2S2
3S1 3S2
4S1 4S2

R-
FACTORY

Y-
SITE

FACTORY

0.53
0.52
0.52
0.39

B-
SITE

FACTORY

0.50
0.60

SITE

0.4
0.4
0.4
0.4

0.40

0.40

Neutral side
CORE

BETWEEN
TERMINAL

UNIT

R-
FACTORY

Y-
SITE

FACTORY

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 16 of 16

B-
SITE

FACTORY

SITE

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

Core I
Core II

1S1 1S2
2S1 2S2
2S1-2S3
2S1-2S4
Core III 3S1 3S2
3S1-3S3
3S1-3S4
ii.

Core I

1S1 1S2
iii.

Core I

0.9
1.5
3.6
7.3

1
1.9
3.5
7.2
1.8
3.3
7.0

1.5
3.5
7.3

UNIT

FACTORY

SITE

0.7

External Neutral CT -NA


BETWEEN
TERMINAL

CORE

0.9
1.9
3.8
7.2
1.7
3.4
7.1

Neutral Side
BETWEEN
TERMINAL

CORE

1S1 1S2

UNIT

FACTORY

SITE

e) Polarity Test Of Bushing CTS


With 1.5 V DC supply(Connect +ve at P1 and ve at P2)
CORE

BETWEEN

Core I
Core II
Core III
Core IV

1S1 (+ve)
2S1 (+ve)
3S1 (+ve)
4S1 (+ve)

1S2 (-ve)
2S2 (-ve)
3S2 (-ve)
4S2 (-ve)

R-

HV
Y-

B-

OK
OK
OK
OK

OK
OK
OK
OK

OK
OK
OK
OK

f) Current Ratio Test


i.

Primary Injection through Primary Injection Kit at Primary Terminal P1 P2


Measure current on the secondary Terminals
HV side R Phase side
CORE
S1 - S2

PRIMARY
%

CURRENT
ACTUAL

SECONDARY
CURRENT

THEORETICAL
RATIO

ACTUAL
RATIO

% OF
ERROR

Core I
(1S1
1S2)
Core II

20%
40%
80%
20%
40%

0.2
0.405
0.817
0.2
0.407

200
200
200
200
200

200.00
197.53
195.84
200.00
196.56

0.00
1.23
2.08
0.00
1.72

0.2
0.405
0.817
0.2
0.407

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 17 of 16

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

0.813

200

0.2
0.407
0.812
0.201
0.401
0.803

200
200
200
200
200
200

80%
(2S1
Core III
(3S1
3S2)
Core IV
(4S1
4S2)
ii.

20%
40%
80%
20%
40%
80%

196.80
200.00
196.56
197.04
199.00
199.50
199.25

1.60
0.00
1.72
1.48
0.50
0.25
0.37

0.2
0.407
0.812
0.201
0.401
0.803

HV side Y Phase
CORE
S1 - S2

PRIMARY
%

CURRENT
ACTUAL

SECONDARY
CURRENT

THEORETICAL
RATIO

ACTUAL
RATIO

% OF
ERROR

20%
40%
80%
20%
40%
80%
20%
40%
80%
20%
40%
80%

40
80
160
40
80
160
40
80
160
40
80
160

0.203
0.405
0.811
0.202
0.405
0.811

0.202
0.405
0.812
0.201
0.401
0.805

200
200
200
200
200
200
200
200
200
200
200
200

197.04
197.53
197.29
198.02
197.53
197.29
198.02
197.53
197.04
199.00
199.50
198.76

-1.48
-1.23
-1.36
-0.99
-1.23
-1.36
-0.99
-1.23
-1.48
-0.50
-0.25
-0.62

PRIMARY
%

CURRENT
ACTUAL

SECONDARY
CURRENT

THEORETICAL
RATIO

ACTUAL
RATIO

% OF
ERROR

20%
40%
80%
20%
40%
80%
20%
40%
80%
20%
40%
80%

40
80
160
40
80
160
40
80
160
40
80
160

0.203
0.411
0.816
0.204
0.411
0.816

200
200
200
200
200
200
200
200
200
200
200
200

197.04
194.65
196.08
196.08
194.65
196.08
196.08
195.12
198.27
199.00
199.50
199.25

Core I
(1S1 1S2)
Core II
(2S1 2S2)
Core III
(3S1 3S2)
Core IV
(4S1 4S2)
iii.

0.813

HV side B Phase
CORE
S1 - S2

Core I
(1S1 1S2)
Core II
(2S1 2S2)
Core III
(3S1 3S2)
Core IV
(4S1 4S2)

0.204
0.41
0.807
0.201
0.401
0.803

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 18 of 16

SHUNT REACTOR

-1.48
-2.68
-1.96
-1.96
-2.68
-1.96
-1.96
-2.44
-0.87
-0.50
-0.25
-0.37

DOC NO.: D-2-01-03-01-04

i.

Neutral side (Injected through M point, Max current 20A)


CORE
S1 - S2

Phase

Core I
(1S1 1S2)
Core II
(2S1 2S2)
Core II
(2S1 2S3)
Core II
(2S1 2S4)
Core II
(3S1 3S2)
Core II
(3S1 3S3)
Core II
(3S1 3S4)

Applied
Current

R
Y
B
R
Y
B
R
Y
B
R
Y
B
R
Y
B
R
Y
B
R
Y
B

20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20

SECONDARY
CURRENT
(mA)

THEORETICAL
RATIO

ACTUAL
RATIO

% OF
ERROR

100.1
98.2
101
40.5
39.8
40.2
20.2
20.1
20.4
10.1
10.1
10.2
39.8
40.7
40.6
20.1
19.8
20.2
10.2
10.2
9.8

200
200
200

199.80
203.67
198.02
493.83
502.51
497.51
990.10
995.02
980.39
1980.20
1980.20
1960.78
502.51
491.40
492.61
995.02
1010.10
990.10
1960.78
1960.78
2040.82

-0.10
1.83
-0.99
-1.23
0.50
-0.50
-0.99
-0.50
-1.96
-0.99
-0.99
-1.96
0.50
-1.72
-1.48
-0.50
1.01
-0.99
-1.96
-1.96
2.04

500
500
500
1000
1000
1000
2000
2000
2000
500
500
500
1000
1000
1000
2000
2000
2000

g) Magnetising Curves Performance


(Not to be done for metering Core)
Knee Point Voltage (KVp) = for 1s1-1s2 - 200Volt
For 2s1-2s2- 250 Volt
For 3s1-3s2- 250 volt
i.
HV Side R Phase
VOLTAGE
TO BE APPLIED

ACTUAL
VALUE(V)

UNIT

CORE I
1S1-1S2

0.25 x KVp
0.50 x KVp
0.75 x KVp
1.00 x KVp
1.10 x KVp

50
100
150
200
220

mA
mA
mA
mA
mA

25.1
35.0
40.1
53.8
65.1

ii.

CURRENT MEASUREMENT
CORE II
CORE III
2S1-2S2
3S1-3S2

9.4

13.2
17.5
22.9
23.8

8.7
12.5
15.1
21.7
28.8

HV Side Y Phase

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 19 of 16

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

VOLTAGE

CURRENT MEASUREMENT
CORE II
CORE III
2S1-2S2
3S1-3S2

TO BE APPLIED

ACTUAL
VALUE

UNIT

CORE I
1S1-1S2

0.25 x KVp
0.50 x KVp
0.75 x KVp
1.00 x KVp
1.10 x KVp

50
100
150
200
220

mA
mA
mA
mA
mA

25.5

8.9

35.6
47.5
62.9
71.6

13.1
16.8
22.7
27.4

iii.

9.8
14.5
19.1
25.12
29.6

HV Side B Phase
VOLTAGE

TO BE APPLIED

ACTUAL
VALUE

UNIT

CORE I
1S1-1S2

0.25 x KVp
0.50 x KVp
0.75 x KVp
1.00 x KVp
1.10 x KVp

50
100
150
200
220

mA
mA
mA
mA
mA

24.6
35.3
46.6
63.8
72.5

CURRENT MEASUREMENT
CORE II
CORE III
2S1-2S2
3S1-3S2

7.6

12.1
16.3
20.3
24.5
27.9

12.3
16.8
24.5
29.4

Note: 1.0 CT should not saturate at 110% of Knee Point Voltage (KVp)

2.0 If Knee Point Voltage is not mentioned then Knee Point Current may be taken into
consideration.

h) Magnetising Curves Performance (Neutral side)


(Not to be done for metering Core)
Knee Point Voltage (KVp) = for 1s1-1s2 - 200Volt
For 2s1-2s2- 250Volt , For 2s1-2s2- 500Volt, For 2s1-2s2- 1000Volt
For 3s1-3s2- 250 volt, For 2s1-2s2- 500Volt, For 2s1-2s2- 1000Volt
iv.

Neutral Side R Phase


VOLTAGE

TO BE APPLIED

ACTUAL
VALUE(V)

UNIT

0.25 x KVp
0.50 x KVp
0.75 x KVp
1.00 x KVp
1.10 x KVp

50
100
150
200
220

mA
mA
mA
mA
mA

v.

CURRENT MEASUREMENT
CORE I
ACTUAL
1S1-1S2
VALUE(V)

25.1
35.0
40.1
53.8
65.1

CORE III
3S1-3S2

9.4

8.7
12.5
15.1
21.7
28.8

13.2
17.5
22.9
23.8

Neutral Y Phase
VOLTAGE

TO BE APPLIED

ACTUAL
VALUE

UNIT

CORE I
1S1-1S2

0.25 x KVp
0.50 x KVp
0.75 x KVp
1.00 x KVp
1.10 x KVp

50
100
150
200
220

mA
mA
mA
mA
mA

25.5

vi.

62.5
125
187.5
250
275

CORE II
2S1-2S2

35.6
47.5
62.9
71.6

CURRENT MEASUREMENT
ACTUAL
CORE II
VALUE(V)
2S1-2S2

62.5
125
187.5
250
275

8.9

13.1
16.8
22.7
27.4

CORE III
3S1-3S2

9.8
14.5
19.2
25.12
29.6

Neutral B Phase
VOLTAGE

TO BE APPLIED

ACTUAL
VALUE

UNIT

CORE I
1S1-1S2

0.25 x KVp

50

mA

24.6

CURRENT MEASUREMENT
ACTUAL
CORE II
VALUE(V)
2S1-2S2

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 20 of 16

62.5

7.6

CORE III
3S1-3S2

12.1

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

0.50 x KVp
0.75 x KVp
1.00 x KVp
1.10 x KVp

100
150
200
220

mA
mA
mA
mA

35.3
46.6
63.8
72.5

125
187.5
250
275

12.3
16.8
24.5
29.4

16.3
20.3
24.5
27.9

Note: 1.0 CT should not saturate at 110% of Knee Point Voltage (KVp)

2.0 If Knee Point Voltage is not mentioned then Knee Point Current may be taken into
consideration.
i.

Neutral Side R Phase


VOLTAGE

TO BE APPLIED

ACTUAL
VALUE(V)

UNIT

0.25 x KVp
0.50 x KVp
0.75 x KVp
1.00 x KVp
1.10 x KVp

125
250
375
500
550

mA
mA
mA
mA
mA

ii.

3.9
6.3
9.0
11.8
13.8

4.0
6.6
9.0
12.2
14.2

ACTUAL
VALUE(V)

CORE II
2S1-2S4

CORE III
3S1-3S4

250

2.0

500
750
1000
1100

3.3
4.5
6.1
7.0

2.1
3.4
4.5
6.3
7.3

ACTUAL
VALUE(V)

CORE II
2S1-2S4

CORE III
3S1-3S4

250

1.8

500
750
1000
1100

2.9
4.0
5.4
6.7

1.9
3.1
4.4
6.2
7.0

ACTUAL
VALUE(V)

CORE II
2S1-2S4

CORE III
3S1-3S4

250

1.8

500
750
1000
1100

3.0
4.1
5.5
6.3

2.0
3.3
4.5
6.2
6.9

Neutral Y Phase
VOLTAGE

TO BE APPLIED

ACTUAL
VALUE(V)

UNIT

0.25 x KVp
0.50 x KVp
0.75 x KVp
1.00 x KVp
1.10 x KVp

125
250
375
500
550

mA
mA
mA
mA
mA

iii.

CURRENT MEASUREMENT
CORE II
CORE III
2S1-2S3
3S1-3S3

CURRENT MEASUREMENT
CORE II
CORE III
2S1-2S3
3S1-3S3

3.5
6.0
8.3
11.1
12.4

3.8
6.4
9.0
12.2
14.2

Neutral B Phase
VOLTAGE

TO BE APPLIED

0.25 x KVp
0.50 x KVp
0.75 x KVp
1.00 x KVp
1.10 x KVp
iv.

ACTUAL
VALUE(V)

UNIT

125
250
375
500
550

mA
mA
mA
mA
mA

CURRENT MEASUREMENT
CORE II
CORE III
2S1-2S3
3S1-3S3

3.9
6.2
8.4
11.0
12.9

4.0
6.5
8.7
11.6
13.1

Note: 1.0 CT should not saturate at 110% of Knee Point Voltage (KVp)

2.0 If Knee Point Voltage is not mentioned then Knee Point Current may be taken into
consideration.

XIV.

Contact Resistance Measurement at 100 Amps

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 21 of 16

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

CONTACT RESISTANCE

UNITS

R-

Y-

B-

4.2
4.1
5.0
Across HV Bushing Terminal Joint
4.6
Across Neutral Bushing terminal joint

NGR terminal connector


The value of Contact Resistance should not be more than 10 Micro ohms per Joint /
Connector

XV.

Protection And Alarms

i.
DEVICE

SET FOR

SL
NO

ALARM

EXCESSIVE WINDING TEMPERATURE.

EXCESSIVE OIL TEMPERATURE.

PRESSURE RELIEF VALVE (MAIN TANK )

NA

PRESSURE

NA

MAIN TANK BUCHHOLZ RELAY

NGR BUCHHOLZ RELAY

FAN FAILURE\

LOW OIL LEVEL ( MAIN TANK )

RELIEF VALVE ( NGR )

PROVED
TRIP

ok

ALARM

TRIP

NA

ok

NA
ok

ok

NA

NA

LOW OIL LEVEL ( NGR )

NA

NA

10

HIGH OIL LEVEL ( MAIN TANK )

NA

NA

11

OTI ( MAIN TANK )

12

OTI ( NGR )

13

WTI ( MAIN TANK )

100

14

DIFFERENTIAL

NA

ok

NA

ok

15

BACKUP IMPEDENCE RELAY

NA

ok

NA

ok

16

EARTH FAULT RELAY ( REF )

NA

ok

NA

ok

17

INTER TRIP , IF ANY

NA

NA

18

TRIP FREE CHECK

NA

NA

19

TEED PROTECTION

NA

20

On Line DGA alarm

ii.

90

Protection setting applied as per engg.approved settings

100
110

Yes

No

Remarks

Not Ok

Remarks

Yes

iii.
iv.

Stability test of differential and REF protection (at 10


kV)

Ok
Ok

Delta formation of single phase units and spare switching arrangement scheme checked
Yes

No

Remarks
NA

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


Page 22 of 16

SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

NOTE : Prove the tripping of associated breakers by actual operation of the various devices

and relays as per the schemes.


XVI.

Final Documentation Review


Yes

i.

Factory test results are available

ii.

All electrical test results compared with factory test results & found to
be in order

iii.

Final documents of Pre- Commissioning checks reviewed and approved

iv.

No

Yes

Document regarding spares equipment, O&M manuals etc available at


site

Yes

No

Yes

No

Yes

No

Yes

No

XVII. Checks After Charging Of Reactor

Record the following after charging


i.

Any abnormal sound emanating from the reactor

ii.

No load current at relay terminal

iii.

R-

Y-

B-

Yes

No

Remarks

No

Remarks

Temperature at the time of charging


OTI
WTI
AMBIENT

C
C
C

iv.

Maximum temperature after 24 hours____________ C

v.

Thermo vision scanning done at least after


24 hours of loading & repeated one week.

vi.

VIBRATION MEASUREMENT TEST

Yes

a) Vibration measurements are to be carried out


after energization of the reactor. This will be a
reference data for future Measurements.
b) Various locations are to be shown in the
Format No.: CF/SR/02/ R-4,DATED 01/01/2013
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SHUNT REACTOR

DOC NO.: D-2-01-03-01-04

diagram with x,y co-ordinates for easy


identification.
SL.
NO

DATE OF
MEASUREMENT

LOCATION

VALUE

REMARKS

Signature:

Signature:

Signature:

Signature:

Name:

Name:

Name:

Name:

Desgn.:

Desgn.:

Desgn.:

Desgn.:

Organization:
(Supplier
Representative)
(Wherever
Applicable)

(Erection Agency)

(POWERGRID Site
I/C)

(POWERGRID
Commg. Team)
Members:
1.
2.
3.

Format No.: CF/SR/02/ R-4,DATED 01/01/2013


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