Bam Nuttall Hv Test Report

SEQUENT POWER SERVICES LIMITEDCarillion Package Substation - HV Test Report

Client - BAM NuttallDocument Prepared by - Ron Richardson

Document Date - 29/11/2010

1 - HV Report Overview

3 - HV Testing

Pre and post Insulation Resistance Testing

a) Transformer

b) Ring Main Unit

HV Pressure Testing

a) Test Theory

b) Ring Main Unit

c) Transformer

Table Of Contents

2 - General Operation & Visual Checks

Ring Main Unit

Transformer

4 - Secondary Tests

Transformer Ratio Checks

Secondary Injection testing

Oil Sample Results

1 - HV Report Overview:

The following report has been produced to help give clear indication of the testing procedures and the respective results of the tests that were necessary for the successful implementation of the new Carillion ‘Package’ Substation which has been installed at the Eastern Goods Yard site at kings Cross.

Switchgear & Transformer Testing:

Due to the existing configuration (RMU ‘close-coupled’ to the Transformer) in order to carry out the testing of the Transformer it would be necessary to disconnect the ‘new’ previously installed HV termination at the RMU and then use the switching ‘on’ positions to test through the switches onto the HV windings of the Transformer. The HV test voltage values and durations would then have to be considered to ensure no possibility of ‘Over-stressing the HV Equipment. Functional Switching Checks were also carried out to confirm Switching operation reliability.

Secondary protection tests were also carried out to check that the Switchgear would operate under fault conditions as well as Insulation resistance checks for the Current Transformers

Method Statements and Risk assessments were constructed prior to the work commencing highlighting the Process and Immediate risk(s) in connection with the tasks.

The equipment tested was subjected to the following electrical tests consisting of :

1 - Pre and post Insulation resistance testing @ 5KV

2 - Uni-polar HV Testing @ 25KV (for 1 min)

3 - Secondary Injections Currents (0 - 20 amps) for Trip Testing Simulations

*Important Notes -

1 - Any recorded values lower than 75 Mega Ohms for Transformer tests will need to be reported to the manufacturer prior to any Energization activity as this may representative of a potential Failure.

2 - Any HV Cables tests with Insulation resistance values lower than 500 Mega Ohms prior to Energization will be subject to further investigation works as this may again be representative of imminent or possible near future Failure.

HV Report Overview (Cont’d):

Switching Schedules:

The Switching schedules and the associated support documents were produced to ensure that correct procedure was followed at all times for the duration of the task.

Permit To Work & Sanctions To Test Documents:

Permits and Sanctions were issued to the Sequent Power Services operatives on receipt of the Isolation and Earthing Certificate which had been issued by the EDF Engineer. Safety Locks were then applied to the RMU (Carillion S/S) to ensure safety measures against potential remote energization from Up-stream Substations.

2 - General Operation & Visual Checks

General Operation & Visual Checks (Transformer)

11000/415 TransformerDevice Type

PassGeneral Conditions

PassCooling Fins

PassOil Level

Pass (See Results)Oil Quality

Fitted (New Type)Silca Gel Breather

Transformer Specifications

Type - BowersSerial Number - 58302-1Year of Manufacture - 2009Bowers Job Number - SP58926Diagram DWG Number - WD0201High Voltage Rating - 11000Low Voltage Rating - 433 voltsHV Current - 52.5 ampsLV Current - 52.5 ampsFrequency - 1333.4 ampsImpedance - 4.54%Vector Group - Dyn 11 Number of Tap positions - 5 (HV range = 10450-11550 volts)

Litres of Liquid - 635 KgWeight of Liquid - 1455 KgTotal Weight - 2965 Kg

Pass (See Ratio Check)Tap Change Operation

Pass Danger Signage

Ring Main UnitDevice Type

GoodGeneral Conditions

PassSwitching operations

PassSF6 Gas Pressure

Pass HV Cable Boxes

Fitted (New Type)Silca Gel Breather

RMU Specifications

Type - Merlin Gerin Ringmaster RN2CSerial Number - PES 6914AYear of Manufacture - 2006Panel Type - RN2C - T/21Service Voltage - 13.8KVHighest System Voltage - 15KVImpulse Voltage Withstand - 95KVFrequency - 50/60 HzMass of Unit (Max) - 300kgSF6 Gas Filling Pressure at 20 degC - 0.55 bar G

Normal Current (Busbars) - 630 ampsNormal Current (Switch) - 630 ampsNormal Current (Circuit Breaker) - 200 amps

Short Time Current 3 seconds (Busbars) - 21kAShort Time Current 3 seconds (Switch) - 21kAShort Time Current 3 seconds (Circuit Breaker) - 21kA

Pass HV Cable Boxes

Pass (See Test Results)Tripping Operations

Pass (See Test Results)Current Transformers

Pass Earthing

Pass Danger Signage

General Operation & Visual Checks (Ring Main Unit)

3 - HV Pressure Testing

This section covers the Insulation resistance testing and HV Pressure of the Ring Main Unit and 11000/433v Transformer. For each of the above devices, the data shows the ‘Charging’ Characteristics when subjected to the designated test voltage over a specific time. The data has been inputed into a program and the 3D graph is then produced in ‘realtime’. The results can also be viewed from any angle within a 3D Hemisphere which is very useful when other parameters are installed in the program. With the 3D graph drawn it is then rotated in various directions to best show the comparison from a static view/snap shot. It is also possible to compare other components with their test results all within the same Hemisphere. The HV testing theory has been shown with the Test figure and how it is Derived.

Transformer IR Test:

RMU IR Testing - Ring Switch 1

RMU IR Testing - Ring Switch 2

This figure is 2x the RMS value and is used to theoretically simulate some of the 'in rush currents that are associated at the point of energisation.

Peak Value

11000 √3

Value = 1.732

This figure is used to establish the voltage in any individual 'phase

Root 3

This figure is the system voltage, and is the phase to phase value that the cable/switchgear is subjected to

System Voltage

6351 x 1.414 x 2.55 x 1.1

25185 voltsTest value = 25 KV (Per Phase - DC Test)

x 1.414 x 2.55 x 1.1

11000 1.732

x 1.414 x 2.55 x 1.1

This figure takes is the nominal voltage based on 10% more than the system voltage (11 KV)

Nominal voltage

1 - Insulation resistance test results should be greater than 10 gig ohms when testing each individual core to earth as well as phase to phase testing.2 - Insulation resistance tests that are less than 10 gig Ohms will result in further inspection of the cable installation for any possible causes.3 - If there is a large variation in core test results when carrying out insulation resistance tests then further investigation will be required.

Additional notes (For new cables)This figure takes into consideration the transient voltage at the peak of the sinewave

Transient Voltage

HV Pressure Testing Theory (25 KV Testing):

HV Pressure Testing (Ring Main Unit):

HV Pressure Testing Data / Results: (Carillion HV Package Sub station)

Serial No.- 15TE0649T&R PT 30/10HV Pressure Test Set

Serial No.- 060306/7398Megger BM11DInsulation Resistance Set

Ring Main UnitDevice Type

Ring Switch Number 1Test Connection Point

3 x phases with the Switches open or closed Type of Test

25 KV (for 15 Min)Test Voltage (DC)

<0.1maMilliamp Leakage

PassTest Conclusion

Signature- Ron Richardson (MGR)Tested By

Level 3 CommunicationsWitnessed By Signature-

RMU Specifications

Type - Merlin Gerin Ringmaster RN2CSerial Number - PES 6914AYear of Manufacture - 2006Panel Type - RN2C - T/21Service Voltage - 13.8KVHighest System Voltage - 15KVImpulse Voltage Withstand - 95KVFrequency - 50/60 HzMass of Unit (Max) - 300kgSF6 Gas Filling Pressure at 20 degC - 0.55 bar G

Normal Current (Busbars) - 630 ampsNormal Current (Switch) - 630 ampsNormal Current (Circuit Breaker) - 200 amps

Short Time Current 3 seconds (Busbars) - 21kAShort Time Current 3 seconds (Switch) - 21kAShort Time Current 3 seconds (Circuit Breaker) - 21kA

3 TestsNumber of Tests

HV Pressure Testing Data / Results: (Carillion HV Package Sub station)

Serial No.- 15TE0649T&R PT 30/10HV Pressure Test Set


11000/415 TransformerDevice Type

Ring Switch Number 1 (Closed)Test Connection Point

3 x phases (Via Delta) with the LV Winding Earthed Type of Test

25 KV (for 1 Min)Test Voltage (DC)

<0.1maMilliamp Leakage

PassTest Conclusion

Signature- Ron Richardson (MGR)Tested By

Level 3 CommunicationsWitnessed By Signature-

Transformer Specifications

Type - BowersSerial Number - 58302-1Year of Manufacture - 2009Bowers Job Number - SP58926Diagram DWG Number - WD0201High Voltage Rating - 11000Low Voltage Rating - 433 voltsHV Current - 52.5 ampsLV Current - 52.5 ampsFrequency - 1333.4 ampsImpedance - 4.54%Vector Group - Dyn 11 Number of Tap positions - 5 (HV range = 10450-11550 volts)

Litres of Liquid - 635 KgWeight of Liquid - 1455 KgTotal Weight - 2965 Kg

HV Pressure Testing (Transformer):

HV Test Connection Setup No.1

Location - Eastern Goods Yard - Kings CrossDevice - Carillion HV Package substationTest Procedure Number - 1 (Ring Switch 1 to Ring Switch 2)Date of test - 24/11/2010

RMU

L1 - 3

L3 - 3

L2 - 3

L1 - 1

L2 - 1

L1

L2

L3

L3 - 1

Front Section of RMU

Testing Point

Feed to Transformer

Terminals isolated

Live test Path

HV Pressure Test (25 KV DC)

Leakage CurrentTest Voltage

L1-3,L2-3,L3-3 (Looped together)

25 KV (15 Min) <1mA = Pass

Earthed Terminal(s)

None

RMU

L1 - 3

L3 - 3

L2 - 3

L1 - 1

L2 - 1

L1

L2

L3

L3 - 1


Testing Point

HV Pressure Test (25 KV DC)

LV Winding

HV Winding

ResultTest Voltage

L1-3 (Test Point) 25 KV (1 Min) <1mA = Pass

HV winding is in 'Delta' Configurartion

Earthed Terminal(s)

All LV Terminals

Terminals Isolated

Live Test Path

Winding Earthed

Location - Eastern Goods Yard - Kings CrossDevice - Carillion HV Package substationTest Procedure Number - 2 (HV Winding Pressure Test)Date of test - 24/11/2010



Insulation Resistance Test(Timed at 60 second Durations)

ResultTest Voltage

L1-3 (Test Point) 5 KV 4.76 GΩ

HV winding is in 'Delta' Configurartion

Earthed Terminal(s)

All LV Terminals

RMU

L1 - 3

L3 - 3

L2 - 3

L1 - 1

L2 - 1

L1

L2

L3

L3 - 1


LV Winding

HV Winding

Megger

Location - Eastern Goods Yard - Kings CrossDevice - Carillion HV Package substationTest Procedure Number - 3 (HV Winding IR Test)Date of test - 24/11/2010

Terminals Isolated

Live Test Path

4 - Additional Tests:

This section covers the secondary tests on the RMU and Transformer to help confirm operational suitability prior to the substation being energized.

Transformer Ratio Check:

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

2.65 volts

110 Volts (AC)Test Connection:L1 - L2 on HV WindingTap Position 1

2.29 volts

0.37 volts

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

0.38 volts

110 Volts (AC)Test Connection:L1 - L3 on HV Winding

2.26 volts

2.56 volts

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

1.29 volts


2.64 volts

1.33 volts

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

2.66 volts


2.34 volts

0.38 volts

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

0.39 volts


2.37 volts

2.70 volts

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

1.35 volts


2.66 volts

1.34 volts

Transformer Ratio Check

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

2.69 volts


2.39 volts

0.40 volts

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

0.41 volts

2.36 volts

2.72 volts

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

1.37 volts

2.72 volts

1.36 volts

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

2.86 volts

Tap Position 5

2.53 volts

0.44 volts

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

0.45 volts

2.49 volts

2.93 volts

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

1.48 volts

2.86 volts

1.44 volts

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

2.81 volts

Tap Position 4

2.46 volts

0.42 volts

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

0.43 volts

2.42 volts

2.78 volts

L1 - N (LV side)

L2 - N (LV side)

L3 - N (LV side)

1.39 volts

2.81 volts

1.42 volts

110 Volts (AC)Test Connection:L2 - L3 on HV Winding110 Volts (AC)

Test Connection:L1 - L3 on HV Winding

110 Volts (AC)Test Connection:L1 - L2 on HV Winding 110 Volts (AC)



110 Volts (AC)Test Connection:L1 - L2 on HV Winding 110 Volts (AC)



Transformer Ratio Check (Cont’d)

Ring Main Unit Additional Tests

Switchgear Secondary Testing

Serial No.- 77422-8T&R ADM SCITS 100ASecondary Injection Set


1.22 g ohmsL1 Phase

1.47 g ohmsL2 Phase

1.85 g ohmsL3 Phase

Signature- Ron Richardson Tested By

Testing Notes

The TFL were removed from the respective phases and then a secondary current of 5 amps was injected across the trip coil contacts. The net result being that the HV Circuit (Previously switch to the 'On' position) would 'Trip'

TFL Protection

Tripped/PassL1 Phase

Tripped/PassL3 Phase

CT Insulation Resistance @ 1 KV

PassAuxiliary Wiring @ 1 KV

Oil Sample Test Results

Oil Testing Results

Bottom TankSample Point

22/11/2010Date Sampled

22/11/2010Date Received

< 5Hydrogen (VPM)

23447Oxygen (VPM)

5Carbon Monoxide (VPM)

Rogers Ratio Code

108Co2 : Co Ratio

13Moisture mg/Kg

60 +Electrical Breakdown Kv

Pass Elec W/stand 22kv - 1 min

1 to 2Colour

Testing Notes

The gases were low and satisfactory, also the oil quality was good having low water, low acidity contents and high electrical strength. The PCB Content was below 10mg/kg and therefore the oil should not be expensive when the time of disposal arrives. The oil is not an injurious substance and the tank does nor have to be labelled as containing PCB's

0.005Acidity (mgKOH/g)

<0.1Ethylene (VPM)

<0.1Ethane (VPM)

Some shortFibre Count

PCB's

<0.5TYPE 1260 (mg/kg)

<0.5TYPE 1254 (mg/kg)

<0.5TYPE 1242 (mg/kg)

TOTAL PCB's

28 Wessex Way, Cox Green , Maidenhead, Berkshire, United Kingdom SL6 3BSTel: +44 1628 782679 / Mobile - +447515 384458

email - [email protected]

Sequent Power Services LimitedInstallation Services: HV & LV Cable Jointing up to 33 KV HV & LV Construction Up to 33 KV Protection Testing / Grading Surveys Full HV and LV Commissioning

Maintenance & Analysis (Online & Offline) HV & LV Maintenance Up to 132 KV Power Quality Analysis / Power Auditing Thermal Imaging Ultrasonic Testing Partial Discharge Testing

Additional Services: Technical Consultancy Technical Media Development Asset Management Project Management Training (On site and system specific)

Bam Nuttall Hv Test Report

Documents

hv equipment

hv windings

hv cables tests

transformer tests

switchgear transformer

unipolar hv testing

hv test voltage values

installed hv termination