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M A N UA L

Installation and maintenance

Power capacitors, banks and filters

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ABB Power Products
HV Components/ Capacitors
SE-771 80 Ludvika, Sweden

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ABB Contact centre
Phone: +46 (0)240 780 20 00

abb.com/powercapacitors

SECAP B003 VERSION D.30 AUG 2018

© Copyright 2018 ABB. All rights reserved.

Specifications subject to change without notice.
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This manual describes, in general, installation and
maintenance of capacitor units, banks and filters
delivered by ABB, Sweden. It should be used in
conjunction with order specific documentation.

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These instructions do not cover every possible installation,
operation, or maintenance scenario, nor propose to cover all
details or variations in equipment. If any requirements or
questions should arise, please contact ABB Capacitors.
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Table of contents

01 Definitions 06 13 Optional accessories 22

13.1 Pressure switch
02 Safety regulations 06 13.2 Bird caps
13.3 Noise reduction accessories
03 Personnel qualifications 07
14 Commissioning 23-25
04 Intended use 08 14.1 Documents
14.2 Inspection prior to energization
05 Emergency and preparedness 08-09 ss Inspection
5.1 Electric shock 14.3 Tests before energization
5.2 Explosion ss Capacitance measurements
ss Environmental safety ss Current transformer's primary injection test
5.3 Leakage ss Voltage measurements
5.4 Safety equipment ss Tightening torque
14.4 Inspection after energization
06 Packaging 10-11 ss Voltage measurements
6.1 Goods labeling ss Current measurement
6.2 Stackability ss Unbalance current
6.3 Standard marking
6.4 Parcel number 15 Maintenance 26-27
6.5 Packing list 15.1 Preventive maintenance
ss Capacitance measurement
07 Transport or unloading 11 ss Visual inspection
15.2 Corrective maintenance for disconnected bank
08 Delivery inspection 12 ss Discharge and ground before maintenance
8.1 General ss Discharge and grounding of the capacitor bank
8.2 Damaged goods ss Paint damage or formation of rust
ss Replacement of faulty capacitor unit
09 Storage port or site 12
16 Troubleshooting 28
10 Unpacking 13 16.1 Alarm
16.2 Trip
11 Assembly preparation 14-15 16.3 Leakage
11.1 Work at heights
11.2 Documents 17 Waste or disposal of units 29-30
11.3 Tightening torque 17.1 Packaging waste
11.4 Rating plates 17.2 Capacitor unit
ss Capacitor unit rating plate 17.3 Capacitor bank or filter
ss Rack name plate
ss Bank rating plate 18 Appendix 31-45
ss Filter rating plate 18.1 Checklist - Filter commissioning
18.2 Checklist - Discharge and grounding
12 Installation 16-21
12.1 Support insulators
12.2 Capacitor module
12.3 Grounding and potential settings
12.4 Grounding where insulator supports are used
12.5 Connection insulators and bus bars
12.6 Connection conductors
12.7 Cable lugs and tools
12.8 Installation of filters
6 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S D E F I N I T I O N S | S A F E T Y R E G U L AT I O N S | P E R S O N N E L Q U A L I F I C AT I O N S 7

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01 Definitions 03 Personnel qualifications

Capacitor element Capacitor stack This document does NOT serve as a replacement • Do not lift or move a capacitor or a capacitor
The single wound section comprising aluminium One or more capacitor modules stacked and sup- for proper training and certifications required module without adequate equipment and
foil and dielectric paper and/ or plastic film ported by insulators. to transport, operate, store, install the product precautions
as appropriate. safely. • Use the proper “rigging” when handling the
Capacitor bank units and always connect to the designated
Capacitor unit A single-phase set of capacitor units which — lifting points
Note
The steel case complete with bushing(s), capaci- comprises one or more capacitor stacks and is All persons working with the equipment must have experi- • Always inspect the equipment to ensure that
tor elements connected in series and parallel, in- complete with all interconnections. ence and the necessary knowledge in dealing with high volt- nothing has entered that might create a safety
ternal connections and if used, element fuses and age equipment. hazard such as debris, animals, etc
internal discharge resistors. Filter • Ensure the lifting accessories are rated to han-
An application constituted of capacitors, reactors Only qualified technicians may attempt to work dle the weight of the product and that the cor-
Capacitor module and resistors. on electrical equipment. rect lifting calculations are used according to
The steel rack supporting one or more the angles of the cables or chains
series groups of capacitor units including A risk assessment should be conducted to deter- • Do not remove supporting fixtures, cables or
interconnections. mine what hazards are present that needs to be bolts which support the positioning of the
addressed in the project plan. equipment until it reaches the final installation
• Always wear the appropriate clothing and location
footwear when working on or around the • Make sure all power is disconnected and prop-

— equipment
• When working at heights, fall protection should
erly grounded before attempting to work
• Only install or operate the capacitor module in

02 Safety regulations be worn

• Never lift anything above persons and also con-
sider the risks if something is dropped
the orientation as shown in outline drawings
• Use material handling equipment or obtain as-
sistance in assembling or removal of heavy ca-
• When moving material, ensure that there are no pacitors. Use proper lifting techniques
other interferences that might come into con- • The proper PPE (Personal Protective Equip-
tact with the unit such as overhead power lines ment) and insulated tool should always be used
• Never override or bypass any provided protec- when working around potentially energized
tive devices equipment
• In the event of a fire, do not use water to extin- • Do not energize the capacitors without proper
guish the flames. Use a suitable quenching connections (check drawings)
Read all instructions carefully before attempting should be maintained. If further information is re- agent such as, CO2 • Do not tamper with interlocks, alarms, or the
to handle, install, use, or service this equipment. quired, or particular problems arise which are not • Make sure minimum clearance is sustained control circuit
Complying with these instructions will help to re- covered, please contact the manufacturer. • Terminals are for electrical loading only; use
duce hazards, accidents and increase the reliabil- flexible connectors to avoid mechanical strain
ity and service life of the equipment. A project These regulations do not replace or overrule
plan should be developed and communicated to any local safety regulations when they are
all affected parties. Clear lines of communication more stringent.
8 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S I N T E N D E D U S E | E M E R G E N C Y A N D P R E PA R E D N E S S 9

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04 Intended use

Any improper use of the equipment may lead to Contact the manufacturer for any additional
the exclusion of liability for physical defects and questions.
5.2 Explosion 5.4 Safety equipment
may violate any warranty terms agreed to under
While handling the goods during unloading
purchase contract. Risk for explosion
and installation, it’s important to consider local
In extreme cases, failure during operation, might laws and regulations regarding personal safety
cause case rupture with oil leakage and fire as a equipment.

— possible consequence.

Environmental safety
Under no circumstances may the bushings be
exposed to external force or impact.

05 Emergency and preparedness An absorbing agent should be used when clean-

ing up waste fluids. Treat waste impregnation —
Note
fluid as hazardous to the environment. Capacitor units must never be lifted by the bushings.

5.3 Leakage

Risk for leakage

Upon capacitor unit leakage, avoid skin contact

5.1 Electric shock with the impregnation fluid. In the event of skin
contact, wash with soap and water. If fluid is
splashed into the eyes, rinse with lukewarm water
Risk of electrical shock
and seek medical care. For detailed information
Until the bank is short-circuited and grounded, it about the impregnation fluid (Faradol), see the
shall be considered as energized. After the capac- safety data sheet. For measures to be taken in the
itor bank has been disconnected, voltage remains event of leakage, see Section 16.3.
in each capacitor until it has been properly dis-
charged.

Capacitors with discharge resistors: Grounding

may only be conducted once the discharge period
has passed. The discharge period is counted from
when the circuit breaker is opened. Wait at least
10 minutes (IEC) or 5 minutes (IEEE). There after
the unit must be short-circuited.
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Capacitor units without discharge resistors: In Figure 5.1.1
these cases, special care must be taken. The dis-
charge circuit must include suitable resistance
and the discharge tool must have extra insulation
to withstand full voltage.
10 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S PA C K A G I N G | T R A N S P O R T / U N LO A D I N G 11

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06 Packaging

By default, there are four kinds of packaging:

6.3 Standard marking 6.4 Parcel number 6.5 Packing list
pallets, cages, wooden boxes and plywood
boxes assembled with torx screws. Each package has a unique parcel number. Each package is accompanied by two packing
Packages have a standard label that provides in- These numbers are marked on all four sides of lists. One stapled outside and one placed inside
The packaging is designed to withstand the load- formation on e.g. crate number, handling precau- the package. the package.
ing, unloading and transport in containers. Pack- tions, content, weight, dimensions, etc. They are
aging with a length exceeding 2 meters is pro- marked with the standard international manage-
vided with skids for ease of loading/ unloading. ment symbols according to SS-EN ISO780:
Insulators and major apparatus (reactors, resis-
tors) usually delivers in its OEM packaging.
Mounting material supplied separately,
such as copper cables and mounting hardware
are packed in plastic bags to protect from mois- Center of gravity
ture during transport. At gross weight> 1,000 kg or if weight is ex-
tremely out of center in packaging. Can be

6.1 Goods labelling seen on all four sides.

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Packages from ABB have standardized labelling
that provides information concerning for example
07 Transport or unloading
the number of packages, contents, weight, etc. This way up
All the packages carry the ABB logo. This is not In the upper left corner on all four sides of
permitted to be masked or removed in any way. packages.
All packaging complies with ISPM15, the standard Ensure that suitable lifting devices are available People shall never be under lifted goods.
for phytosanitary measures, and is labeled upon arrival for unloading and handling for the
accordingly. weight of the goods. Keep manual lifting of heavy objects to a mini-
mum. Follow local safety rules and regulations,
Each package is equipped with goods labelling Fragile Check that the load has been properly strapped this manual, marking of goods, use applicable
printed on a landscape A4 sheets on two sides, Packages containing capacitors, insulators, and stabilized before the transport to site. Plan lifting devices and safety equipment.
one long and one short side. CB 2000 or other electrical appliances. the method of unloading. Use an exclusion zone
Location as for "This way up" around the loading/ unloading area to keep peo- Use the right tools and machinery for the job.
ple who are not involved away from the work.
6.2 Stackability

Boxes with the same design and size is normally

loaded on each other up to 3 in height if the pres- Sling here
sure does not exceed 600 kg/m², if not else is Packages containing capacitor modules, labelled
stated on the box. Even packages with different on two opposing sides.
dimensions can be stacked on each other, pro-
vided that the pressure on the bottom of the
package does not exceed 600 kg/m².
12 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S D E L I V E R Y I N S P E C T I O N | S TO R A G E P O R T / S I T E | U N PA C K I N G 13

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08 Delivery inspection 10 Unpacking

Be careful during unpacking to make sure that the

8.1 General 8.2 Damaged goods goods is not damaged!
• Tools be used to facilitate opening:
Upon arrival of the equipment, carefully check If there is damage, document this with photos
• Crowbar
for transport damage and that the delivery and contact the freight forwarder as soon as pos-
• Cordless screwdriver torx with standard bits
is complete. sible. Immediately send the photos, along with
• Socket wrench kit
the part number of the damaged material, to the
In the event of missing material or if transporta- supplier to minimize the risk for unnecessary de-
The content in the boxes shall be verified against
tion damage has occurred, and it comes under lay of replacement material.
the packing lists during unpacking, unless this
the D conditions of Incoterms 2010, it must be
has already been made upon arrival of the goods.
immediately reported to ABB AB. Non ABB customers should report via an NCR
Unpack in accordance to assembly sequence. For
(Non Conformance Report). ABB customers
unpacking of insulators and apparatuses as cur-
More information concerning the delivery condi- should report damaged goods to ABB via CCRP
rent transformer, reactors, resistors etc., see the
tions can be found on the Swedish Trade Council (Customer Care Response Process).
manual respectively.
website (Incoterms 2010).

For capacitor units supplied with short-circuit

wire, see picture, remove the wire before use.

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09 Storage port or site

Goods for outdoor installation shall be stored on Storage in moist environments can cause discol-
an even and well-drained surface that is suitable oration of zinc-coated surfaces. This discoloring
for the load. The area should be a well ventilated is known as “white rust” and primarily consists of
and covered with a roof. Other equipment should zinc oxide and zinc hydroxide, and is the result of
be stored dry and indoor in their OEM packaging. a chemical reaction between the pure zinc on the
Storage in wet packaging will harm the goods. If surface and moisture.
this is encountered, the goods shall be unpacked
and dried. The long-term rust protection will not be affected
by the "white rust", and the steel-zinc layer under
the surface will remain unaffected. In accordance
with applicable practice "white rust" is not a rea-
son for returning the goods.
14 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S I N S TA L L AT I O N / A S S E M B LY P R E PA R AT I O N 15

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11 Assembly preparation

Identify the overhead lines. Take precautions to Stainless steel nuts/ bolts on bus bar The plate shows the individual unit 0192. +3 is the • Rated voltage: r.m.s. value of the alternating
the equipment - any work is only allowed in de-en- connections (with contact grease such as Vase- capacitance deviation from the requested nomi- voltage for which the capacitor has been de-
ergized, earthed and short circuited conditions line/ Vasenol). nal value. This means that the actual capacitance signed
only. Check the applicable module and assembly for this unique unit is within the window +2.5 to • Rated frequency: Frequency for which the ca-
drawing(s). Follow instructions, local safety rules Nut/ Bolt Size Torque Nm 3.49% above the nominal capacitance. pacitor has been designed
and regulations. Use safety equipment. M6 8 • Insulation level: maximum r.m.s. voltage which
M8 20 Rack name plate the equipment can sustain for a given time in
Wear adequate workwear according to local regu- M10 35 The purpose of the rack name plate is to identify specified conditions
lations. Provide visual inspection of the insulators M12 65 in which order to assemble the racks and to show • Temperature category: Temperature of the air
before assembly. Protect fragile material. M16 187 the weight of the individual rack so that a safe lift at the proposed location of the equipment
can be carried out. • Min. time between disconnection and reclosure:
Other, galvanized, nuts/ bolts (without lubricant). The minimum time between disconnection from
11.1 Work at heights a network and reconnected back into operation
Nut/ Bolt Size Torque Nm • Time to discharge to 75 V: Voltage remaining on
Follow local safety rules and regulations, use M6 10 the terminals after given time
safety equipment and applicable lifting devices. M8 25 Side A Side B • ABB reference No: The delivery order number
Marking side
Use the right type of safety equipment for work- M10 50 (Front of rack)
ing at height. Inspect the equipment before use. M12 85 Filter rating plate
X-Y-Z
Use equipment that prevent a fall (scaffolding or M16 205 Only included in filter applications, one rating
a mobile elevating work platform). M20 430 plate per filter branch.
Marking side of the racks means the side that the • Main standard: The overall standard that the
Make sure work is properly planned and rack name plate is located. The letters, X-Y-Z, equipment is designed to fulfill
supervised.
11.4 Rating plates show either number of banks – number of stacks • Tuning frequency
– level from bottom or Item designation acc. to • Rated output: Reactive power for which the
Capacitor unit rating plate
specification – phase – level. equipment has been designed
11.2 Documents • No. 1 HSDU007973A0192: Identification number
• At rated voltage: r.m.s. value of the alternating
structured as a serial number comprised of
voltage for which the capacitor has been de-
The following documents are required in relation project number and individual capacitor unit
signed
to the installation/ assembly: number
• Insulation level: maximum r.m.s. voltage which
• This manual • C40001176: Sales order number
the equipment can sustain for a given time in
• Dimension drawing/ assembly drawing • TYPE: Capacitor unit model
specified conditions
• Bill of material • Int. Fuse: Shows if the capacitor has a fuse con-
• Temperature category: Temperature of the air
• Packing lists nected in series with an capacitor element
at the proposed location of the equipment
• Specific equipment installation manuals i.e. • U: Capacitor rated voltage
• ABB reference No: The delivery order number
reactors, resistors etc. • C: Rated Capacitance value µF followed by devi-
ation sign
Bank rating plate
• Q: Rated power/energy of the unit
11.3 Tightening torque • I: Rated current
Only included in bank applications, one rating
plate per bank.
• f: Frequency for which the capacitor has been
Nuts on the capacitor bushings with clamps for • Standard: The applicable standard that the
designed
copper cables are torqued to 30 Nm. equipment is designed to fulfill
• R: Total resistance value of all connected resis-
• Connection: The physical and electrical arrange-
— tors within the capacitor
Note ment of the capacitor units within the bank.
• Temp. cat: Ambient temperature class for which
Capacitor units produced before 2003 requires a lower
torque at 20 Nm. the capacitor is designed
• AC/BIL: Test voltage to container fundamental
AC voltage/ lightning impulse
• Standard: The applicable standard that the ca-
pacitor is designed to fulfill
16 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S I N S TA L L AT I O N 17

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12 Installation

It is important that the insulators are in level.

Check all foundations, Once this has been fulfilled, the insulators are po-
make sure they are in level. sitioned. Do not fully tighten them, adjustments
may be necessary at a later stage. Use spacing
washers/ shims where necessary to relieve stress
on the insulators.

If a separate manual for insulators is included in

the documentation - read this manual before
starting the work.

All equipment must be

lifted and handled accord- 12.2 Capacitor module
ing to lifting instructions The capacitor bank is delivered with capacitor If there is more than one module per phase or if
units mounted in racks. Each module has a pre- the three phases are placed above one another,
found in the manual for re- defined position in the bank with an individual the first module must be tightened before con-
spective apparatus. number that matches the suppliers' assembly tinuing with the next phase or module.
drawings.
Read instructions before
If the insulators are heavy, they should be lifted
lifting activities start. As many components as possible are fitted to with a lifting device and secured with bolts.
each module prior to delivery. All additional mate- If the insulators are light, it can be easier to lift
rials, such as bolts, insulators, bus bars and the module and bolt the insulators in place from
sleeves that are needed during assembly at the beneath before the entire module with the insula-
site, are packed in separate boxes. tors is lifted into place.

12.1 Support insulators Follow the assembly drawing so that the modules
are positioned correctly in the capacitor bank, in
If applicable, the support insulators other words, correct phase, correct level and cor-
with threaded holes shall be posi- rect orientation, see marking of racks. It is im-
tioned on steel beams of sufficient di- portant to place the module on the insulators
mension. with care since they can be damaged.

Insulators with through-holes can in-

stead be placed on the foundation and
secured with expansion bolts or bolts
cast into the concrete.
18 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S I N S TA L L AT I O N 19

12.3 Grounding and potential settings 12.5 Connection insulators and

When lifting the modules, use lifting slings
bus bars
Side A Side B attached to the rack.
Once all modules are in place and properly tight-
ened, begin fitting the connection insulators and
Marking Side If paint damage occurs on the capacitor units
bus bars. The assembly drawing specifies where
during assembly, see Section 15.2.(Paint damage/
On high voltage equipment, all metal parts must the connection insulators and bus bars are to be
formation of rust).
have a well-defined potential. This potential can fitted to the rack.
either be ground potential or a potential that is
Bushings on the capacitor units may not be sub-
connected to the system voltage.
jected to external pressure or impact. Moreover,
the capacitors shall not be lifted by the bushings.
In a capacitor bank, it is primarily the racks that
are critical. These must always have a fixed poten- —
tial. 12.4 Grounding where insulator Installation of HV and neutral bar

For 3-phase banks with a maximum system volt-

supports are used
age of 24 kV and insulated neutral (such as Y and
Y-Y connected banks), the capacitor units are of-
All supports, for capacitor banks as well as other 12.6 Connection conductors
equipment like reactors and resistors, shall be
ten insulated for full system voltage. All three
connected to ground. These conductors are either insulated cables or Prior assembling the cables should be cut to the
phases are then in the same stack without insula-
non-insulated copper conductors of 50-70 mm2. correct lengths and the cable lugs/ end sleeves
tors between the racks, which are then (usually) —
Note crimped onto the ends.
grounded. In these cases, there are no insulators
No closed loops below reactor only one connection to The assembly drawing specifies how to wire and
between racks and ground. ground, see picture below. connect cables between the bushings on the ca-
pacitor units and the bus bars. Note whether
When a bank/ stack has insulators in between
there are to be parallel cables.
modules, there should be one (and only one) po-
tential connection to the rack. The basic rule is
that this is connected to the middle point. This is Type Dimension Article No. End sleeve Cable lug, dim.
done to provide the optimal voltage distribution CU 50 mm2 DK5101124-002 1HSN000001-018 9ADA568-16, M12
9ADA568-18, M16
for the unit's insulation (see picture below).
CU 70 mm2 DK5101502-002 1HSN000001-019 9ADA568-20, M12
9ADA568-22, M16
Insulated 50 mm2 DK5101128-027 - 9ADA568-16, M12
Insulated 70 mm2 DK5101128-031 - 9ADA568-20, M12

It is of the greatest importance that the cable, electrical point. The assembly drawing specifies
cable lug and bus bar are cleaned and lubricated how to wire and connect the cables. Before con-
with contact grease (such as Vaselin/ Vasenol) nection to aluminum bar, make sure to trim and
before assembling. grease connections points. Verify correct rack po-
tential connections. Note whether there are to be
The cables shall be cut long enough to enable ex- parallel cables.
pansion/ retraction due to heat, but not too long
to compromise air clearance to any other
20 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S I N S TA L L AT I O N 21

Even if the modules have (in most cases) factory

When using a single 70 mm2 CU installed copper cables, it is important to check
wire, add a copper rod in the the air clearance between copper cable and
bushing. See section 14.2 and IEC 60871-1.
empty groove in the clamp to im-
prove the pressure on the cable. Use color marking to keep track of torqued nuts
and bolts. Check all air clearances, as it might
have changed during torqueing. Look through all
capacitor levels, and other equipment for tools, as
they can create a short circuit before energizing.

12.7 Cable lugs and tools 12.8 Installation of filters

In conjunction to a bank installation a typical fil-

Tools table for contact pressing of cable lugs.
ter is equipped with more apparatus. See assem-
Mechanical tools Hydraulic tools bly drawing and manual for each equipment com-
mm2 KZ die MRD26T MRD29 Y500CT Y35/Y35BH Y260 DBHM Y450 DBHM ponent. Read the manual for each included
code BCT500 Y750/Y750BH apparatus before starting the work. It is
BAT35/BAT750 recomended to use the Checklist, filter commis-
50 14 MD50D/MD50C 20MH 50MH W14DKT UDK U-dies with U-dies with sioning in Appendix.
MD50V/MD120 14KTC 1410DKTC 14BGE2T adaptor adaptor
MD120D 26UADP 45UADP
70 16 MD120D - 50MH W16DKT UDK
1606DKTC 16BGE2T
22 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S OPTIONAL ACCESSORIES | COMMISSIONING 23

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13 Optional accessories 14 Commissioning

13.1 Pressure switch Make sure that tools and material used during in- 14.2 Inspection prior to
stallation are removed before commissioning.
Provide suitable fire protection. Follow local
energization
The pressure switch is a protection device which
emergency procedures for the site.
triggers the relay in case of over pressure. Inspection
• Check all tightening torques for the nut on the
Avoid working when weather conditions threaten
top of the bushing, as well as all other electrical
the health and safety of people. Follow local
connections. The correct torques can be found
safety rules and regulations. Be aware of safety
in section 11.3.
distance to installed equipment.
• Check that installation is correct according to
the assembly/ dimension drawings and units
14.1 Documents are at the correct positions according to the
positioning charts
The following documents are required in relation • Check that all internal connections are properly
to Commissioning. made, follow the current path from the incom-
• This manual ing terminal through the complete capacitor
13.2 Bird caps • Dimensions drawing/ assembly drawing bank
• Bill of Material • Check that all interconnection cables seems to
The ABB Capacitor Bird Cap is the solution to
• Positioning charts be of the correct dimension and that parallel
problems caused by accidental contact in HV ca-
• Equipment manuals for reactor, resistor etc, conductors are used where this is specified
pacitor banks. The Bird Cap used together with
(if applicable) • Check the grounding and potential connections
insulated wiring between capacitor units will in-
for the complete capacitor bank
crease the insulation sufficiently to mitigate the
The following tool might be required in relation to • Check that the capacitor bank is properly
risk for flash-over or short-circuiting in the bank.
Commissioning: secured towards the foundations
The Bird Cap is designed to fit on all standard
• Torque wrench, hand tools • Check for damages/ defects (painting,
bushings. It is easily mounted on the bushings af-
• Multimeter galvanizing, porcelain etc.)
ter the connecting wire has been fastened.
• Measuring tape • Check all air clearances within the capacitor
• Relay rest unit ( optional ) bank. The following table gives some minimum
The Bird Cap is suitable for most climatic condi-
• Harmonic analyzer ( optional ) air clearance distances as per IEC 60871-1 27.9.2
tions, pollution levels and temperatures. The
polypropylene plastic material ensures a long ser-
vice life without risk for deterioration of the insu- System Voltage (kV) Insulation level BIL(kV) Air clearance distance (mm),
lation, and a good capability to endure high tem- phase-phase and phase-ground
perature. 3.6 40 60
7.2 60 90
If insulated wire is used: 20 mm on each wire is 12 75 120
without insulation for grounding purposes (1 per 17 95 160
unit). 24 125 220
36 170 320
Mount the bird caps after re-tightening the top of 52 250 480
the bushings 72.5 325 630
123 450 900

13.3 Noise reduction accessories 123 550 1100

145 550 1100

Noise reduction accessories for power More information regarding the different 145 650 1300
capacitor units or banks are an effective solu- types can be read in the manuals for Noise 170 650 1300
tions to help reduce and comply with specific Cover, 1HSD101386-509 and Noise Cap, 170 750 1500
noise restrictions. 1HSD101386-525.
24 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S COMMISSIONING 25

14.3 Tests before energization 14.4 Inspection after energization

Capacitance measurements For the capacitance measurement we recom-
Voltage measurements Unbalance current
All capacitor units delivered from ABB have mend to use an ABB Portable Capacitance meter
It’s recommended to perform a voltage measu- The purpose with the measurement of the unbal-
passed the routine tests as per applicable stan- CB2000, which allows to perform the measure-
rement before and after the capacitor bank is ance current is to verify that the capacitor bank
dard. Transport and installation of the units ment without removing the interconnections be-
energized. The purpose of the measurement is has been properly balanced.
should not have any impact on the units. tween the capacitor units.
to check the change of the voltage level in the
network before and after the capacitor bank is Checklist for commissioning of filter apparatus
It is not necessary to measure the capacitance A capacitor unit with capacitance that has
connected. See Appendix for checkpoints for filter
prior to energization. However, we recommend to changed more than approximately 10% compared
commissioning.
perform a capacitance measurement, if a capaci- with the value in the routine test report, should
Current measurement
tance bridge has been included in the scope of be replaced.
The purpose with the current measurement is to
supply, to get an extra reference measurement
confirm that the current do not exceed the design
after installation for future maintenance, and also Current transformers’ primary injection test
values for the equipment.
the benefit of maintenance staff having a chance The purpose of the test is to check the integrity
to get familiar with the equipment. The best test and measurement accuracy of the electrical
record is a positioning chart with factory test val- circuit between the primary winding of the CT
ues shown. and the protection relay. The test shall be per-
formed by injecting current to the primary side
of the CT and reading the measured value on the
relay display.

Description Serial number Injected current Relay display Expected value Comments
Primary injection
test

CT1

Voltage measurements to the secondary side of magnetic voltage trans-

The purpose of the voltage measurement is to re- formers connected line-line or line-ground. Please
cord the harmonic voltage distortion in the sys- note that capacitive voltage transformers nor-
tem prior to energization of the filter. By compari- mally have a frequency dependent ratio.
son of the voltage distortion before and after
filter energization, the efficiency of the filter can Tightening torque
be evaluated. The measurement shall be per- Check all tightening torques for the nut on the
formed during normal system operation condi- top of the bushing, as well as all other electrical
tions by means of a harmonic analyzer connected connections. The correct torques can be found
in section 11.3.
26 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S MAINTENANCE 27

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15 Maintenance

Under normal operating conditions, a capacitor Insulators

Discharge and grounding of the capacitor bank capacitance as possible. Preferably the replace-
bank requires minimal maintenance. To obtain re- Ensure that no insulators are damaged. For insu-
A proper discharge grounding of the bank/ units ment unit should have the same or adjacent devi-
liable operation however, regular checks should lator replacement you need to disassemble the
should be done in the following way: ation sign, compared to + or - faulty unit. The sign
be made. modules above the insulator. For instructions re-
• Switch off the bank is stated on the capacitor unit rating plate, the
garding the mounting after the replacement, see
• Verify that sufficient safety distances are kept routine test report or the positioning chart. See
Section 12.1.
15.1 Preventive maintenance to energized nearby components and buses. If chapter “Rating plates”.
not, take proper action so it can be kept
Unbalance current
Capacitance measurement • Wait according to the bank rating plate regard- If no such replacement unit with similar sign is
Regularly check the unbalance current and note
At least every third year, capacitance measure- ing discharge time to allow the units to be dis- available, ABB can assist in performing a new bal-
the measured values. In the event of faults, the
ment of all capacitor units shall be conducted, charged by means of the internal resistor before ancing and unbalance calculation. In this case,
unbalance current changes in steps. Small contin-
and the results compared with the values in the grounding and short-circuiting there’s a risk that a few more capacitor units have
uous deviations occurs due to temperature varia-
routine test documentation or the values noted • Ground the incoming phases and let them re- to be moved within the capacitor bank, to obtain
tions.
during commissioning. Units with internal fuses main grounded during the complete work an acceptable balancing of the capacitor bank.
where the capacitance level has decreased by 10 • Short-circuit each unit inside the bank on which When replacing a capacitor unit, use a lifting de-
Relay protection settings
percent or more should be replaced. 10 percent is work is going to be performed vice recommended by ABB. Make sure there is a
Check the relay protection settings values
a typical value and is valid unless nothing else is proper grounding where the capacitor bracket
and function.
mentioned in the order specific data. First after all units have been discharged work is meets the rack.
allowed inside the bank.
Thermographic survey
If the capacitor bank has capacitor units with ex- When ordering a replacement unit, it is important
It is recommended to perform a thermographic
ternal fuses, the capacitance of all capacitor units Paint damage/ formation of rust to notify the factory of exactly which unit(s) to be
survey after commissioning and before mainte-
should be measured if the unbalance current indi- Minor paint damage can be repaired in place by replaced, which means the unit number that can
nance to identify potential electrical hot-spots.
cates element faults in one of the units. When un- cleaning the damaged point and applying paint. be found in the unit rating plate. It is recom-
certain, contact ABB for limit values for when ex- Rust can be removed by a brass brush. Note that a mended to take a photo of the rating plate and
ternally fused units should be replaced. You may 15.2 Corrective maintenance steel brush may contaminate the stainless steel send to ABB.
be advised to change a capacitor unit with a surface. Contact ABB for special painting instruc-
faulty element even if the external fuse has not
of disconnected bank tions in the event of more extensive paint dam- The capacitor lifting device tool facilitates safe
yet blown. age. handling during removal and installation of large
Before beginning work, see Section 02, Safety
and heavy capacitor units in an open stack sub-
regulations. For check list, see Appendix - Check-
Furthermore, use a torque wrench to ensure that Replacement of faulty capacitor unit station bank. There are two types, counter weight
list, discharge and grounding.
bushing tops and electrical connections are tight- Upon replacement of a faulty capacitor unit, it and top mounted, see below:
ened to the correct torque. should be aimed to achieve as small deviation in
Discharge and ground before maintenance
A capacitor bank/ unit is disconnected from the
Also check that fuse holders are torqued for ca-
network does not imply that there will not be any
pacitor units with external fuses.
residual voltage. It is therefore very important to
— ground the bank and discharge the units in a cor-
Note rect way. Both for personal safety but also for the
Internally fuse unit will get lower capacitance due to
element failure while units without internal fuses including lifetime of the equipment. Until the bank/ units
externally fused units will get higher capacitance. are grounded it should be considered as live
parts,(under voltage).
Visual Inspection

Cleaning
Conduct an ocular inspection regularly for e.g.
soiling, paint damage or leaking capacitor units.
Insulators and bushings are wiped clean as neces-
sary. Capacitor bank can be cleaned with water, in
the event of heavy soiling, cleaning should be — —
more frequently conducted. Manual for counter weight lifting device: 1HSD101122-006 Manual for top mounted lifting device: 1HSD101122-017
28 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S T R O U B L E S H O OT I N G | W A S T E / D I S P O S A L 29

— —
16 Troubleshooting 17 Waste or disposal of units

16.1 Alarm 16.3 Leakage 17.1 Packaging waste to guard against splashing into the eyes is recom-
mended. The capacitor unit's connections must
The packaging consists of wood with metal rein- be short-circuited while working. Puncture the
If the capacitor bank has capacitor units with in- Leakage of less than 1 dl can be sealed with poly-
forcements. Plastic bags are made of polyeth- container and drain the impregnation fluid before
ternal fuses, the fuse isolates the faulty capacitor urethane putty, depending on the location of the
ylene. When recycling, follow local regulations. fully opening the container. Remove the capacitor
element. Occasional faults do not affect opera- leak. If more than 1 dl, replace the unit.
element package from the container and short
tional reliability or the service life of the capacitor • Note the serial number of the capacitor unit
circuit the capacitor elements before removing all
bank. If the unbalance current exceeds the alarm • Make an estimation of the leakage and clean the 17.2 Capacitor unit soldering and copper bus bars. Both the fluid and
value, alternatively 50 percent of the tripping contaminated area
capacitor unit can be burned in an incinerator. Re-
value, the capacitance of all capacitor units • Monitor if the leakage continues. If so replace Impregnated capacitor elements shall be dis-
maining after incineration are primarily aluminum
should be measured, see Section 14.3 (Capaci- the unit posed according to the local environmental direc-
and a small amount of copper.
tance measurements). Capacitance measurement tives by qualified personnel, using applicable PPE
can only be conducted on a disconnected bank. A small amount/ drops of impregnation fluid can for the work.
enter the top of the bushing. This occurs in such
case very soon after delivery and stops as soon as During work in which one can come in contact
16.2 Trip the seal in the bushing is sufficiently moistened with wet capacitor elements, the use of protec-
by the impregnation fluid and cooled. Wipe off tive gloves (rubber) and safety goggles or a visor
When a capacitor bank trips the recommendation
the impregnation fluid and check that it does not
is to read and note data from the relay protection
reoccur. Spilled impregnation fluid can be ab-
settings, which can be helpful when troubleshoot-
sorbed with sawdust or similar material. A rag Wet capacitors Material in approx. Handling when Classification of
ing the capacitor bank.
soaked with a cleaning agent, such as petroleum Part Material % of weight recycling/ scrapping hazardous substances
spirits, can be used for cleaning.
Which function activated the relay protection Element film Polypropylene 30 Plastic shall be treated N/A
setting? film according to local regulations
Safety directives for impregnation fluid and a ma- for plastic handling
terial safety data sheet can be sent upon request Impregnation Faradol 600 or 20 The capacitor unit is filled with According to
Which values were rated on the current
by ABB. fluid 810. impregnation fluid. (regulation (EG)
and/ or the voltage? This shall be emptied and sent No. 1272/2008)
for destruction to appropriate
company. For more information,
Make a visual inspection and note possible obser-
see safety data sheet.
vations on the capacitor module. Can Ferritic stainless 16 Recyclable N/A
steel,
Element foil Aluminium 15 Recyclable N/A
Symptom Fuse type Possible cause Corrective action
Insulation Paper, 5 Incineration N/A
Unbalance signal alarm Internally fused/ no fuse Element fault Check the bank (impregnated) pressboard
at the next shutdown Bushing Porcelain 3 Recyclable N/A
Unbalance signal and/ or Externally fused Element fault Schedule shutdown within
Terminals Nickel-coated 1 Recyclable N/A
external fuse has blown External flash-over near future See Section
brass
15.2(Replacement of faulty
capacitor unit). Element Sn, Pb, Zn 1 Hazardous According to
soldering substance (regulation (EG)
Unbalance signal has tripped Internally fused/ no fuse Element fault See Section 15.2
No. 1272/2008)
circuit- breaker External flash-over
Bus bars, Tin plated 1 - N/A
connection copper
Unbalance signal has tripped Externally fused Element fault See Section 15.2
wires, fuses
circuit- breaker External flash-over
—
1 Depending on unit size, minor deviations may occur.
30 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S APPENDIX 31

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18 Appendix

17.3 Capacitor bank or filter 18.1 Checklist, filter commissioning

Bank/ filter materials Handling when Classification of

recycling/ scrapping hazardous substances Technical Specification, filter data
Part Material
Racks, lifting Steel The part can be detached and N/A
devices, foundation recycled separately. —
plates. Etc. Filter data
Connection bars, c Aluminium The part can be detached and N/A
orona rings recycled separately Type
Insulators Porcelain & iron The part can be detached and N/A Generated power Mvar
recycled separately Rated voltage kV
Conductors, wires Copper, plastic This part of the equipment N/A Fundamental
and cables shall be recycled according to frequency Hz
local regulations for electronic waste
Tuning frequency Hz
Noise damping Aluminum, The part can be detached and N/A
cover. plastic, rubber recycled separately Dimension drawing
Reactors, See the applicable manual N/A Phase 1 Phase 2 Phase 3
resistors, CT, for the apparatus respectively
VT, arresters

—
Capacitor C1 bank data

Rated power Mvar

Rated voltage kV
Rated frequency Hz
Insulation level kV / kVp
Bank connection
Serial number
Phase 1 Phase 2 Phase 3

—
Capacitor C1 unit data

Rated capacitance µF
Rated voltage kV
32 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S APPENDIX 33

—
Capacitor C2 bank data C-filter

Rated power Mvar

Rated voltage kV
Rated frequency Hz
Insulation level kV / kVp
Bank connection
Serial number
Phase 1 Phase 2 Phase 3

—
Capacitor C2 unit data C-filter

Rated capacitance µF
Rated voltage kV

—
Reactor data

Rated inductance mH
Rated power Mvar
Dimension drawing

Serial number
Phase 1 Phase 2 Phase 3

—
Resistor data

Rated resistance Ω
Rated power Mvar
Dimension drawing

Serial number
Phase 1 Phase 2 Phase 3
34 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S APPENDIX 35

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Current transformers

Type
Rated voltage kV
Ratio / A
Accuracy class : VA
Burden
Bank connection
Serial number
Phase 1 Phase 2 Phase 3

Required documents Recommended tools

Assembly drawing Torque wrench
List of details Multimeter
Technical specification Auxiliary power supply for current injection
Relay protection settings (Capacitance bridge)
Filter/ capacitor bank dimension drawing (Frequency analyzer)
Reactor dimension drawing
Resistor dimension drawing
CT dimension drawing
Capacitor unit test report
Capacitor unit positioning chart
Reactor manual
Resistor manual (if applicable)
CT manual (if oil type)
VT manual (if applicable and oil type)
Surge arrester manual (if applicable)

—
Visual inspection, general

Approved
Description Comments
Yes No N/A
Access to equipment allowed
(working permit)
If line is connected equipment earthed for safe access
Area clean and free of tools, lift and transport devices
Erection according to the erection drawings
Connection according to the connection diagram
Rating plates, instruction plates, warning
signs in place
Check mechanical load on all terminals
Check that conductor area corresponds to
expected current
Check electrical clearances between all live parts and
between live parts and ground.
Verify settings of protective relays
Check that relay protection and circuit-breakers have
been commissioned
Check the tightness of electrical connections
Re-tight if necessary
36 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S APPENDIX 37

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Capacitor bank

Approved
Description Comments
Yes No N/A
Erection of the capacitor bank is in accordance with
the assembly drawing
Check fixation to the foundation, mechanical integrity,
surface damages, corrosion, cracks
Rack- and unit location according to the
positioning chart
Check grounding and potential connections
of the rack
Check the torque at bushing, re-tight if necessary
Check that the capacitor units are free from damages.
surface damages, corrosion, and oil leakages
Check mechanical load on terminals

—
Reactors

Approved
Description Comments
Yes No N/A
Installation according to the assembly drawing
(including inductance on rating plate)
Check fixation to the foundation, mechanical integrity,
surface damages, corrosion, cracks
No closed loops within the requested
clearance distance
Check the reactor and its components for damage
during transportation/ installation
Remove the red marked transport/ lifting elements
and the associated hardware (if applicable)
Check the tightening torque of all bolt connections
which have been made at site in the course of
assembly, erection and electrical connection
Check the electrical leads to the reactor for proper
alignment and sufficient sag to avoid introduction of
undue static loads on the terminals
Check the cooling ducts for foreign particles, in
particular for bolts, nuts, washers and wires and
remove them prior to energization
Check the surface of the reactors and insulators
for contamination. Clean reactors and insulators
if necessary
Check the reactor winding for damage to the surface
finish and repair damage, if necessary
Remove all components which do not pertain
to the operation of the device, such as tools, bolts
and other metal parts, ladders, tarpaulins, etc.
prior to energization
Check tap if applicable
Check mechanical load on terminals
38 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S APPENDIX 39

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Resistors

DO NOT TOUCH ACTIVE PART DURING ERECTION, INSTALLATION OR MAINTENANCE

Approved
Description Comments
Yes No N/A
Installation according to the assembly drawing
(including resistance on rating plate )
Check fixation to the foundation, mechanical integrity,
surface damages, corrosion, cracks
Remove the rear & front panels using proper tools
to unscrew the bolts

Check the resistor banks to ensure that they are free

from foreign bodies

Check porcelain indoor insulators. Broken insulators

must be replaced. If porcelain indoor insulators have
been contaminated during transportation or storage,
they have to be cleaned (refer to maintenance section)

Check the tightening of internal connections and bolts

(bolts can be unscrewed during transportation and
shipping due to vibration)
Check mechanical load on terminals
Check that the cooling air-gap around resistor
(rule of thumb is >200 mm)

—
Note:
During first energizing a smoke may exhaust from resistors, smoke will not affect the resistors.
40 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S APPENDIX 41

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Current transformers

To be performed on each individual Current transformer (CT) within the scope of supply

Approved
Serial number Comments
Yes No N/A
Erection according to the erection drawing and
erection instruction
Nameplate details correct as per design
Make sure that the secondary winding is not open
Check oil level, if applicable
Check grounding of the CT and of the
secondary winding
Check the electrical burden of the CT
Check mechanical load on terminals

Approved
Serial number Comments
Yes No N/A
Erection according to the erection drawing and
erection instruction
Nameplate details correct as per design
Make sure that the secondary winding is not open
Check oil level, if applicable
Check grounding of the CT and of the
secondary winding
Check the electrical burden of the CT
Check mechanical load on terminals

Approved
Serial number Comments
Yes No N/A
Erection according to the erection drawing and
erection instruction
Nameplate details correct as per design
Make sure that the secondary winding is not open
Check oil level, if applicable
Check grounding of the CT and of the
secondary winding
Check the electrical burden of the CT
Check mechanical load on terminals
42 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S APPENDIX 43

—
Voltage transformers

To be performed on each individual VT within the scope of supply

Approved
Serial number Comments
Yes No N/A
Erection according to the erection drawing and
erection instruction
Nameplate details correct as per design
Make sure that the secondary winding is
not short-circuit
Check oil level, if applicable
Check grounding of the VT
Check the electrical burden of the VT
VT connected as fast discharge of
capacitor bank or not.

Approved
Serial number Comments
Yes No N/A
Erection according to the erection drawing and
erection instruction
Nameplate details correct as per design
Make sure that the secondary winding is
not short-circuit
Check oil level, if applicable
Check grounding of the VT
Check the electrical burden of the VT
VT connected as fast discharge of
capacitor bank or not.

Approved
Serial number Comments
Yes No N/A
Erection according to the erection drawing and
erection instruction
Nameplate details correct as per design
Make sure that the secondary winding is
not short-circuit
Check oil level, if applicable
Check grounding of the VT
Check the electrical burden of the VT
VT connected as fast discharge of
capacitor bank or not.
44 I N S TA L L AT I O N A N D M A I N T E N A N C E P O W E R C A PA C I TO R S , B A N K S A N D F I LT E R S APPENDIX 45

—
Surge arresters

To be performed on each individual surge arrester within the scope of supply

Approved
Description Comments
Yes No N/A
Erection according to the erection drawing and
erection manual
Special care if surge arrester is of multi unit type
Rated voltage corresponds to expected line voltage
and protection level
If counter note number of counting’s before
energization

Approved
Description Comments
Yes No N/A
Erection according to the erection drawing and
erection manual
Special care if surge arrester is of multi unit type
Rated voltage corresponds to expected line voltage
and protection level
If counter note number of counting’s before
energization

Approved
Description Comments
Yes No N/A
Erection according to the erection drawing and
erection manual
Special care if surge arrester is of multi unit type
Rated voltage corresponds to expected line voltage
and protection level
If counter note number of counting’s before
energization

18.2 Checklist, discharge and grounding

Filter item number

Filter switched off
Correct filter switched off verified
Discharge time has passed
Filter grounded
Access to filter allowed
Visual inspection after work done
Filter groundings removed

Before energization: carry out a visual inspection and make sure that nothing
is forgotten inside the filter, then remove the groundings.