Instruction and Maintenance Manual

24kV … 170kV CURRENT TRANSFORMER

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 CONTENTS

Section No. Contents

1 Construction
1.1 Scope
1.2 General construction
1.3 Terminal details
2 Receipt of CT and Inspections
2.1 Packing
2.2 Receipt of CT at Site and Visual inspection
2.3 Check Seal of Oil Sampling Valve
2.4 Storage of CT at Site
3 Erection
3.1 Lifting, shifting and erection of CT
3.2 Mounting of CT
Procedure for removal of foam strips from Hood and Visual
3.3
Check for Oil from Oil Presence Indicator
3.4 Electrical connections
4 Commissioning
5 Maintenance
5.1 Periodic maintenance
5.2 Tan delta Measurement on CT
5.3 Bellow level setting of CTs at site
6 Diagrams
6.1 Cross-sectional drawing of a typical CT
6.2 Horizontal & Vertical Transportation
7 Safety
7.1 Instructions for disposal of materials
7.2 Instruction for mitigation control
7.3 Material safety data sheet ( MSDS)

CAUTION!
If User fails to strictly comply with relevant requirements regarding
Storage Erection, Commissioning, Periodic Maintenance specified in this
Manual, CG reserves right to revoke guarantee on product quality.

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1.1 Scope

This instruction manual is applicable to live tank outdoor current transformers (CT) manufactured
by CG Power and Industrial Solutions Limited, India. These CTs step down current proportionally
for measurement and protection devices in the electrical system with highest system voltage
(HSV) from 24 kV to 170 kV and Rated frequency 50 or 60 Hz.
This instruction manual gives information on recommended procedures for inspection after
receipt, handling, commissioning and periodic maintenance of CT after dispatch from our works.
The drawings and other informative data in this manual may vary slightly from the equipment
supplied. In all cases drawings submitted by CG and identified with the respective equipment will
be correct in all details.
The contents of this manual cover majority of circumstances that may occur in practice. In case
additional understanding is needed, contact CG Power and Industrial Solutions Limited, India.

CAUTION!
Customers or users are required to perform installation, testing,
regular inspection and maintenance of the equipment by
qualified and trained personnel.

1.2 General construction

Design:

CT works on electromagnetic transformer principle to transform high voltage line current to

standard measurable value. Our IOSK, CT & CGC type CTs are of Top Core (Live Tank)
construction.
Major items of CT are:

1.2.1 Aluminium Tank [5]

Aluminium alloy tank accommodates primary winding and shell. Shell is an aluminium cast
housing to accommodate secondary windings.

1.2.2 Primary Winding [4]

Primary winding consists of Aluminium / Copper rods tubes and or sections accommodated in
the tank. The primary connections are performed using primary terminals (P1 & P2) on the sides
of the tank. Ratio selection by primary turns adjustment can be achieved by changing terminal
position on P2 side of tank (as shown in figure No. 2 & 3). The Rating & Schematic diagram on
secondary box of CT indicates position of Primary terminal for ratio selection.

Tightening torque for primary reconnection bolts (in case if it is present): 20 N-m

1.2.3 Secondary Winding [9]

The secondary windings are of insulated copper wire uniformly wound over the ring type toroidal
cores. Each layer of winding is perfectly insulated from each other using high quality insulating
material. The cores with secondary windings are accommodated in aluminium cast shell. The
secondary leads are taken through capacitor graded bushing to the base of the CT and are
terminated in the secondary box at the base of CT.
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1.2.4 Insulation

Major insulation between Shell [3] (at ground potential) and Aluminium Tank [5] (at high potential)
is of high quality electrical grade insulating Kraft paper. Complete CT after assembly is dried and
impregnated with high quality of mineral oil under fine vacuum. The drying and oil impregnation is
carried out in specially designed autoclaves and a well defined drying and impregnation cycle is
followed. The insulation of the bushing through which secondary leads are passed, is provided
with condenser grading. This helps in achieving optimum and consistent impulse withstand
capability.

1.2.5 Hermetic sealing

The oil filled metallic bellows [2] compensates for the oil volume variation due to ambient
temperature variation. Bellows serves the purpose of oil level indication. The CT is hermetically
sealed by using these bellows. With this hermetic sealing, the insulating characteristics of
dielectric are maintained during the service life of product. We do not recommend any repair /
rework on CTs at site without our consent.

1.2.6 Insulator [6]

Brown or Grey (on request) glazed porcelain insulator / Composite insulator (Optional) are
offered. Shed profile and creepage distance are selected as per voltage level and ambient
conditions of site. Insulator is fixed to aluminium alloy flanges on both sides with suitable bonding
agent for providing optimum mechanical strength.

1.3 Terminal details

1.3.1 Primary Terminal

Primary terminal of CT can be cylindrical or NEMA pad type (palm / flat). For dimensions of
primary terminal, refer contractual drawings. Primary terminal of the CT can be with fixed or ratio
changeover arrangement. For details of offered primary changeover arrangement refer
contractual drawings.

 Primary changeover – Double Ratio

Reconnection link P2 Aluminium Boss P2

Higher Ratio Lower Ratio

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For higher ratio : Reconnection link should be bolted to the fixed terminal P2 of the CT. Threaded
holes are provided on the Reconnection link at the centre for fixing it to P2 terminal.

For lower ratio: Unscrew the Reconnection link from fixed terminal P2 and bolt it to the two
aluminium bosses which are welded on the tank on each side of the P2 terminal. Threaded holes
are provided on each aluminium boss for bolting.

 Primary changeover – Triple Ratio

A detachable primary terminal (P2) is provided for primary changeover arrangements.

P2-2 P2- 4 P2-1

Middle Ratio Lower Ratio Higher Ratio

P2-2 P2- 4 P2-1

 For higher ratio the detachable terminal should be connected to fixed aluminium pad marked
P2-1.
 For middle ratio the detachable terminal should be connected to aluminium pad marked P2-2.
 For lower ratio the detachable terminal should be connected to aluminium pad marked P2-4.

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1.3.2 Secondary terminals

Secondary Terminals are housed inside the secondary terminal box at the base of CT. Terminal
designations are shown in the schematic diagram. Be sure that burden values given in rating
plate are adhered to and secondary windings not in use are short circuited. Use Torque wrench
to tighten secondary terminals. Use Torque values M4- 3 Nm; M5- 3 Nm; M6-5 Nm.

CAUTION!
Always ensure that terminals of unused secondary windings are short
circuited. If multiple ratios are present, the terminals of highest ratio must
be shorted.

CAUTION!
Capacitance & Tan delta terminal “Cx” must be grounded before
charging the CT.

CAUTION!
Tighten stud type secondary terminals to the respective maximum
torque.

1.3.3 Earthing terminals

Minimum two holes are provided on diagonally opposite legs of base [14] of CT for earthing
connection. It is necessary that CT is independently earthed. Separate earth lead needs to be
used for earthing. The earthing connection must be mechanically rigid and capable to carry the
system’s fault current.

CAUTION!
Inadequate or defective earthing connection may cause danger to life in
case of human contact with CT.

2.1 Packing

The CTs are suitably packed in wooden / steel crates OR base. Cushions are provided inside
packing case to hold the unit during shipment. Packed CTs are transported in horizontal position.

CAUTION!
Do not change orientation of packing during horizontal transportation.
Follow all transport markings on the packaging.

2.2 Receipt of CT at site and visual inspection

 Scrutinize shipping documents with your contract and the markings on the packing case.
 Conduct visual inspection for any external damage.
 In case any damage is noticed and goods are insured by you, immediately inform your
insurance company and proceed further as guided by the insurance company.
 In case any damage is noticed and goods are insured by us , proceed as below,
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 - Inform us by email or fax, Conduct & Prepare FIR
- Take photographs of the damaged packing case and CT, send it to us.
- We would take necessary actions and would keep you informed.

2.3 Check Seal of Oil Sampling Valve

Oil Sampling Valve of CT is sealed before despatch of CT from factory. On receipt of CT it is

necessary to check presence of Seal on oil sampling valve.

Seal on Oil
Sampling Valve

2.4 Storage of CT at site

CTs are transported in horizontal condition in packing case. It is necessary to remove CTs from
packing case immediately after it reaches to the site. If CT is required to be stored for longer
time, ensure that it is stored in vertical condition in a clean, protected, less polluted environment
on a hard levelled surface till commissioning.

CAUTION!
Do not keep Current Transformer (CT) in Horizontal Position for more than
3 months.

3.1 Lifting, shifting and erection of CT

Open packing case and unscrew all nuts and bolts used for clamping CT (on tank side and base
side) in the packing case.

 On removal from packing case, CT should be kept on levelled ground. Ensure wooden
supports are kept in a position to prevent damage to CT Primary terminal.

 Refer Fig. 3 & 4 for making CT vertical. During whole erection phase, rope must be at 90
degree angle to ground. Also ensure that a wooden support is firm on the ground to avoid
heavy swinging of the CT during making it vertical.

 During Vertical handling and shifting vertically avoid heavy jerks. Use lifting lugs which are
provided on top tank for vertical handling of CT. Ensure sufficient rope length to avoid the
damage of hood.

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3.2 Mounting of CT

Four mounting holes are provided on the Base [14] for fixing CT firmly on support structure.
Refer relevant drawings against contract for details.

3.3 Procedure for removal of PVC Sheet from Hood and Visual Check for Oil from Oil
Presence Indicator

Unscrew Hood Remove Hood Remove PVC sheet

Check Seal on Re fix Hood Tighten screws of Hood

Bellows top

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3.4 Electrical Connections

3.4.1 Earthing Connections

Use earthing holes provided on the base for connecting CT to Substation earth. Earthing system
should be capable of carrying full short circuit current of the system. Remove protecting coating
(in case provided) around the earthing holes to ensure firm contact.

3.4.2 Secondary Connections

Use Secondary Terminal Blocks for connecting leads of instruments, relays etc. Connections
must be done as per Rating plate & Schematic Plate. Ensure that Burden (VA) values given on
the rating plate are adhered to & are not exceeded.

3.4.3 Primary Connections

Before starting with the primary connections ensure that –

 Base [14] of CT is firmly mounted on the support structure.
 Ensure product earthing as explained earlier
 Secondary connections are in position.
Now connect Primary terminals [4] of CT in series with main high voltage line. While doing
these connections ensure –
 Pull on primary terminals [4] does not exceed limits specified in relevant National
/International Standards.
 Clean contact area of primary terminal before connecting it to terminal connector.
 Copper Busbar or Copper Cable should not come in contact with Aluminium Terminal. If it is
unavoidable then cold welded bimetallic strip shall be used between aluminium and copper,
while providing suitable weather resistance coating at the transition zone. In order to avoid
corrosion at bimetallic joints, we recommend usage of silicon or resin based “Weather
Resistance Protective Coating” over the transition region.
 All screw/bolts shall be used with correct size plain and spring washers to ensure adequate
clamping pressure. The connection must be mechanically firm and shall be checked,
tightened (if required) during first few weeks of operations.
 We recommend that it should be checked after exposure to mechanical force resulting from a
rope strike, storm or earthquake. Periodic plan for above checks must be prepared & adhered
to.
CAUTION!
In case of tapped secondary winding (say 1s1, 1s2, 1s3, 1s4) if the
instrument is connected to any one section (say 1s1, 1s2) the other
sections (1s3, 1s4) of the same winding should not be shorted.

CAUTION!
Secondary windings not in use must be short circuited firmly by
shorting links. Otherwise it will lead to dangerous high voltage across
the secondary windings & failure of product.

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4 Commissioning

Check following points before charging of CT. We recommend that the checks to be performed
on each CT and tick-marked in status column after having completed the check. After
completion of all pre-commissioning checks, the CT can be charged to its operating voltage.

Sr. No. Checks Status

1 Tightness of all secondary connections
2 Porcelain insulator [6] is clean
3 CT Base [14] is firmly connected to earth
4 PVC sheet are removed from Hood [1]
Measure Capacitance and tan Delta at 5 kV to 10 kV and
5
compare results with factory test report
6 "Cx” lead is connected to earth
7 Secondary winding, which is not in use, is short circuited

Burden values of the connected instruments do not exceed

8
the values specified on rating plate for particular winding

Polarities of primary and secondary connections are as per

9
schematic diagram on rating plate
Desired ratio is correctly selected as per the schematic
10
diagram on rating plate
Bellow [2] position of the CT is in between minimum and
11
maximum positions marked on the Hood [1]
12 Secondary box cover [11] is closed firmly

13 Oil Sampling/ Drain Valve [13] is in sealed condition

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5.1 Periodic Maintenance

For periodic maintenance of CTs we recommend to carry out following checks at

recommended time intervals.

LEGEND CHECKS DESCRIPTION

Check tightness of bolts used for earthing.
Verify
Ensure that CT base is always connected to earth. This is
correct
A MUST when CT is in operation.
earthing
(grounding) Ensure that secondary winding is connected to earth at one
point only.
Verify that all Primary, secondary and earth connections are tight ensuring
B connections low contact resistance.
are correct Ensure that all the joints are corrosion free.
Burden (including cables) connected across secondary
winding should be within the rated values for which the CT is
Unused designed.
secondary
Refer rating plate for the value of rated burden.
C windings of
Unused secondary windings MUST be short circuited.
CT are short
circuited Voltage across secondary winding (if kept open) can be
dangerously high that may cause damage to product and
personnel.
Step down ratio of CT can be measured by injecting 5% of
Measure rated
secondary current at rated frequency thru the primary connections (i.e.
currents P1-P2)
D against Disconnect primary connection from high voltage lines before
values performing this test.
specified on  Connect low resistance ammeter to respective secondary
rating plate terminal of the core.
Short circuit unused windings of CT.
Oil level indicated by bellow position must be between MIN
and Max markings at all ambient and service temperatures.
In a three phase system all bellows should be about the
same position between MIN and MAX markings. (Difference
should be clearly detectable from ground – about 3 cm or
more).
Check bellow
E If position of Bellow is above MAX, CT MUST be taken out of
position
service.
If position of Bellow is at MIN or below MIN level, check for
oil leakage.
If oil leakage is observed, take out CT from service.
If no oil leakage is observed, Bellow level can be restored.
Refer Clause no. 5.3.
Following parts of CT MUST be checked for oil traces ,
Aluminium Tank (Head)
Examine for Primary Terminals
F
oil traces Terminal Box
Oil Filling Plug
Oil Sampling valve
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 Insulator joints with Tank and base.
If oil traces are detected at these locations, CT should be
taken out of service. and consult CGPISL. Based on nature
and location of leakage, CGPISL may recommend on site
repair.

CAUTION!
Any site repairs conducted without written
consent of CGPISL will void the guarantee and
warranty of product

Inspect  The terminal box should be kept clean dry and free from
cleanliness of insects.
G secondary  If rain water has entered the box, inspect rubber gasket on
terminal box the door and if necessary tighten the clamping bolts of
& its sealing cover.
Minor damage to porcelain insulator shed can lead to hairline
cracks which are initially too small to see and later lead to oil
leakage.
Inspect In case of damage thorough examination is recommended.
insulator and Heavy pollution on the insulator surface combined with
H
its moisture can lead to surface corona, flashover etc.
cleanliness Keep insulators clean in accordance with local (plant)
experience, clean (if required).
Follow safety rules while cleaning. Refer local regulations.
(See IEC 60815).
Visual
inspection for Inspect connections for corrosion, especially if unlike metals
I corrosion of are in direct contact with one another.
secondary If necessary improve corrosion by painting.
terminal box
 Check temperature of P1 and P2 terminals by thermo vision
Check
J camera.
Temperature
 In case hot spot is observed, tighten connections.
Tan Delta
K Measurement  Refer Clause No. 5.2
on CT
 Ageing of oil is prevented by hermetical sealing of CT.
 It is recommended that testing of oil sample be performed
after every 5 years of service life.
 Ensure that oil sampling is done in dry air with procedure
Check recommended in IEC 60415.
Insulating Oil The sample should be taken only by a trained specialist and
L
analysed by a qualified laboratory.
 Ensure that minimum oil volume is sampled from CT which
is sufficient for the required test.
 Maximum four samples are recommended.
Tan Delta Tests to be performed as per IEC 60250.
BDV Tests to be performed as per IEC 60156.
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 Moisture
(Water Tests to be performed as per IEC 60814.
Content)

Parameter Limits on Oil parameters for CT to be taken out of service

Tan Delta at
> 0.2
90 Degree
Breakdown
< 50
Voltage (kV)
Moisture
(Water
> 20
content)at
20°C (ppm)
 Sample should be taken only by a trained specialist and
analyzed by qualified laboratory. For additional information
Dissolved
see IEC 60567.
gas analysis
M  Contents of following gases should be analyzed:
of insulating
oil

Gases Typical limits (in ppm) for CT to be taken out of service

H2 > 500
CO > 1000
CO2 > 4000
CH4 > 75
C2H6 > 70
C2H4 > 25
C2H2 > 10
The health of CT will be further assessed by other tests to determine
Note
further usage in consultation with CG.

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* Partial Discharge Measurement (PD)

The PD measurement as a diagnostic tool can only be used if there are suitable equipments to
measure on site. For tests in laboratories limits of IEC 61869 are recommended, Because of
the high noise on site, PD is not recommended for routine check of the Current Transformer
(CT), but only as additional information.

LEGEND
TIME INTERVAL A B C D E F G H I J K L M

Before energizing, after

• • • • • • • • • •
any movement of CT
Routine Inspection
Daily •
Quarterly •
Yearly • • • • •
After every 10 years in
• • • • • • • •
service (approx.)
After electrical
overloads or when the • • •
bellows of the CTs in
•
the 3 phases of a line
differ in position
Before re-energizing,
after change of burden
• • • •
or connections
After excessive
mechanical loads on
•
CT(storm, earthquake)
When secondary
current readings are
• • • •
doubtful

5.2 " Tan delta " Measurement on CT:

Tan delta measurement can be conducted at site after CT is disconnected electrically from the
transmission line. Measurement needs to be conducted between HV terminal (P1-P2) and Tan
delta testing terminal, Cx. Test equipments by renowned manufacturers can be used. Test
procedure to be in line with the test equipment manufacturer. Ensure that measurements are
conducted between the test voltages of 5 kV to 10 kV.

5.2.1. Cx Terminal:

CG provides separate Tan delta testing terminal “Cx” inside secondary terminal box. This
terminal needs to be used for tan delta measurement.

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 CAUTION!
Except for the measurements, Capacitance and Tan delta terminal
terminals MUST be connected to earth (ground). If left open, while the CT is
in operation, it will lead to explosive failure.

Notes:
 Capacitance & tan delta measurements at site are most sensitive and can be affected
by the atmospheric conditions & electrical environment prevailing at site. Always
ensure that the measurements are carried out under dry atmospheric conditions.
 We recommend the CT to be tested for tan delta before commissioning and the value
obtained shall be considered as a reference value for further monitoring during
service. Tan delta should be < 0.005 before commissioning.
 CT is to be tested for tan delta as mentioned in Periodic Maintenance in this Manual.
Limiting value of tan delta is 0.010. In case tan delta exceeds this value, contact us.
 CT is tested at factory for capacitance & tan delta under controlled conditions and at
rated voltages specified in standards.

5.3 Bellow level setting of CTs at site

Oil sampling is recommended for DGA and other tests as a part of periodic maintenance.
Since CT is hermetically sealed, oil sampling will result in to reduction of bellow level. CGPISL
supplies special oil filling kit and adaptor (optional) in order to restore the bellow level of CTs at
site. Without opening the air tight system, oil can be pumped back in to CTs in order to restore
correct level of bellows. In case of any requirements contact CGPISL.

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6.1 Cross-sectional drawing of a typical CT

Fig. 1

[1] Hood [2] Bellow [3] Shell [4] Primary Terminal

[5] Tank (Housing) [6] Insulator [7] Centre Pipe [8] Oil Presence Indicator
[9] Secondary winding [10] Secondary Terminal Box [11] Rating Plate
[12] Gland Plate [13] Oil Sampling Valve [14] Base

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6.2 Horizontal and Vertical Transportation

Note: Centre of Gravity lies approximately by the first or second porcelain shed.

Fig. 2

Ensure simultaneous
crane movement in
vertical and horizontal
direction to avoid
dragging of CT.

Ensure fixed
location of
wooden block to
avoid jerk on CT
while making it
vertical.

Fig. 3 Fig. 4

Note: The rope must always hang vertically (i.e. 90 0 to ground) when erecting.

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7.1 Instructions for disposal of materials

We have used environmental friendly materials for manufacture of CT. Treat this equipment as
industrial waste when disposing it.

After useful service life of CT, care should be taken to dispose insulating oil and some of below
components. Insulating oil used on our CTs is mineral, naphthenic base which is transparent
and free of particles. It does not contain PCBs.

Sr. Hazardous Handling/Storage/Disposal

Material
No Waste Method
Incineration as per local
1 Oil soaked paper Yes regulations. Emission of CO,
CO2.
Insulating Oil Recycle or refer local
2 No
(Mineral, Naphtha based) regulations for disposal
3 Copper and Brass components No disdisposaldisposalreprocdis
posalprodisposadisposal
4 Epoxy and Bakelite Mouldings No
procedure

7.2 Instruction for Mitigation Control

In case of abnormal & emergency condition during life cycle of Current transformer & Condenser
Bushings to minimize environmental pollution:

 Ensure no storage of packing wood for long duration in humid condition as it will cause land
pollution. Alternatively incinerate/bury the infected wood as per local regulation.

 Rusting of steel used in packing case as it will cause contamination of water & soil. Take
action as per local regulation.

 In case of fire caused by explosion of product, immediately switch off the high voltage circuit if
it is not tripped. Use fire protecting equipment to extinguish the fire. Take actions as
recommended by the local regulation. Inform us.

7.3 Material Safety Data Sheet (MSDS)

Insulating oil used on the CTs is Naphthenic base mineral oil conforming to IEC 60296 and IS
335. The oil is produced using Indian based refineries. The oil is stable during storage and
handling and is not hazardous in nature.

After service life of CT, in case insulating oil is taken out of CT, care should be taken that
it is stored at cool, dry and clean location. It must be protected from heat and flames.

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It is non-toxic, non-irritating, use of protective measures are recommended as below

Skin : Use oil resistant gloves to minimize skin contact.

Eye : Wear safety glasses
Respiratory : Avoid inhalation of mist.
Safety : Use safety shoes while handling oil drums.

FIRST AID MEASURES:

Skin Contact : Remove oil – soaking clothing. Wash affected parts of the body thoroughly
with soap and water.
Eye contact : Hold eyelids open and flush eye with water.
Inhalation : In the event of dizziness or nausea, remove casualty to fresh air. If
symptoms persist obtain medical attention. If breathing stops give assisted respiration by the
mouth to mouth or mouth to nose method.

ACTION IN CASE OF SPILLAGE:

Absorb a small spillage with sand or earth. Sweep up and contain absorbent and then remove
it to an appropriate facility for disposal in compliance with local regulations.
Large spillages should be prevented from spreading by the use of sand or earth. If possible
transfer the spilled oil to a salvage tank; otherwise treat as for a small spillage.

DISPOSAL OF USED PRODUCT AND CONTAINER (WHERE APPLICABLE) :

Used oils may contain harmful impurities, which present risks to health that are not present
when handling the new oil. It is not possible to be more specific since the presence or absence
of harmful impurities is use dependent therefore used oil should not be allowed to contaminate
soil or water and should be disposed of in accordance with prevailing regulations, preferably to
a recognized collector or contractor.

This information is based on our knowledge as of and is intended to describe the product for the
purposes of health and safety requirements only. It should not therefore be construed as
guaranteeing any specific property of the product.

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…………………………...................................................................................................................

IN CASE OF TRANSIT DAMAGE MARK LOCATION OF DAMAGE ON THIS DRAWING

AND SEND IT TO US

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CG Power and Industrial Solutions Limited, India.
(Formerly Crompton Greaves Limited)
Vacuum Interrupters and Instrument Transformers Division: Power Systems
D2 & D1/2, MIDC, Waluj, Aurangabad - 431 136, Maharastra, India,
Tel:-+91 0240-2558000, 2558031
Fax:- +91-240-2554697
Email: [email protected]
[email protected]
[email protected]
[email protected]

S6/CT/T/374//R0, Dated. 06.10.2017

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