QASCO CommissioningTest Report

SITE TEST REPORT FOR 6.6 /0.420kV 2.
5 MVA POWER TRANSFOMER, CCM

CLIENT: CONSULTANT: MAIN CONTRACTOR:
DASTUR ENGINEERING
INTERNATIONAL, GmbH
QATAR STEEL COMPANY DUSSELDORF M.N DASTUR &
COMPANY (P) LTD. KOLKATA SIEMENS W.L.L
EF5 PROJECT Contract No :
2.5MVA TRANSFORMER COMMISSIONING REPORT Date : 07-07-2013
Name of Substation : CCM LCSS Bay Number : 1F12
Name of Equipment : 2.5MVA Transformer Manufacturer :SIEMENS
Test Procedure, Forms with Applicable Standards.

This document details the visual checks, mechanical and electrical tests on
the Transformer. It is organized in several sheets in Method Statement which
briefly gives information related to
 Test Set Up
 Test Procedure
 Test Results
 Acceptance Norm
Test Instruments
The following equipment were used during test.
Testing
Equipment-1 Equipment-2 Equipment-3 Equipment-4
Equipment
Equipment Used: IR Measurement CPC100 Multi meter Clamp meter
Sr. No 100710 / 2595 LJ552T / HK059 97100545 15730023
Make / Model Megger-MIT510/2 Omicron Fluke/179 Fluke/365
Calibration
13-07-2012 12-07-2012 06/07/2012 10/07/2012
Date:
Calibration Due: 12-08-2013 11-08-2013 06/08/2013 10/08/2013
DASTUR ENGINEERING
INTERNATIONAL, GmbH DUSSELDORF
W.L.L QATAR M.N DASTUR & COMPANY (P) LTD. QATAR STEEL
KOLKATA COMPANY
Signature Signature Signature
Name Muhammad Rafique Name Name
Date Date Date
Date: 16/06/2013 Page 1

SITE TEST REPORT FOR 6.6 /0.420kV 2.5 MVA POWER TRANSFOMER, CCM
DASTUR ENGINEERING
INTERNATIONAL, GmbH
C. SAFETY PRECAUTIONS:
 Safety Labels has been installed in Power Transformer Area (e.g. Power
Transformer testing under progress).
 Barricades have been provided near Power Transformer during testing.
 Testing area has been kept clean and have sufficient space during testing.
 Power Transformer earthed properly before starting the testing.
 Power Transformer identified before starting the commissioning.
2.5MVA POWER TRANSFORMER SITE TEST REPORT
1. TRANSFORMER NAME PLATE DETAILS:
Bay reference : 1F12 CCM Serial Number : Nr LEL-111449
Year of Mfg : 2012 Power Rating : 2.5MVA
Vector Group : DYn11 Type of Cooling : ONAN
Th. Short CIRCUIT

Rated Frequency : 50Hz : 2.850KA
Current/2Sec
Rated HV Voltage : 6600V Rated LV Voltage : 420V
HV Current : 218.7A LV Current : 3437A
Tap Changer : DETC Range of Taps : 5
Insulated Oil Type : ERGON HYVOLTI Ambient Temperature : 55◦C
%Impedance at tap Temperature Rise

: 7.7% : 50/45K
No.3 Winding/Oil
Bushings Breather
Date: 16/06/2013 Page 2

DASTUR ENGINEERING
INTERNATIONAL, GmbH
Make
-
2. VISUAL INSPECTION AND GENERAL CHECKS:
Type of
S. No Description Result
Check
1 Checked as per Erection Control Form Visual O.K
75.7KV, Test
Oil dielectric strength
conducted
2 Acceptance Standard : O.K
with BDV
BDV - 60kV> 1 min with gap Setting of 2.5 mm
KIT,
3 Valve Positions Visual O.K
4 Phase Sequence of Auxiliary Supply. Electrical O.K
5 LV Bushings Visual O.K
6 Transformer Main Earthing Visual O.K
7 Transformer’s Equipment Earthing Visual O.K
3. MEASUREMENT OF EXCITATION CURRENT:

Apply 3-phase (415 V) to the high voltage bushings. Measure voltage between phases
and current on each phase. This test is to be applied immediately after
installation, before applying any voltage to the transformer and when the
transformer is completely de-magnetized.
Tap Applied Voltage (V) Measured Current (mA)
R – Y Y - B B – R R Y B
1 414.7 415.03 414.85 25.86 20.21 26.41
Date: 16/06/2013 Page 3

DASTUR ENGINEERING
INTERNATIONAL, GmbH
3 415.01 415.01 414.84 28.18 21.97 28.74
5 415.07 415.03 415.04 30.77 23.97 31.40
Apply 3-phase (415 V) to the low voltage bushings. Measure voltage between phases
and current on each phase.
Applied Voltage (V) Measured Current (A)
Tap
R – Y Y - B B – R R Y B
3 415.02 414.97 414.98 3.7333 3.7718 4.7629
4. INSULATION RESISTANCE MEASUREMENT:
Applied Polarization Index

Measured Values ( GΩ )
Connection Voltage
(Volts)
R60 R300 R600 R300/R60 R600/R60
HV - (LV + E) 2500 1.21 2.1 2.40 1.74 2.0
LV – ( HV + E) 250 1.61 3.54 4.25 2.2 2.64
HV – LV 250 2.01 3.79 4.51 1.89 2.24
(HV+LV) – E 250 1.62 2.88 3.36 1.77 2.027
Acceptance Norm: 1 Mega Ohm / kV of the Insulation
Transformer Insulation is excellent, satisfying the IEC standards i.e. IEC 60076-2000
part 1, IEEE 62. For very good / excellent condition, polarization Index (P.I) must
be above 1.3
Date: 16/06/2013 Page 4

DASTUR ENGINEERING
INTERNATIONAL, GmbH
5. MEASUREMENT OF WINDING RESISTANCE:
Test Procedure
 Isolate primary/secondary/neutral earth.

 Measure winding resistance between phase to neutral for all taps in case of
star connection and phase to phase in case of delta
 First measure the winding resistance at nominal tap for base reference and
later carry out measurement in all taps from start to finish.
 Compare the resistances between all three phases and observe changes in
each tap and the overall trend.
 Measures the resistance with Omicron Kit.
 Compare its value with the factory test reports.
 The Omicron kit will automatically performs a discharging of the winding
after saving the measurement.
HV Winding Resistance:
Measured Resistance
Tap Mean Value at Reference Temp.75◦ C
Between Phase to Phase (Ω)
Position %
Measured Factory Factory
No. Value at Deviation
Value at
R – Y Y - B B – R Value at Value at Reference
Reference
39.0 ◦ C 26 ◦C Temp.
Temp.
1 0.1308 0.1309 0.1314 0.1310 - 0.1487 - -
3 0.1244 0.1238 0.1246 0.1242 0.121 0.1411 0.1437 1.80
5 0.1172 0.1165 0.1171 0.1169 - 0.1327 - -
According to IEC standards 600076-2000, part 1, caluse-102; tolerance ±3% is

generally acceptable for the measured values at site over the factory test report
value.
LV Winding:
Date: 16/06/2013 Page 5

DASTUR ENGINEERING
INTERNATIONAL, GmbH
Measured Resistance
Mean Value at Reference Temp.75◦ C
Between Phase to Neutral (mΩ)
Factory % Deviation
Meas. Value Factory Value at
Value at
R - Y Y – B B – R at Value at Reference
Reference
39.0◦ C 26 ◦ C Temp.
Temp.
0.4633 0.4545 0.4638 0.4605 0.4290 0.5210 0.5095 -2.25
6. CHECKING OF VECTOR GROUP:
Test Set Up
Test Procedure
 Select the normal tap

 Short R – r, Apply 3 phase 415V to R – Y – B terminals.
 Measure the voltages given below.
 From the measured voltages check the following conditions for the vector
group.
Dyn11
 R r = 0,
 RY = R n + Y n,
 Bb< By
 Yb = Yy
Date: 16/06/2013 Page 6

DASTUR ENGINEERING
INTERNATIONAL, GmbH
Test Results
 Short R & r
 Apply Voltage (Volts)
R – Y 415.4
Y – B 414.4
B – R 414.3
Measure Voltage across (Volts)
R r 0 Y b 391.4 B y 414.4
R Y 415.2 R n 16.07 Y y 391.3
B b 390.7 Y n 399.20 - - -
 Compare the values for the following combinations
Dyn11
 R r = 0,
 RY = R n + Y n,
 Bb< By
 Yb = Yy
 Conclusion on the Test :
Remarks: VECTOR GROUP Dyn11 - OK
Date: 16/06/2013 Page 7

DASTUR ENGINEERING
INTERNATIONAL, GmbH
8. TURNS RATIO TEST:
Test Set Up
Test Procedure

 Switch on the Omicron kit.
 Select the transformer page.
 As per the instructions given by manual enter the test current and pressing
the start button, the test card displays.
 For this test, a test voltage of up to 415V is injected on HV side.
 This voltage is measured internally with high precision.
 The ratio is calculated automatically.
 Repeat the same procedure for all other taps and other phases
Date: 16/06/2013 Page 8

DASTUR ENGINEERING
INTERNATIONAL, GmbH
Test Results
Tap
Applied Rated Measured HV/LV Ratio % Error
Position
Voltage HV/LV
No.
(V) Ratio Average
R-Y/r-n Y-B/y-n R-B/b-n R-Y/r-n Y-B/y-n R-B/b-n
Ratio
1 415 - 28.625 28.625 28.625 28.625 - - -
2 415 - 27.927 27.927 27.927 27.927 - - -
3 415 27.217 27.270 27.270 27.270 27.270 -0.19 -0.19 -0.19
4 415 - 26.545 26.545 26.545 26.545 - - -
5 415 - 25.855 25.855 25.855 25.855 - - -
IEC Standard 60076-2000, Part 1, states that maximum allowable ratio error for the
principle tap is ± 0.5 % i.e. got it within the limit.
Date: 16/06/2013 Page 9

DASTUR ENGINEERING
INTERNATIONAL, GmbH
9. MAGNETIC BALANCE TEST:
Test Set Up
Test Procedure

 Select the normal tap, Apply single phase voltage between R & B.
 Measure the voltages in Y – R & B – Y, r & n , y & n, b & n.
 Repeat the same procedures for the all other sequences in both primary and
secondary of the transformer.
Test Results:
APPLIED VOLTAGE 230V HV SIDE APPLIED VOLTAGE 230V LV SIDE

R – Y Y – B B – R r – n y – n b – n
230.4 177.3 53.35 229.5 142.1 87.5
116.4 230.5 114.2 114.6 227.5 113.2
56.84 173.3 230.3 111.4 117.3 228.7
The measured values must be in conformance to the values in the factory Acceptance
report of this transformer. Normally in a well balanced magnetic circuit, voltage
applied at one phase would be the summation of other two phases. The required result
is achieved.
Date: 16/06/2013 Page 10

DASTUR ENGINEERING
INTERNATIONAL, GmbH
11. TRANSFORMER SHORT CIRCUIT IMPEDANCE MEASUREMENT:
Test Set up
Test Procedure

 Short all the three phases on the LV side of the transformer.
 Apply 3-Phase Voltage on HV Side,
 Measure the Voltage and current in all the three phases in HV Side
 Calculate the impedance by voltage/current (V/I).
Test Results
Temp 40◦C
Tap Voltage applied (V) Measured Current (A) Name Plate Values
position
Connection. R-Y Y-B R-B Average R Y B Average %Z MVA Current % Z
3 134.80 133.0 130.9 132.9 35.2 35.8 34.6 35.30 12.19 2.5 218.7 7.7
Date: 16/06/2013 Page 11

DASTUR ENGINEERING
INTERNATIONAL, GmbH
According to IEC Standard 60076-2000, Part 1, Clause 10.1, % impedance at principle

tap is within the measuring accuracy / tolerance limit i.e. below 1%.
16. Oil Break Down Test Report

S. No Oil Break Down Value After Top Up Oil Break Down Value before oil Top Up
1 80.2 KV 58.9KV
2 80.1 KV 68.4KV
3 71.8 KV 72.9KV
4 80.2 KV 75.9KV
5 80.0 KV 71.8KV
6 80.1 KV 72.6KV
Mean Value 78.8 KV 70.1KV
Oil quality is very good, satisfied the IEC Standards 60156-95, for new oil the BDV
must be above 60KV
17. Insulation resistance test:
Measurement
DESCRIPTION Test voltage
value
Heaters, Lighting and Breather > 2.2 Mega Ohm

WTI 1,WTI 2,OTI Alarm & Trip
> 2.2 Mega Ohm 500VDC
Contacts
Buchholz relays, PRDS, Oil Level
> 2.2 Mega Ohm
indicators Alarm and Trip Circuit
Transformer Signaling Circuit Done it
18. Mechanical Protective device Testing Procedure:

18.1. Buchholz relay:
 Simulation by Draining Oil Alarm and Trip Contact status checked.
18.2 Pressure relieve device:
 Switch operated manually, checked Contacts status.
18.3 Oil Level Flow Gauge
 Two Switches provided to operate and reset correspondingly. Switches operated
manually and checked Contact status. Max & Min oil Level alarm Signals Checked by
Moving of Indication Needle.
18.4 Oil temperature setting.
 Setting for OTI: Alarm: 85◦C, Tripping: 90◦C.
Date: 16/06/2013 Page 12

DASTUR ENGINEERING
INTERNATIONAL, GmbH
Date: 16/06/2013 Page 13

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SITE TEST REPORT FOR 6.6 /0.420kV 2.

5 MVA POWER TRANSFOMER, CCM

Test Procedure, Forms with Applicable Standards.

Equipment Used: IR Measurement CPC100 Multi meter Clamp meter

Sr. No 100710 / 2595 LJ552T / HK059 97100545 15730023

Make / Model Megger-MIT510/2 Omicron Fluke/179 Fluke/365

Calibration Due: 12-08-2013 11-08-2013 06/08/2013 10/08/2013

Date: 16/06/2013 Page 1

2.5MVA POWER TRANSFORMER SITE TEST REPORT

1. TRANSFORMER NAME PLATE DETAILS:

Bay reference : 1F12 CCM Serial Number : Nr LEL-111449

Year of Mfg : 2012 Power Rating : 2.5MVA

Vector Group : DYn11 Type of Cooling : ONAN

Th. Short CIRCUIT

Rated HV Voltage : 6600V Rated LV Voltage : 420V

HV Current : 218.7A LV Current : 3437A

Tap Changer : DETC Range of Taps : 5

Insulated Oil Type : ERGON HYVOLTI Ambient Temperature : 55◦C

%Impedance at tap Temperature Rise

Date: 16/06/2013 Page 2

2. VISUAL INSPECTION AND GENERAL CHECKS:

1 Checked as per Erection Control Form Visual O.K

3 Valve Positions Visual O.K

4 Phase Sequence of Auxiliary Supply. Electrical O.K

5 LV Bushings Visual O.K

6 Transformer Main Earthing Visual O.K

7 Transformer’s Equipment Earthing Visual O.K

3. MEASUREMENT OF EXCITATION CURRENT:

Tap Applied Voltage (V) Measured Current (mA)

1 414.7 415.03 414.85 25.86 20.21 26.41

Date: 16/06/2013 Page 3

3 415.01 415.01 414.84 28.18 21.97 28.74

5 415.07 415.03 415.04 30.77 23.97 31.40

3 415.02 414.97 414.98 3.7333 3.7718 4.7629

4. INSULATION RESISTANCE MEASUREMENT:

Applied Polarization Index

HV - (LV + E) 2500 1.21 2.1 2.40 1.74 2.0

LV – ( HV + E) 250 1.61 3.54 4.25 2.2 2.64

HV – LV 250 2.01 3.79 4.51 1.89 2.24

(HV+LV) – E 250 1.62 2.88 3.36 1.77 2.027

Acceptance Norm: 1 Mega Ohm / kV of the Insulation

Date: 16/06/2013 Page 4

5. MEASUREMENT OF WINDING RESISTANCE:

 Isolate primary/secondary/neutral earth.

1 0.1308 0.1309 0.1314 0.1310 - 0.1487 - -

3 0.1244 0.1238 0.1246 0.1242 0.121 0.1411 0.1437 1.80

5 0.1172 0.1165 0.1171 0.1169 - 0.1327 - -

According to IEC standards 600076-2000, part 1, caluse-102; tolerance ±3% is

Date: 16/06/2013 Page 5

0.4633 0.4545 0.4638 0.4605 0.4290 0.5210 0.5095 -2.25

6. CHECKING OF VECTOR GROUP:

 Select the normal tap

Date: 16/06/2013 Page 6

R Y 415.2 R n 16.07 Y y 391.3

 Compare the values for the following combinations

 Conclusion on the Test :

Remarks: VECTOR GROUP Dyn11 - OK

Date: 16/06/2013 Page 7

8. TURNS RATIO TEST: