Condition Monitoring of Electrical

Equipments (EEL 426)

Makarand Sudhakar Ballal

What is off line Condition monitoring ?

Off line condition monitoring is defined as,

Testing of the equipment before taking into

service.
What is off line Condition monitoring ?
Inspection of the electrical machinery before
charging.

Make judgment about the status or condition of the

equipment before connected with rated name plate
supply and load by measurement of some Important
parameters defined in IEEE standards or in IS.
What are the tests carried out in off line
Condition monitoring ?

The tests carried out are categorized in

following three categories.

Routine Tests: Routine tests are performed

during manufacturing on all equipments
after the active part assembly completed.
Routine Tests: Routine tests are carried
out in industries.
Type Tests : Type tests are tests made on a
equipment which is representative of other
equipments to demonstrate that they comply with
specified requirements not covered by routine
tests.
Special tests: Special tests are tests, other than
routine or type tests, agreed between
manufacturer and purchaser.

Special tests are performed upon customer

request.
What is off line Condition monitoring ?
What is the necessity of off line
Condition monitoring of Transformer?
Pre-commissioning tests of Transformer
Routine Off line methods/Tests
There are various Test required on
Transformer to conform performance of
Transformer.
Mainly two types of transformer are done by
manufacturer before dispatching the
transformer mainly
(1) Type test of transformer and
(2) Routine test.
Transformer Tests done by Manufacturer as per IS 2026

(A) Routine Tests

(B)Type Tests
(C) Special Tests
Transformer Tests done at Site

(D) Pre Commissioning Tests

(E) Periodic/Condition Monitoring Tests

(F) Emergency Tests

Transformer Tests done by Manufacturer IS 2026
Tests done by Manufacturer on Current Transformer IS 2705
Transformer Tests done by Manufacturer
Transformer Tests done by Manufacturer
Routine Off line methods/Tests
(A) Routine tests:
A Routine test of transformer is mainly for confirming operational
performance of individual unit in a production lot.
Routine tests are carried out on every unit manufactured. All
transformers are subjected to the following Routine tests:
Insulation resistance Test.
Winding resistance Test.
Turns Ratio / Voltage ratio Test

Polarity / Vector group Test.

No-load losses and current Test.

Short-circuit impedance and load loss Test.
Routine Off line methods/Tests
(A) Routine tests contd:
Winding Continuity Test
Magnetizing Current Test
Magnetic Balance Test
High Voltage Test.
Dielectric tests
Separate source AC voltage.
Induced overvoltage.
Lightning impulse tests.

Test on On-load tap changers, where ever required.

(B) Type tests
Type tests are tests made on a
transformer which is representative of
other transformers to demonstrate that
they comply with specified requirements
not covered by routine tests:
Temperature rise test (IEC 60076-2)
IS 2026 Part 2 (2010).
Dielectric type tests (IEC 60076-3).
IS 2026 Part 3 (2009).
C) Special tests

Special tests are tests, other than

routine or type tests, agreed between
manufacturer and purchaser.
Dielectric special tests. Winding Tan delta, Bushing Tan
delta
Zero-sequence impedance on three-phase
transformers.
Short-circuit test on every tap.

Harmonics on the no-load current.

C) Special tests contd.....
Power taken by fan and oil-pump motors.

Determination of sound levels.

Determination of capacitances between windings and

earth, and between windings.

Determination of transient voltage transfer between

windings.

Tests intended to be repeated in the field to confirm no

damage during shipment, for example frequency response
analysis (FRA).
D) Pre commissioning Tests
The Test performed before commissioning the
transformer at site is called pre commissioning test of
transformer.
These tests are done to assess the condition of
transformer after installation and compare the test
results of all the low voltage tests with the factory test
reports.
All transformers are subjected to the following
Pre- commissioning tests:
1. IR value of transformer and cables
2.Winding Resistance

3.Transformer Turns Ratio

D) Pre commissioning Tests contd...
All transformers are subjected to the following
Pre- commissioning tests:
4.Polarity Test

5.Magnetizing Current

6.Vector Group

7.Magnetic Balance
8.Bushing Tan Delta (HV )
9. Winding Tan Delta (HV )
10.Protective relay testing / Cold trials
11.Transformer oil testing
12. High potential (Hi-pot) test also called as Dielectric
withstand test
DIAGNOSTIC TESTING
Insulation Resistance and Polarization Index
Test Purpose: Test Instruments:
Insulation resistance test of For LT System: Use 500V or
transformer is essential to 1000V. Megger or IR Tester
ensure the healthiness of For MV / HV System: Use
overall insulation of an 5000V or 10000V Megger or
electrical power transformer. IR Tester

Tests can detect:

Weakness of Insulation.
I R Test
Insulation Resistance and Polarization Index
Insulation Resistance and Polarization Index
Oil temperature should be noted at the time of
insulation resistance test of transformer. Since the
IR value of transformer insulating oil may vary with
temperature.

IR values to be
recorded at intervals of
15 seconds, 1 minute
and 10 minutes.
With the duration of
application of voltage,
IR value increases.
Insulation Resistance and Polarization Index
The increase in IR is an indication of dryness
of insulation.
Dielectric Absorption
Coefficient
= 1 minute value/ 15 second
value.

Polarization Index
= 10 minutes value / 1minute
value
Insulation Resistance Test:
Test Procedure:
1. First disconnect all the line and neutral terminals of the
transformer.
2. Megger leads to be connected to LV and HV bushing studs to
measure Insulation Resistance (IR) value in between the LV and
HV windings.
3.Megger leads to be connected to HV bushing studs and
transformer tank earth point to measure Insulation Resistance IR
value in between the HV windings and earth.
4.Megger leads to be connected to LV bushing studs and
transformer tank earth point to measure Insulation Resistance IR
value in between the LV windings and earth.
Note: It is unnecessary to perform insulation resistance test of transformer per
phase wise in three phase transformer. IR values are taken between the windings
collectively as because all the windings on HV side are internally connected
together to form either star or delta and also all the windings on LV side are
internally connected together to form either star or delta.
The increase in IR is an indication of dryness of
insulation.

The total current flow,

when a DC voltage
is applied, starts at a
relatively high value and
then drops, settling at a
value just slightly above
the leakage current.

Megger connection schematic is shown in Fig. (above).

It is used to measure resistance in Mega Ohms.
The increase in IR is an indication of dryness of
insulation.

In bad or deteriorated insulation, the total current will

drop slowly, or may even increase.

Mergers' output Voltages of 100, 250, 500, 1,000, 2500,

5,000, and even 10,000V are used
(Table ) next slide.
Insulation Resistance
The most common voltages are 500V and 1,000V.
Higher voltages are used to stress an insulation to a
greater degree and thus obtain more accurate
results.

Table.
Recommended test
voltages for routine
maintenance
insulation-
resistance tests of
equipment rated to
4,160V and above.
Insulation Resistance
A mega-ohm-meter, usually called Megger is equipped with three
terminals. The "LINE" (or "L") terminal is the so-called "hot"
terminal and is connected to the conductor whose insulation
resistance you are measuring. Remember: These tests are
performed with the circuit de-energized.

The "EARTH" (or "E") terminal is connected to the other side of

the insulation, the ground conductor.

The "GUARD" (or "G") terminal provides a return circuit

that bypasses the meter. For example, if you are measuring a
circuit having a current that you do not want to include, you
connect that part of the circuit to the "GUARD" terminal.
Various insulation tests
Basically, there are three different tests that can be done
using a Megger.
1) Insulation resistance (IR)
1) Insulation resistance (IR)
This is the simplest test. After the
required connections are made, you
apply the test voltage for a period of
one min. (The one-min interval is an
industry practice that allows
everyone to take the reading at the
same time.)

(In this way, comparison of readings will be

of value because, although taken by
different people, the test methods are
consistent.) During this interval, the
resistance should drop or remain relatively
steady.

Larger insulation systems will show a steady decrease, while smaller

systems will remain steady because the capacitive and absorption
currents drop to zero faster on smaller insulation systems. After one min,
read and record the resistance value.
Insulation Resistance Test

Note that IR is temperature sensitive. When the temperature goes up, IR

goes down, and vice versa. Therefore, to compare new readings with
previous readings, you need to correct the readings to some base
temperature.
Usually, 20°C or 40°C are used as comparison temperatures; tables are
available for any correction. However, a common rule of thumb is that IR
changes by a factor of two for each 10°C change.
For example, suppose we obtained an IR reading of 100 mega ohms with
an insulation temperature of 30°C. The corrected IR (at 20°C) would be 100
mega ohms times 2, or 200 mega ohms.
Insulation Resistance IR
Also note that acceptable values of IR will depend upon the
equipment.

The interNational Electrical Testing Assoc. (NETA)

specification NETA MTS-1993, Maintenance Testing
Specifications for Electrical Power Distribution Equipment
and Systems, provides much more realistic and useful
values.

Test results should be compared with previous readings and

with readings taken for similar equipment. Any values below
the NETA standard minimums or sudden departures from
previous values should be investigated.
2) Dielectric Absorption Ratio (DAR)
This test recognizes the fact
that "good" insulation will
show a gradually increasing
IR after the test voltage is
applied.
After the connections are
made, the test voltage is
applied, and the IR is read at
two different times: Usually
either 15 and 60 sec, or 60
sec and 10 min.
The later reading is divided by the earlier reading, the result
being the dielectric absorption ratio (DAR).

The 10 min./60 sec. ratio is called the polarization index (PI).

2) Dielectric Absorption Ratio (DAR)
For example, let's assume we apply the mega
ohmmeter as described earlier with the appropriate
test voltage impressed.
The one min. IR reading is 50 mega ohms, and the
10 min. IR reading is 125 mega ohms. Thus, the PI
is 125 mega ohms divided by 50 mega ohms, or 2.5.

Various sources have tables of acceptable values of

dielectric absorption ratios (see Table below). This
is given in upcoming slides.
3) Step voltage test
This test is particularly useful in evaluating aged or
damaged insulation not necessarily having moisture
or contamination. A dual voltage test instrument is
required here. After the connections are made, the
IR test is done at a low voltage, say 500V.
The test specimen then is discharged and the test is
done again, this time at a higher voltage, say 2500V.
If more than a 25% difference exists between the two
IR readings, age deterioration or damaged insulation
should be suspected.
What is total current ?

An equivalent circuit for electrical

insulation is shown in Fig.

The top terminal might be the centre

conductor of a power cable, and the
bottom terminal, its shield.

The current flowing through the

cable's insulation would be that
current noted as "total current" in
the diagram.

As you can see, the total current is equal to the sum of the

Total current = capacitive (or polarization) current +

conductive current + surface leakage current +
Absorption current
Current through insulator
Let's provide some basic definitions here

Capacitive ( or polarization )current. A capacitor is

created when two conductors are separated by an
insulator. This is the situation in a power system
If a DC voltage is suddenly applied (closing the
switch in Fig), electrons will rush into the negative
plate and be drawn from the positive plate. Initially,
this current flow will be very large, but it will
gradually reduce to a much smaller value, eventually
approaching zero.
The current labelled "capacitive charging current"
in Fig. shows how this current varies with time after
DC voltage is applied.
Current through insulator
conduction leakage current. No insulation is perfect; even
new insulation will have some leakage current, albeit small.
This leakage current will increase as the insulation ages.
It also will worsen when the insulation is wet or contaminated.
The "conduction leakage current" shown in Fig. is a graphical
representation of leakage current. Notice that it starts at zero,
and quickly increases to a final value of 10 micro amps.
Current through insulator
This is the way that good insulation behaves. As insulation
ages and deteriorates, however, two changes may occur in
leakage current.

One change may be that the final value of conduction leakage

current may increase and not level off. For example, instead
of levelling off at 10 micro amps, the final current may
increase to 20 micro amps.

The other change may be that, instead of rising quickly to a

final value and the levelling out, the conduction leakage
current simply may continue to increase. In this scenario, the
insulation eventually will fail.
Current through insulator

Absorption current. The charges that form on the plates of

the capacitor attract charges of the opposite polarity in the
insulation, causing these charges to move and, thus, drawing
current.
The largest charge motion occurs
in the initial moments and then
gradually tapers off to near zero.
This current is called dielectric
absorption, or just absorption
current. A time plot of this current,
labelled "absorption current," also
is shown in Fig.
Current through insulator
A time plot of this current, labelled "absorption current," also
is shown in Fig.
Current through insulator
surface leakage current (Not shown in graph)

This is the current in micro amperes which takes the

path from the surface of the object under test.

This is the current flows in large amount if the

surface is not clean. It means if the surface have
dust particles, oil spots, moisture etc, the surface
leakage current is more.
surface leakage current
The best practice to
eliminate this
current is to send it
to ground during
testing. This is
achieved by making
connection of
surface with Guard
terminal.
If Guard terminal provided, surface leakage
current 0
What is total current ?

If Guard terminal connected,

surface leakage current 0

Polarization current 0 after 1 minute

Absorption current 0 after 10 minutes

due to alignment of induced dipoles
Total Current reduces, why?

Time based DAR / PI Tests.

DAR = R 60 sec = Capacitive current +Conductive current

R 15 sec Total current

PI = R 600 sec = Conductive current .

R 60 sec Capacitive current +Conductive current

Note that the total current is not the load current flowing through the
system. Rather, it's the current that flows from the energized
conductor through the insulation to ground.
Insulation Resistance and Polarization Index
What is the purpose of insulation resistance test?

Insulation resistance testing puts a qualitative value on the

condition of conductor insulation and the internal insulation of
different pieces of electrical equipment. As an insulation
resistance test begins, apply a direct current (dc) voltage to the
conductor or equipment under test.
Proof test
Proof testing is an important
step in the installation of new
machinery to protect against
mis-wired and defective
equipment.

A proof test is often referred to

as a go/no go test because it
tests the system for errors or
incorrect installation..

The test is accomplished by applying DC voltage through the de-energized circuit

using an insulation tester. If no failures occur during the measurement, the test is
a success
Proof testing voltages are much higher than those used in routine maintenance
test methods. The general guideline for choosing a test voltage is based on the
equipment's nameplate rating.
Follow the equation below to arrive at an acceptable test voltage.
Step 1: (2×nameplate rating)+1,000V=Factory AC Test
Step 2: 0.8×Factory AC Test×1.6=DC Proof Test Voltage