Preface

This Electrical Maintenance Manual is compiled based on the equipment instructions provided
by electrical equipment manufacturer of PACITAN 2315MW coal-fired power plant and relevant
materials. It is only suitable for electrical system in this power plant.
The manuals will be revised and improved with the project progress development.

Page 2 of 326

CONTENTS
1

GENERATOR OVERHAUL PROCESS.........................................................................6

1.1

TECHNICAL SPECIFICATIONS

1.2

MAINTENANCE PERIOD

1.3

FUNDAMENTAL REQUIREMENTS

1.4

THE ACCEPTANCE

1.5

RELEVANT TESTS............................................................................................................ 27

1.6

EXCITATION SYSTEM MAINTENANCE TECHNOLOGY............................................................30

1.7

OVERHAUL REFERENCE MATERIAL...................................................................................42

1.8

LISTS

OF

AND

CONSTRUCTIONS.............................................................6

AND ITEMS....................................................................................8

AFTER

OF

GENERATOR OVERHAUL...............................................15

GENERATOR OVERHAUL/MINOR OVERHAUL.................................26

GENERATOR SPARE PARTS (EMERGENCY SPARE PARTS).....................................42

TRANSFORMER MAINTENANCE HANDBOOK..........................................................................44

2.1

EQUIPMENT

2.2

MAINTENANCE

OVERVIEW.................................................................................................... 44
PERIOD AND ITEMS OF MAIN TRANSFORMER AND HIGH VOLTAGE AUXILIARY

TRANSFORMER......................................................................................................................... 51

2.3

MAINTENANCE

2.4

HANDOVER

OF

AND

DRY TYPE TRANSFORMER....................................................................61

ACCEPTANCE

AFTER

TRANSFORMER OVERHAUL.......................................64

THE MAINTENANCE TECHNICAL MANUAL

AC

OF

MOTOR............................................................76

3.1

THE

3.2

MAINTENANCE PERIOD

3.3

MAINTENANCE TECHNIQUE REQUESTS

3.4

MAINTENANCE TECHNIQUES

3.5

MAINTENANCE

3.6

ATTACHED-TABLES........................................................................................................ 100

3.7

SPARE

TECHNICAL SPECIFICATION OF

OF

DC

AND

HIGH/LOW VOLTAGE MOTOR..............................................76

MAINTENANCE ITEMS............................................................81
OF

FOR

HIGH VOLTAGE MOTOR....................................82

LV THREE PHASE ASYNCHRONOUS MOTOR.......................92

MOTOR.........................................................................................96

PARTS............................................................................................................... 103

MAINTENANCE TECHNOLOGY OF DISTRIBUTION DEVICE..........................................103

4.1

150 KV GIS............................................................................................................... 103

4.2

6KV AUXILIARY POWER SYSTEM...................................................................................122

4.3

0.4KV AUXILIARY POWER SYSTEM................................................................................126

4.4

TRANSFORMER............................................................................................................. 130

4.5

SPARE LIST

AND

ATTACHMENT

FOR

OIL STANDARD (UNAVAILABLE

FOR INTERIM)............135

MAINTENANCE TECHNOLOGY MANUAL OF CABLE..................................................135

5.1

GENERALS.................................................................................................................... 135

5.2

TECHNICAL PARAMETERS

5.3

MAINTENANCE PERIOD

5.4

MAINTENANCE CONTENT

5.5

FABRICATING CABLE CONNECTORS................................................................................138

AND

OF

CHARACTERISTICS

OF

CABLE............................................136

CABLE..................................................................................136

OF

CABLE...............................................................................137

DC SYSTEM MAINTENANCE MANUAL...................................................................143

6.1

ARRANGEMENT,

6.2

MAINTENANCE

SPECIFICATION AND REQUIREMENTS OF

OF THE

EQUIPMENTS

IN

DC

SYSTEM................................143

DC SYSTEM.......................................................148

Page 3 of 326

6.3

SEARCHING

6.4

SPARE PARTS

OF

DC SYSTEM EQUIPMENT FAILURE PART..................................................149

OF

DC SYSTEM EQUIPMENT.....................................................................152

APPENDIX:.......................................................................................................... 155
I.

SUMMARIZATION.................................................................................................................. 1

TECHNICAL INDEX................................................................................................................ 1

USING CONDITIONS............................................................................................................. 2

BASIC METHODS FOR OPERATING INTELLIGENCE MONITOR EQUIPMENT..................................2

5.

CHARGE MANAGEMENT........................................................................................................ 9

6.

COMPUTER COMMUNICATION..............................................................................................10

MAINTENANCE

MANUAL OF RELAY PROTECTION...........................................................................16

Page 4 of 326

1 Generator Overhaul Process

1.1

Technical Specifications and Constructions

1.1.1

Major technical specifications of generators

Item

Model
parameter

or Item

Model or parameter

1. Generator
Model

QFSN-315-2-20B

Rated power

315MW

Rated voltage

20KV

Rated current

10726.7A

Rated rotation speed

3000r/min

Rated capacity

370MVA

Rated power factor

0.85 (lag)

Rated frequency

50HZ

Rated excitation current

2152A

Rated
voltage

Number of Phase

Connection method

2-Y

Number of outlet terminals

Cooling mode

Water-hydrogen-hydrogen

Direct-axis
reactance

excitation 472V

sub-transient 115.58% (during Rated

hydrogen 0.3 MPa
saturation)
pressure

Max. hydrogen pressure

Efficiency
value)

0.35 MPa

Short circuit ratio

(guarantee 98.8

0.654

Bearing
vibration 0.025mm
(guarantee value)

2. Insulation grade and temperature limit value

Insulation grade of stator
winding

Insulation grade of B/F

rotor winding

Insulation grade of stator

iron core

Rotor
winding 115
temperature

Stator
winding
and 90
outgoing line outlet water
temperature

Temperature
90
between the stator
winding layers

Stator
iron
temperature

Temperature
of 120
stator end structure
element

core 120

Collector ring temperature

120

Bearing and oil seal return oil

temperature

70

Bracket
temperature

90

3. Hydrogen
Purity

98

Humidity

Page 5 of 326

(rated 4g/m3

hydrogen pressure)
Cooling
temperature

hydrogen 30-46

Hot
hydrogen 65
temperature

4.Inner cooling water

Inlet water temperature

453

3t/h

45t/h

Inter water pressure

0.10.2 MPa
6.58

pH

Water capacity (including

stator outlet water capacity
3t/h)
20

0.51.5s/cm

Conductivity

0.51.5s/cm

hardness2g/l

5.Cooling water of hydrogen cooler

Number
cooler

of

hydrogen 4

Outlet water temperature

90

Inlet water pressure

0.10.2MPa

Inlet
temperature

water 455

Water capacity

4100t/h

2. Sealing oil parameter

Inlet oil temperature

35--45

Outlet
temperature

oil 70

Hydrogen side oil capacity

217.5L/min

Air side oil capacity

Rated inlet oil pressure

0.35 MPa

275L/min

7.Size and weight of main components

External diameter of iron 2550mm
core

Internal diameter of 1270mm

iron core

Length of iron core

5100mm

Gas gap
side)

(single 75mm

Stator slot number

54

Parallel
number

branch 2

Hollow

16

Solid

Rotor slot number

32

External diameter of 1120mm

rotor

56

Wire turn number of each 11

slot of rotor

Retaining
diameter Dk

Effective length of rotor 5100mm

proper

Shaft diameter

Retaining ring length Lk

Length of insulation 0.5mm

between rotor turns

External

diameter

690mm
of 410mm

ring 1200mm
450mm

Size of rotor slot m 34..5174mm

Page 6 of 326

collector ring

Xh

Rotor weight

51.5t

8.Hydrogen-filled and water-filled capacity of generator

Hydrogen-filled capacity

72m

Manufacturer

Manufactured by Dongfang Electrical Machinery Co., Ltd.

KKS

#110MKA01

1.1.2

Water-filled capacity 0.3m

of stator winding
(including outgoing
line)

#220MKA02

Constructions
In this power plant, the QFSN-315-2-20B generators are used, which is provided by
Dongfang Electrical Machinery Co., Ltd.The generator adopts static excitation of selfshunt excitation and water-hydrogen-hydrogen cooling mode.It uses welded base
structure and the bearing is support by welded end cover.The generator casing has
two vertical hydrogen cooler to its ends.There is isolation vibration device between the
stator base and iron core.The rotor is of forged alloy steel assembly and provides
with aresymmetrical axial flow fans on both ends.The generator uses water-hydrogenhydrogen cooling mode,that is, using water cooling for stator inner winding and
hydrogen cooling for rotor inner winding. in addition, iron core of stator and its
stuctural components use hydrogen surface cooling while the collecting ring is of air
cooled mode.

1.2

Maintenance Period and Items

1.2.1.1

The generator should be overhauled every 4 years, and the overhaul time limit is 50
to 55 days.

1.2.1.2

The generator should be repaired every 4 to 8 months, and the repair time limit is 18
days.

1.2.2.1
Major overhaul
items

Overhaul for the

stator

Overhaul for the

rotor

Overhaul for the

cooling system

Page 7 of 326

Overhaul for the

outgoing line
cover

Item

Standard Item

Special Item

1. Disassembly the connectors between

generator and enclosed bus.

1. Replace part of the stator

wire bar or repair the stator
bar insulation.

Content
name
Stator

2. Disassembly the generator inside and

outside cover; check the inside and 2. Re-weld the winding joint
outside cover, fan cover, twinescreen of stator end.
circle and pad; purge to remove the dirt.
3. Replace more than 25% of
3. Purge and check the stator winding, the duct wedge and end pad
outgoing line and bushing.
or re-bar the tie wire.
4. Check the insulation supporter, screw, 4. Local repair of the core.
pad, tie lines in the
stator winding
5. Improve the structure of
horn orifice; clean the greasy dirt and
the winding end.
deal with the loose screws.
6. The drying of the
5. Check and clear up the ventilation
generator.
passage, ventilation duct, stator core
and the insulation in ventilation duct to 7. Find out the earth fault of
see whether the core is damaged and stator bar.
wedge in the duct is loose, and resolve
8. Replace more than 25% of
these problems.
the insulation water pipe.
6. Check whether there is abrasion,
9. Replace the temperature
overheating and electrical corrosion of
measurement devices.
stator bar and deal with them.
7. Check whether the stator insulation water
pipe is damaged and deal with it.
8. Carry out backwashing and water
pressure test on stator bar and outgoing
line.
9. Carry out flow test on stator bar and
outgoing line.
10. Measure the relevant gap.
11. high-voltage test and its coordination
(test items: AC withstand decided by the
manual
package
insulation,
DC
withstand,
AC
impedance,
DC

Page 8 of 326

resistance, insulation, etc. )

12. Check the remaining parts of the
stator.

Page 9 of 326

1. Measure the air gap and pull the 1. Car spinning slip ring.
generator rotor out.
2.
Pull retaining ring to
2. Check the clear-up retaining ring, fan check the end windings and
leaves, ventilation holes, body, center the insulation pad.
ring and balance block, etc.
3. Deal with grounding and
3. Check and clear up air guiding blade, inter turn faults.
and replace it according to the actual
4.
Replace
the
rotor
situations.
structural components (heart
4. The flaw detection and coordination of ring, retaining ring, wedge,
rotor blade, retaining ring and center ring key, flexible devices,
hole.
etc.).

Rotor

5. Rotor speed test.

5. Replace the twine board.

6. The inspection of rotor positive and 6. Replace the lead, and

negative blow and the rotor ventilation adopt sealing and insulating
test and air-proof test.
treatment.
7. Clean and check the brush holder, slip 7. Replace the slip ring.
ring, lead, carbon brush, brush grip,
8. Repair the key and
spring clip and cable, and deal with the
keyway, etc.
cases according to the actual situations.
8. High voltage test and its coordination.
Cooling system

1. Disassemble the cooler.

2. Clear-up and check the cooler.
Remove the scale of it and brush with
rust-proof paint.
3. Check and repair the cooling system
devices, such as filter.
4. Hydraulic test.
5. Check calibration
measurement device.

temperature

6. The copper duct of the cooler

expands.

Page 10 of 326

Replace hydrogen cooler or

other major components.

Outgoing
line cover

1. Check the soft connecting parts and

transition leads.

1. Replace the lead and

porcelain casing.

2. Cooling device inspection.

2. Replace
transformer.

3. The inspection of porcelain casing

and current transformer.

the

current

3.
Replace
the
soft
connection or silver-plated
4. Inspection of water incoming &
layer on re-plated contact
outgoing bus duct and insulating water
surface.
guiding pipe. Check the sewage
discharging pipe and carry out the water
pressure test on outgoing waterway.
4. Replace the sealing
devices and components.

1.2.2.2

Items for a minor repair

1.2.2.2.1

Eliminate the faults in operation.

1.2.2.2.2

Check and clear-up the generator outgoing line and the pad of the coil end. (Check
the generator across the manhole. Check and clear-up twice a year.)

1.2.2.2.3

Back-wash the stator Bar and outgoing line.

1.2.2.2.4

Find out and handle the hydrogen leakage.

1.2.2.2.5

Check and clean every part of the main exciter and slip ring, brush holder, brush grip
and leads of the main exciter, and replace the brush.

1.2.2.2.6

Check and clean every part of the assistant exciter.

1.2.2.2.7

Carry out predictive test according to pretest regulation and equipment situations.

1.2.3

Maitainance during outage

1.2.3.1

Long-time outage
During the long-time of outage, the hydrogen is vented outside, both the seal oil
system and other auxiliary system has stopped. The maitainance items are as follows:

1.2.3.1.1

Discharge completely the hydrogen in generator.

Unscrew the bolts located on the upper and lower parts of air seal cover between the
generator pedestal and end cover. Discharge the hydrogen gathered in the air seal
cover.
Purge all the dead zones on the top of the pedestal with compressed air. Discharge all
the hydrogen in generator.

1.2.3.1.2

Discharge the water remaining in the water pipeline of the stator winding

Page 11 of 326

1)

Open the blowdown port beneath collecting pipe of the turbine end and excitation end,
discharging the water in the collecting pipe.

2)

Dismount the water inlet and outlet pipelines. Cover the water outlet flange with a
cover plate. Connect the hose with the water inlet flange at the excitation end. The
compressed air should be clean without oil and dust.

3)

Switch on the air compressor. Blow out the water in the water loop of the stator from
time to time until there is no moisture contained in the exhaust air. Then, seal the port
of the collecting pipeline.

4)

Extract the water remaining in the water loop of the stator winding which is difficult to
be discharged only with compressed air.

1.2.3.1.3

Maintenance on water circuit of stator winding

In order to avoid the inner wall of hollow copper line from being oxidized, flush the
inlet & outlet of water circuit of stator winding with nitrogen slowly and regularly. Then,
seal the water inlet and outlet fanges.

1.2.3.1.4

Maitenance on hydrogen cooler

Clean up the hydrogen cooler. After cleaning, discharge the remaining water and dry
the water pipeline with compressed air to prevent corrosion. For details, see section
3.3.5 Maitenance of Hydrogen Cooler

1.2.3.1.5

Anti-condensing in the generator

Dismount the two covers of the man hole. Install the air heater or the air dryer in this
position to make the air in generator dried continuously. Considering that the air in
circulation can go through the generaor thoroughly, the air heater or air drier should
be located properly.
The air in generator can be maintained dry in various weather conditions through the
above process. The condensing will not occur. Therefore, the insulation is prevented
from being damped due to condensation, the retaining ring from stress corrosion.

1.2.3.1.6

Maintenance on the rotor

During the long-time outage, if the rotor is kept inside the generator for a long time,
the rotor should be turned by 90every three days so as to prevent the permanent
deformation.

1.2.3.1.7

Safety measures
The hydrogen alarming system is in service. It is recommended to dismount the
hydrogen supply pipeline during the outage to prevent hydrogen refilling due to
accident.

1.2.3.2

Short-time outage

1.2.3.2.1

General

Page 12 of 326

Dring the short-time outage, the generator is filled with hydrogen, the oil sealing
system is in normal service . Operate the water cooling system of the stator winding
normally.
The common preventive measures include preventing condensation and ensuring
adequate sealing oil. Maintain the low conductivity of the cooling water of the stator
winding for generator restart up as soon as possible. Therefore, the following
parameters should be supervised and recorded regularly:
Temperaturer and pressure of the sealing oil
Purity, humidity and pressure of the hydrogen
The hydrogen that probably leaks into the enclosed bus.
Temperature and conductivity of the stator cooling water
1.2.3.2.2

Hydrogen sealing
Maintain the normal running of the oil sealing system. Keep the pressure of the seal
oil at 0.056MPa, the temperature at 30. Ensure the seal of hydrogen.

1.2.3.2.3

Hydrogen purity
Inspect the hydrogen prity regularly and keep the hydrogen over 95% through refilling
fresh hydrogen.

1.2.3.2.4

Condensation preventing
Keep the relative humidity inside the generator at 50% to prevent dewing. During the
outage, the relative humidity has something to do with the ambient temperature of the
generator. Inspect the generator regularly. Inspect the relative humidity when the
temperature dcecreases by over 8. If it is found that the relative humidity is
excessively high, discharge some hydrogen from the generator. Refill the dry
hydrogen into generator from hydrogen supply system so as to decrease the relative
humidity.

1.2.3.2.5

Cooling water in the stator winding

The stator winding is cooled by circulating cooling water. The temperature of the
cooling water should be kept 5 higher than that of hydrogen in generator so that the
dewing in the stator winding and oxidization corrosion of hollow copper is avoided.
Inspect the cooling water conductivity of the stator winding. The conductivity of the
water in the water tank should be within the range stipulated in Summary Sheet of
Technical Data.

1.2.3.2.6

Maintenance of the cooler

To prevent corrosion and dust deposit in cooling water pipeline, the water at low flow
should go through cooler all the time. In addition, flush the cooler twice per week with
large-flow water.

Page 13 of 326

1.2.3.2.7

Safety measures
Hydrogen alarming system is in sevice state.
The hydrogen exhaustor in the bearing lubrication oil system is in service for
extracting the hydrogen leakage from the generator or hydrogen blended into the
returning oil system.
When the generator is shut down in winter, if the ambient temperature is prossibly
lower than the freezing temperature (the room temperature is less than ). The
water remaining in the cooler should be discharged thoroughly to prevent icing. Keep
the temperature of the circulating water of the stator winding higher than at least 5
to prevent icing.

1.3

Fundamental Requirements of Generator Overhaul

1.3.1

Preparation work for the generator overhaul

1.3.1.1

Implement the standard items for the overhaul and the necessary spare parts,
materials, special equipment and maintenance working hours budget.

1.3.1.2

Put forward the non-standard projects and changed projects according to equipment
operation and problems left over by the last maintenance, and draw up corresponding
technical organizational measures and security measures so as to implement these
projects required materials, spare parts and maintenance working hours.

1.3.1.3

Draw up overhaul plans and determine the progress of each project according to the
overhaul items.

1.3.1.4

Get ready the drawings, maintenance records and account for an overhaul.

1.3.1.5

The maintenance personnel (including external assistance staff) should learn the
knowledge of technical organizational measures and safety precautions.
They had learned the related safety codes and have passed the exams.

1.3.2

Precautions of generator overhaul

1.3.2.1

The generator should have a definite plan of inspection and maintenance to prevent
the failure. The plan can be divided into A-level and C-level maintenance. Each
generator should be established with record card to log the test results and
maintenance records in order to facilitate future reference.

1.3.2.2

A level maintenance requires a comprehensive inspection, cleaning, measurement

and repair of the generator; eliminates the defects of the equipment and systems;
replaces the parts that are expired and needed for periodic replacement. C-level
maintenance only makes a general inspection and maintenance to the generator and
eliminates some minor equipment defects.

1.3.2.3

Cautions on generator disassembly for maintenances and danger point & risk analysis

1.3.2.3.1

Cautions on generator disassembly

Page 14 of 326

1)

Make sure the replacement of generator has been completed; the hydrogen supplying
system has been installed with blocking plate and disassemble the generator
entrance door when the pressure in the generator is zero. Fill in compressed air
through generator sampling valve to blow away the residual hydrogen in the dead
angle of the generator.

2)

Before entering the generator, carefully and strictly detects should be carried out to
the gas inside the generator by the chemical professionals. Conform there is no
flammable before working. Wear special work clothes when coming into the engine.

3) Use 12V voltage lights and explosion-proof lamp holder in the generator. Joint is
prohibited there. The light line must be of static electricity-proof, no-breakage, good
insulation, and there should be no short circuit or virtual access phenomenon. At the
same time, explosion-proof flashlight must be provided and used in generators.
4) The disassembly of generator components should be based on the requirement of
Installation Guide. Safely keep of the disassembled parts to avoid being lost or
damaged.
5) The components may not be damaged in the disassembly. Make the necessary
markers; measure and keep a good record of the location and data components
before being disassembled.
6) The placement of hydrogen cooler should be safe and reliable; keep a good record of
the hanging out hydrogen cooler water pipe; and do not touch, hit, squeeze or press
the hydrogen cooler pipes.
7)

The transport of the generator end shield and air-gap bulkhead should be safe and
reliable. Move them to generator external part according to the order and place them
properly.

8)

Hoisting tools must undergo a rigorous inspection to ensure adequate safety factor
and it should be unified commanded by an experienced lifting workers.

9)

A pad should be used between the stator and rotor to avoid the friction. The hoisting
rope must be padded with a protective layer such as rubber, so as not to scratch the
rotor core; arrange staff to watch at both ends of stator and rotor clearance and
sufficient staff to maintain the rotor balance.

10) Check carefully the process and measures of plugging the generator stator in
operation position and pulling out the rotor and the use of specific tools to predict
possible incidents.
11) It is forbidden to go into the stator bore wearing shoes with nails. When coming into
the stator, do not step directly on the end of the coil. Especially the cooling water
pipes should not be moved or pushed to avoid the insulation tubes and water pipes
being damaged. The lower part of the core should be paved with rubber.
12) The one who goes into the generator stator bore must not take any metal objects and

Page 15 of 326

other objects in his pocket. It is necessary to focus on the end of the ventilation trench
for protection, in order that no foreign body falls into it.
13) Use qualified cleaning agent to clean the generator end coil in order to avoid
corrosion which may reduce the coil insulation level.
14) Take special care of the tools. Register the tools taking in and out of the stator bore in
order not to be lost. Count the number of the removed parts, nuts, bolts, pins, locking
plates and so on. Get the lost ones back and put them in special wooden box, and
label all of them.
15) Take fire fighting measures in advance for the special case of the need to flare up
when working in the stator bore.
16) It is a must to wear the seatbelt and helmet when working on the scaffolding.
1.3.2.3.2

Danger point Analysis on disassembly

1)

There are residual pressure in the generator; therefore, it may cause some wounding
due to the bounce of the manhole door when disassembling it.

2)

Combustible gas comes into the generator, personal and equipment damage
incidents occur in the work.

3)

The generator disintegration may cause the damage of hydrogen cooler and the
stator coil.

4)

When plugging the generator stator in operation position and pulling the rotor out, it
may cause the damage of stator and rotor.

5)

Lifting up large parts of generator may cause people injuries.

6)

When the generator stator bore works, it may result in the damage of stator core, coil
and water pipes.

7)

Foreign matters such as metal may be left in the generator.

8)

Damage the coil at the end of the rotor when unplugging the generator rotor or
installing the retaining ring.

9)

Fire may occur when using the organic solvents to clean spare parts.

10) It is a must to wear the seatbelt and helmet when working on the scaffolding.
11) Pay attention to the under-footing during the work to prevent injuries or damage the
work-piece.
12) Use copper wrench, copper pry bars and copper hammer to disassemble the
important components, and protect them well.
1.3.3

The disassembly of generator

1.3.3.1

Back wash before disassembling of the generator

Page 16 of 326

1)

Back wash the stator coil bar and outcomer before and after generator overhaul, and
before generator minor overhaul.

2)

Back wash the stator coil bar and the outcomer immediately when the generator is
under no load and the water system is not activated. If not, effluent in the water circuit
of the coil bar and outcomer may become dry and affect back wash. Make the record
on flow before and after back wash.Conduct the back wash alternatively every two
hours. The total back wash duration should not be less than 48 hours. The back
washing should proceed without interruption. The flow after back wash should be
higher than that before back wash. Otherwise, increase the pressure for re-back
washing until backwash result can meet the requirement.

3)

If the generator requires long-time outage, conduct the bach wash before internal
cooling pump shuts down. Dry the coil and lead with compressed air of 3kg/cm3 .
Recover the valve to state of running after the above mentioned is finished.

4)

Precautions for back wash

Open the discharging valve of the water inlet pipe and water outlet pipe while washing
to discharge the water in the coil and lead. Make the compressd air of 0.3-0.5kg/cm 3
without oil stain go through coils and leads to remove and the remaining water. Then,
make internal cooling water in service.

After washing, supply the compressed air to remove the water remaining. The
compressed air goes into water inlet pipe and water outlet pipe alternately until the
whole course of back wash is finished.

After washing, discharge the dirt in the blowdown pipe, close the blowdown valve
tightly, inform the inspector to dismount and clean up the filter.

Anylyze and compare the flow before and after the back wash.

1.3.3.2

Disassembling procedure of the generator

1)

The disassembly of generator connecting parts

2)

Dismantle the soft connecting part of the generator main lead. Fasten
the soft
braided behind the screw with white cloth belt so as not to fall down to damage the
porcelain.

3)

Dismantle the slip ring, lead of the brush holder and the leads of AC main exciter and
permanent magnet assistant exciter. Mark both ends of the each lead end.

4)

Remove all the brush spring and put them into special bags after counting the
number.

5)

Place the brush in the position which may not affect the hoisting.

6)

Remove the generator cooler and the cooler flange screws of AC main exciter.

7)

Unlock the generator coupling, and dismantle the oil inlet and outlet pipes of bearing

Page 17 of 326

bush.
8)

Dismantle the slip ring, brush holder and the flange of generator hydrogen system,
and add blocking plate so that the generator is separated from the hydrogen system.

1.3.4

The disassembly of generator internal and external cover and points for attention

1.3.4.1

The disassembly of internal and external cover

1)

Remove the cover bolts of the generator at both steam and excitation ends and hoist
the cover away.

2)

Remove the bearing bush at both ends of cover and the upper bush pillow in the
sealing bush by the steam turbine maintenance professionals.

3)

Remove the twineshield at internal end of both steam and excitation sides, measure
and keep records of the gap between the twineshield and the blade and the gap
between the fan ring and the twineshield ring before hand. Put the twineshields on
both internal sides separately and mark them clearly. Measure rotor clearance at four
points respectively on the upper, lower, right and left sides of turbine end and
excitation end of the generator. The differential value is below 10%.

4)

Hang the rotor hoisting tools on the cover of steam and excitation sides respectively.
Find out center and fix it to the cover with cover fastening screws. Then, use M24
55 bolt to locate and fasten, and pad an iron plate between the suspender and cover.

5)

Measure the gap between the internal cover and blade (four points: top,
bottom,
left and right) and keep a good record. Remove the internal cover
on
upper
half side.

6)

Remove the blades on steam and excitation sides and keep a good record. Place in
different boxes in order.

7)

Hang the generator rotor on the cover of steam side.

8)

Remove the bearing bush on lower half cover of the steam side and the lower bush
pillow of sealing bush (it is completed by machine).

9)

Remove the bolt on lower half cover of the steam side, and descend the cover 0.5m.

1.3.4.2

Cautious during disassembly

1)

Disassembly work can be carried out after making sure that there is no hydrogen in
the generator. Naked flam and smoking is prohibited in the field.

2 Feed the compressed air through the generator sampling valve two days before the
disassembly. Blow off the residual hydrogen in the dead angle of the generator, and
open the manhole.
3)

During the removal of each component, damage is not allowed and marks should be
taken. Keep good records of the location and data of the components before the
disassembly.

Page 18 of 326

4)

Count the number of the removed parts, nuts, bolts, pins, locking plates and so on.
Get the lost ones back and put them in special wooden box, and label all of them.

5)

It should be safe and reliable when hanging the cover and removing the blades. Do
not bump and damage the blades. The strike and hit are forbidden.

1.3.5

Procedure and precautions for rotor disassembly

1.3.5.1

Steps on rotor disassembly

1)

Before removing the rotor, equip the pulley and the guide rail specially used for
removing stator on excitation side. And then sling the macro-axis on excitation side by
using crane; remove the lower end cap bolt on excitation side, descent the lower end
cap 0.5m on excitation side, drop down the macro-axis on excitation side and make
the pulley into its track.

2)

Sling the macro-axis on turbine side by using crane; loosen the tools for slinging rotor
on turbine side.

3)

Find a fixed point and hang a 5T chain block, pull out the rotor from the turbine side to
excitation side, at the same time, the crane should be translated to the excitation side.

4)

When the pendant cord of the crane is going to connect with the turbine end shield,
hang the micro-axis on turbine side to the end shield by using the tools for hanging
rotor. Loosen the crane; connect the dummy spindle on the turbine side rotor. Crane
should sling the rotor macro-axis on turbine side from the first section of the dummy
spindle, (the other two sections of the dummy spindle cannot be drew out), loosen the
end shield tools for slinging rotor.

5)

Pull the chain block on excitation side; translate the crane toward the excitation side
until the crane wire rope connects to the end shield, hang the crane wire rope to the
second section of the dummy spindle by the same way, and removing rotor continues.

6 Make the crane hang to the third section of the dummy spindle and continues
removing rotor to the excitation end by using the same way. At this time, the center of
the rotor should be moved out of the excitation end shield.
7)

At this time, hang the excitation side macro-axis to the end shield by using tools for
hanging rotor. And then loosen the crane wire rope.

8)

Seal the exposed vent hole of the rotor by rubber stopper or plaster.

9)

Hang a balance weight about 4T on the pulley, equip and fix the specialized stay tape
for hanging rotor at the center of the rotor.

10) Sling the central part of the rotor by wire rope, make it balanced and move the crane
slowly, withdraw the generator rotor from excitation side.

Page 19 of 326

Page 20 of 326

1.3.5.2

Attentions on removing rotor

1)

The wire rope, tools for hanging rotor and other tools should be the special tools for
removing rotor, so check them carefully and make sure its intensity and functions are
in good condition.

2)

All the operators should be operating under the unified command; they cannot
operate or command the crane as their own will.

3)

Do not lay the rotor during removing it, if it is necessary, the radian of the saddle
supporting should be in accordance with that of the large gear teeth of the rotor, felt
and board should also be equipped.

4)

In the whole process of removing rotor, the large rotor gear teeth should be in vertical
position, and when removing and laying rotor, the air scoop should not be broken.

5)

Never distort the iron core, air scoop, air fan and insulation during removing rotor.

6)

Do not take the protection sleeves, fan sleeve, center sleeve, slip ring and air scoop
on motor as.

7)

During drawing out the rotor, when some problems happens, it should be told to the
operators and the operation should be stopped until the problems are resolved.

8)

Anyone except the operators is not allowed to be close to the operation site, anyone
is not allowed to stay under the crane and the hung rotor.

9)

When laying rotor, the large gear teeth should be always in vertical position.

1.3.6

Maintenance and quality standard of generator stator

1.3.6.1

Maintenance standard of stator end section

1)

Check that the end section of windings and supporting parts is free of oil crust, check
that the insulation near the bar insulation box is out of expansion.

2)

Check and make sure that the insulated water connecting joints is closely tightened
no gap exists.

3)

Check the polarity and phase connection, shunt connecting wire and main lead for
insulation deterioration, wrinkling, expansion and overheating, check polarity and
phase connection, connector of main lead, shunt connection lead wire for water
leakage.

4)

Check the involute section of the rotor end section, each stent, tie line, vibration-proof
ringarticle pad obliquespacing padslot padconformal materials are not loosening,
deform, overheating, loose and fracture. Once some of them appears, timely
treatment is necessary.

5)

Check that the insulation of the windings end section is out of cracking, the paint film
is not fall off, overheating and cracking. The fixed screw of the copper platen and ring
should be out of loosening, overheating and falling off the paint.

Page 21 of 326

Check that the Tetrafluoroethylene insulation water pipe for crack, wear and quality
deterioration ,otherwise replace it with new pipe even if the it passed hydrostatic test.
1.3.6.2

Maintenance standard on rotor tank

1)

Check that the stator article wedge is free of loosening, the iron core is not
overheating, vent duck goes smooth and out of foreign objects, the insulation of the
bar is not broken, air baffle is not loosening and broken. When cleaning the dust in the
stator chamber, high-power vacuum cleaner should be used, at the same time
compressed air purging is prohibited.

2)

Check the bar grading of corona shielding is out of small black points and faces, or
the black powder should be cleaned by brush, and then brush the low resistance anticorona paint.

3)

After checking, red epoxy enamel can be brushed at the end section.

1.3.7

Maintenance and quality standards of generator rotor

1.3.7.1

Maintenance on rotor
1)

Check that the blade of the rotor fan is free of cracking, deforming and plaque, nut is
fastened, polished surface of the blade should be smooth, do some mental testing on
the blade.

2)

When changing blade, weight the new and the old blades, the angle, weight of the
new blade should be in accordance with the previous one.

3)

Check the protection sleeve, center sleeve and fan sleeve for cracks, deformation and
also do flaw detection testing

4)

Check that the balance block is not loosen, the connection parts of protection ring and
proper should be out of discoloration, electrical erosion, electrical burn. The surface of
rotor should be no color change and rusts or overheated signs.

5)

The wedge is free of cracking, protruding, and displacement, there is no dust, oil
crust, and skew on twine scoop, the retainer of the protection ring key should be free
of deforming, unsoldering, there is no loosening, cracking on nylon twine guide blade.

6) Purge the rotor vent path by 3-4kg/cm 2 compressed air, connect it to the special twine
guides for purging the twine. At first, do the twine rejection back purge in hot air area,
then purge of the twine into scoop in the cold air area, each twine scoop purges twice
on both back and normal sequence. If there are three twine scoops blocked in one
tank, it should be reported to the relative authorities. They can analysis the reasons
and find out solutions. At the same time, large gear teeth twine rejection tank should
also be purged
7) Check and make sure the surface of slip ring is smooth, free of rust staining and burn
marks, uneven degrees should be in 0.5mm, or it should be experience car spinning,
the roughness should be above 1.6 .

Page 22 of 326

8) Guide ring lead screw should be tightened, edges should be tight and sealed rubber
ring should be free of air leakage, vent hole should and hook groove and screwing
aperture should be clean, guide ring should be dried with dry compressed air with
density of 3kg/cm2.
9 Center hole sealed block plate screw of generator and excitation sides should be
fastened, the block plate is free of leaking air.
1.3.7.2

Measurement on each section of the rotor

1)

To measure the gap at the connection part of protection ring and rotor iron core, filler
gauge is used and the gap is divided into eight points.

2)

Divide the external diameter of the protection ring into 2 section 4 points, measure it
by external micrometer.

3)

Measurement on uneven degree of the slip ring surface, and the eccentricity.

4)

Measurement on the largest and smallest diameter of the slip ring.

5)

Compare the above data with the previous ones.

1.3.8

Maintenance and quality standards on hydrogen cooler

1.3.8.1

Disassembly steps on hydrogen cooler

1)

Check that the generator water inlet is closed, when discharging all of the water,
remove the water inlet and outlet pipe flange and nipple, and mark the relative
position of the sealing ring and gasket by paint.

2)

Remove the screw connection between the two ends of the cooler and the cooler
shield, remove the sealing ring of the two twine chambers, then sling the cooler by
crane, lay it on the square timber, mark the symbol and position of each cooler.

3)

Remove and mark the end cover of the cooler, mark the separated parts, bolts and
nuts, record the number and then put them in bag.

1.3.8.2

Cleaning of the cooler

1)

Clean the end cover immediately after it is removed to prevent the mud and scale
becoming dry. Wash the copper tube by 25mm round brush till it is clean.

2)

Clear the mud, scale, rust staining of the end cover, tube plate and nipple, and then
brush the antirust paint.

3)

Check if the sealing rubber washer is not cracking and deteriorated, if so, change
them.

4)

Assembly each parts as what it was when the paint is dry.

1.3.8.3

Hydraulic test and assembly standard of the cooler

1)

Seal the water outlet flange by blocking plate and rubber pad, fill the water to inlet

Page 23 of 326

flange by pumper. Do hydraulic test for the whole set when water is full. The
requirement is that no leak and pressure drop under a water pressure of 0.6 MPa for
30 minutes.
2)

If the leakage and pressure decrease happens, the end cover should be removed, to
find the leakage in each one pipe, do the 0.6 MPa hydraulic test in each pipe for 15
minutes, if the copper pipe is leaking, blank it off at two ends by using the suitable
conical copper plug which is annealed. If the bulged ring is still leaking, bulge it again,
and the hydraulic test should be qualified.

3)

The blocked copper tube should not take more than 5 of the whole tube. After the
hydraulic test is qualified, assembly it follows the symbols, and check the sealing pad
at each part.

1.3.9

Maintenance standard of the generator outgoing, slip ring support and its lead
1)

Check the flexible wiring and transfer connection inside the outgoing housing, to
make sure that they are free of loosening and rupture, the porcelain bushing should
be smooth and clean, the silver coating of each contact are in good condition, and
there is no heating, discoloration, discharging. The insulated materials in each part
are free of heating, discoloration and carbonating.

2)

The insulation water pipe and the Jellyfish tube of the incoming and outgoing should
be out of loosening and rupturing.

3 The silver layer on each contact of the outgoing housing, joints and soft braided
connection line are smooth and in good condition. Before connecting them, clean then
by alcohol. When the soft braided connection line is fixed, check the contact by
0.05mm feeler gauge, the insert depth in each point should be less than 5mm.
4)

Clean the oil crust in the outgoing shield, keep the drain outlet goes smoothly. When
all the tests are qualified, equip the outgoing shield man whole valve, and change its
sealing rubber pad.

5 Clean each brush hands on the brush rack, adjust each brush holder to a distance of
2-3mm to slip ring, make it perpendicular to the slip ring.
6 Exchange the position of anode and cathode in each overhaul on slip ring, in order to
make the degree of wear is similar.
7)

Change the wear or short carbon brush, and make the contact connects well; contact
area should be over 75%. There should be a 0.1mm gap in the brush hand of the
electrical brush.

8)

The brand of the electrical brush should be the same, the brush should be free of
rupture, the brush braid should be fixed firmly, the difference between the contact
resistance should not be too large, the spring pressure should be in the range of
25.887%N, the adjacent brush voltage difference should be 10%, if vibrated, the
presses can increase 50%--75%.

Page 24 of 326

9)
1.3.10

Purge the brush rack and the slip ring by using dried compressed air, to measure the
insulation is in good condition.
Fitting Generator Rotor

1)

Put the generator bearing sleeves and bottom bearing bushings in the lower end
cover, and then sling the lower end cover to the turbine pit with a decrease of 0.40.5m.

2)

Methods on wearing rotor is the same to that of removing rotor, but operates in the
reverse sequence.

1.3.11

Assembly of the generator internal and external end cover

1)

When rotor wears, the internal and external end cover should be assembled
immediately, it is not allowed to hang the rotor on the hanger for a long period.

2)

Clean the insulation board and the internal end cover of the turbine and excitation
sides. Firstly assembly the lower half internal end cover at the two sides and the fan
cover, insulation board and then the lower half external end cover and bush.

3)

Assembly the upper half internal end cover of the two sides together with fan cover
and insulation board. Measure the insulation of the internal end cover to ground is
above 1M by using megger.

4)

Measure the gap between the fan and the fan cover, gaps between air dampers
should be qualified.

5)

All the screws, dowel, flat washers and cone stopper are fixed firmly, and been
checked by a designated person.

1.4

The Acceptance after Generator Overhaul/Minor Overhaul.

1.4.1

The acceptance after overhaul

1.4.1.1

Three level acceptance according to requirements during overhaul.

1.4.1.2

The service personnel should prepare overhaul record, measured data record and
resolve defect record. Acceptance items as follows:
1. Overhaul technology completed after iron core stopped by generator, fasten coil end,
lead to line circuit and water channel and stator bar circuit and water channel,

1.4.1.3

2.

Bar and outgoing line circuit/water channel flow and water pressure test finished.

3.

The rotor overhaul and sealing test finished.

4.

Hydrogen cooler maintenance, water pressure test finished

5.

After AC exciter assembly

It is required to technical personnel should attend to inspect the following items during
whole system acceptance test.

Page 25 of 326

Completion status, technology record status, working process status of maintenance

items must be inspected thoroughly. If overhaul items ignored or not
clear try to
make it complete.

2.

Equipment surface status inspected and repaired, site and equipment cleaned, no
apparent defect, remove if any requirements

3.

Start to test after above items inspected and passed, evaluating entirely after no fault
inspected.

4.

Prepare overhaul technical report within ten days after overhaul

1.4.2

Acceptance after minor overhaul

1.4.2.1

Service personnel should record and collect after minor repair and clean site and
equipment, no apparent defect, remove if any requirements

1.4.2.2

The technical personnel of power planting should inspect minor overhaul items and
accept and evaluate entirely for equipment minor overhaul items and quality condition

1.5

Relevant Tests

1.5.1

Electrical test
If there is no special instructions, discharge all hydrogen as well as cooling water in
stator wire rod and out-going before test. Open the metal wire between temperature
detection latchboard and earthing terminal (steam end and excitation end). Restore
the metal wire after the test. Test working condition (cold or hot state) should be
determined based on actual confition of the test items. The test items are as follows:

Items

1) Measure insulation
resistance and
absorptance of stator coil
before and after maijor
and minor overhaul of
generator.

Test content

The insulation resistance measured with 1000V

Megohmmeter should be 1M. Or compare the value
with the first value under the same temperature, if it is
1/3~1/5 lower than the first value, the cause should be
found out and eliminated. The imbalance coefficient of
each phase can not be more than 2, and the absorptance
should be R60/R151.6.

2) Before
the
generator When there is water in the stator or the residual water is
overhaul, the stator AC blown dry, the time for coil to earth and inter phase current
voltage
resistant
test current withstand test is 1.5UN1 minute.
should be carried out
3) Mwasure the stator DC The voltage will stay at each section for 1 minute when
withstand current and increasing from 0.5UN to 2.5UN, and following
leaked current before and requirements should be met: the leaked current should not

Page 26 of 326

Note

after the overhaul or after increase with the time increasing. Under the required test
widingings replacement.
voltage, the difference between phases should be 100%
higher than minimum value. The maximum leaked value is
below 20A, compare the difference value between
phases, and the value should change obviously. The
earthing plate on steam excitation end collecting pipe and
stator coil out-going assembly pipe flange should be open.

4) Measure
the
DC After the error caused by different lead wire kength is
resistance of stator coil in valibrated, the difference value between maximum and
generator major overhaul
minimum of DC resistance of each phase should not be
2% higher than minimum value. And relative change with
the initial value should not be more than 2%.
5) Measure the insulation The insulation resistance should be 1M when measured
resistance of rotor coil with 500V Megohmmeter, and it should be 0.5M when
before and after the measured with 2500V Megohmmeter.
generator major and minor
overhaul:
6) Measure
the
DC The value can not exceed 2% of initial value.
resistance of totor coil
during motor overhaul
7) After
the
generator Measure with 1000V Megohmmeter, and the value should
overhaul or minor repair, be 30K (regulation of manufacturer with no water
the insulation resistance inside), and it should be 100K when there is no water.
of manifold on steam and
excitation
ends
and
outgoing
manifold
of
stator.

8) After
the
generator The stator out-going bushing can bear 64500V AC
overhaul,
out-going frequency dry-arc electrical strength after the generator
bushing of stator should overhaul. The test should last one minute.
carry out the AC voltage
resistance test.
9) Measure
the
AC The test voltage peak value should not be 463V higher
impedance
of
rotor than rated excitation voltage. The measured value can be
winding after generator much different with initial value.
overhaul

Page 27 of 326

10) Measure the insulation The value should be 1M when measured with 1000V
resistance of generator Megohmmeter.
bearing after overhaul
11) Meaure the shaft voltage When the bearing oil membrane is short circuited, the
after generator overhaul
voltage on two ends of rotor should be equal with voltage
between bearing and the support.

12) Measure
the
no-load
characteristic curve after
generator overhaul oor
winding replacement.

The maximum voltage of rotor is increased to 130% of the

rated voltage under rated rotary speed. This value should
be within the error range compared with data from
manufacturer.

13) Measure the short circuit The data should be within error range compared with
curve
after
winding manufacturer data
replacement
or
when
necessary
14) The stator iron core test there is partial high temperature or short circuit may exist
should be carried out in overhaul.
when the core is damaged
15) Measure that the anti- Measure that the anti-corona coating to ground potential of
corona coating to ground stator is5V when necessary.
potential of stator is when
necessary.

1.5.2

Generator stator bar flow rate test (measured with ultrasonic flow meter)

1.5.2.1

The end covers on both sides of generator are open during overhaul, and then
connect stator cooling water in and clip two sides of output water pipe insulation guide
pipe with ultrasonic flow meter to measure (coat insulation water conduit with
Vaseline). Measure steam side insulation water output pipe during washing, while
measure excitation end insulation water output pipe. The measurement of dlow rate in
out-going bushing is the same.

1.5.2.2

Open the access door to enter the generator to measure when minor overhaul, the
method is the same with above.

1.5.2.3

Compare when the flow rate test of all branches are finished, the difference among all
these value can neither be 20%more than average value nor 20% more than previous
test. Otherwise, find out the cause and eliminate.

Page 28 of 326

1.5.3

Stator bar hydrostatic test

1.5.3.1

Test with system means doing the test with cooling water system directly.

1.5.3.2

Test without system means opening the inlet and outlet water pipe flange of generator
stator cooling water, and then install dedicated test flange pipe to do the test.

1.5.3.3

The cooling water of 0.49-0.687MPa will flow into generator winding and out-going
and keep the water in for 4 hours.

1.5.3.4

Check the water conduit on by one to mare there is no crack, abrasion, damaged
caused by disassembly and deterioration , if there is, replace the pipe wuith new pipe
which can meet the requirement of test.

1.5.3.5

Check the all joints of bars, insulation water conduit joints, parallel lead wire to soft
connection upper joint and pole group joints one by one, and there should be no water
leakage.

1.5.3.6

All parts should be restored into operating state after tests above.

1.5.4

Hydrostatic test on generator out-going

Test criteria and method is the same with test of stator winding.

1.5.5

Generator stator air pressure test

1.5.5.1

During the major overhaul of generator if only coolers need to be disassembled, the
air pressure test can be carried out. Activate oil sealing after the generator assembly.
Inject dry compressed air into stator to replace air test.

1.5.5.2

Close the first valve of hydrogen pipe, carbon dioxide pipe and the first valve of their
meters, and then close out-going blowdown valve.

1.5.5.3

Make clean and dry compressed air flow into generator air temperature meter screw
hole and install a master gauge of 0-0.5MPa.

1.5.5.4

Increase the gage pressure to 0.1MPa and sealing oil pressure to 0.15MPa, check the
leakage point with soap water.

1.5.5.5

After all air leakage points are eliminated, increase the pressure to 0.3MPa gage
pressure and sealing oil pressure to 0.35MPa, continue leakage checking until there
is no leakage point.

1.5.5.6

Keep the pressure inside at 0.3MPa gage pressure, close the air source valve. When
the temperature and pressure change outside is not obvious, the influence on the
pressure inside can be ignored. 24hours later, if the pressure decrease does not
exceed 0.0041MPa and corresponding air leakage is 10m3, then it can be consider
to meet the requirement of test.

1.5.5.7

If the pressure decrease of pipes with hydrogen, carbon dioxide and meters does not
exceed 0.15MPa during air filling test, it meets the requirements of test.

Page 29 of 326

1.6

Excitation System Maintenance Technology

1.6.1

Excitation system description and regulations

1.6.1.1

Excitation system description

Exciting power is applied on the thyristor bridge of the excitation system (usually he
excitation transformer from generator end for and an A.C. exciter). Through a exciting
CB, the controllable thyristor bridge will then provide a D.C. excitation current for the
generator.
The AVR adopts the IPC as the core of the hardware, the peripheral circuit and signal
circuit as auxiliary. By sending synchronous signals to trigger the Thyristor bridge, the
generator rotor current can be controlled, and various of control target can be
achieved.
All kinds of analogue signal such as the generator voltage and current signals which
are sampled at the analogue interface and transmitted to the CPU via the PC bus.
Subsequently, the CPU controller calculates and processes the signal input after
which control signal will be output to the pulse generation unit. Then, the generated
pulse will be transmitted to the thyristor power modulating bridge through the multistrand cable.
It is the respective intelligent I/O module that acquires the binary signal of the power
modulating unit and the de-excitation circuit. Next, the signals are sent to the IPC via
the RS485 Feild bus. Then, the CPU controller inside the IPC will execute logical
control, protection and monitoring.
One LCD operation unit, which is able to display all sorts of analogues, generator
operational condition and AVR fault alarm signal, is installed on the door of the AVR
panel as the station for man-machine interface of AVR.
The dynamic test of the excitation system can be implemented by operating the
operation unit and the local operational panel. Moreover, the operation unit can be
connected to the AVR via RS232.
Sometimes, dual-channel redundancy system is adopted to make the AVR more
reliable. The hardware configuration for analog, on-off input and the regulating
channel are independent from each other but share the same structure. In addition,
the two channels operate in a way that one works as the operating channel and the
other as backup in case that one channel is faulty. If so, the backup channel will come
into operation automatically to replace the faulty one. Either channel can perform as
the operating channel without any priority to the other but the backup channel would
trace the operating one automatically.
Once the operating channel is faulty, the backup channel can come into operation
without disturbance to serve as the operating channel. The thyristor bridge is
controlled by the AVR.

Page 30 of 326

1.6.1.2

Product Model Code

The structure of excitation equipment model code produced by Dongfang electrical
control equipment company is as follows:

Model instruction:
Code

GES

Position

Code instruction:
1)

GES is the excitation system of generator.

2)

3 is GES3000 series product of Dongfang electrical control equipment company.

3)

3 means that regulator uses IPC bus industrial computer.

4)

2 means that the regulator is double channel redundant structure.

5)

0 means generator transformer self-shunt static excitation system.

1.6.1.3

Technical Parameters

1.6.1.3.1

The excitation system can operate continuously if the excitation voltage/current does
not exceed 1.1 times of the rated value.

1.6.1.3.2.

The peak voltage multiple of the excitation system, which is the forced excitation
voltage multiple should not be less than 1.8.

1.6.1.3.3

The allowable forced excitation duration should not be less than 10s.

1.6.1.3.4

The nominal response of the excitation system should not be less than 2 times/s.

1.6.1.3.5

Regulative Scope of AVR:

The AVR should be capable of stably and smoothly regulating the voltage within 30%
to 110% of the rated no-load voltage when the generator carries no load.
The AVR should be capable of stably and smoothly regulating the voltage within 90%
to 110% of the rated generator voltage when the generator is synchronized.

1.6.1.3.6

The voltage output of the AVR should change within a scope from 0.3% of the rated
generator voltage to 1% per second.

Page 31 of 326

1.6.1.3.7

The generator output voltage regulating percentage (reactive power current

compensation percentage) should be set to be from 0 to 15%.

1.6.1.3.8

The AVR should maintain the generator voltage static difference at 1%.

1.6.1.3.9

When the generator carries no load, the frequency should not vary for more than 1%
and the output voltage for less than 0.25%.

1.6.1.3.10

When the generator carries no load, the voltage regulating margin should not be more
than 50% of the percentage with fluctuations for less than 3 times and the regulating
duration should be less than 5s.

1.6.1.3.11

If the generator voltage needs to be suddenly raised from zero, the AVR should
maintains the generator voltage output margin below 15% of the rated value with
fluctuations for less than 3 times and the regulating duration should be less than 10s.

1.6.1.3.12

If the rotor current is less than 1.1 times of the rated value, the rectified voltage
supplied to both ends of the rotor coil should have a maximum transient value that is
not more than 30% of the rotor coil voltage amplitude measured in the test in
manufactory.

1.6.1.3.13

If any parallel branch or serial connection is available, the average current coefficient
thyristor bridge should be at least 0.85, and the average voltage coefficient should be
at least 0.9.

1.6.1.3.14

Signal input: the electrical signal input into AVR is obtained from the PT and CT of
generator output:
3100V

50Hz

Voltage 3100V

50Hz

35A

3 phases

50Hz

Current 35A
1.6.1.3.15

50Hz

3 phases

3 phases

Requirements for Operating Power Supply

The allowable deviation of the A.C. voltage is -15% to +10% of the rated value, and
the frequency is -6% to +4%.
The allowable deviation of the D.C. voltage is -20% to +10% of the rated value.

1.6.1.4 Main Circuit of AVR

Silica-Controlled Rectifier

+FBC

--QF
+SCR

Excitation CB

AVR
+AVR

G
+PRO
Rotor Protection

Self-shunt Excitation System

TE

Transformer for Excitation

Page 32 of 326

Fig. 3-2 Main Circuit of GES-3320 Excitation System

1.6.1.4.1

Excitation TR. (Capacity: 3600KVA, Type: Dry)

The transformer for excitation is the source for the excitation power, and electrically
segregates the excitation devices from the generator output. The HV side of this
transformer is connected at the outlet of the generator while the LV side at the A.C.
input of the large power silica control rectifier.

1.6.1.4.2

Silica-controlled Rectifier
This rectifier converts the A.C. power from the transformer for excitation into D.C.
power which is then transmitted to the generator excitation circuit.
Usually, several bridges operate in parallel to burden with the load. As a result, the
rectifier can still supply stable excitation current into the rotor even if some of the
rectification branches are faulty. How many bridges need to be paralleled and how
much current each bridge can bear should depend the specification of the thyristor
element. But generally speaking, the rectifier should still be capable of the excitation
for rated operating condition of the generator if one bridge is out of service. In some
other cases, the rectifier should be capable of the excitation for forced excitation if
one bridge is out of service.
The silica-controlled bridges are under the control of the AVR which regulates the
output power to change the excitation current of the generator so that the output
voltage and reactive power of the generator can be regulated.

1.6.1.4.3

CB for Excitation
This CB has got the alias of de-excitation CB or field CB which is the visible fracture
between the rotor coil and the rectifier. It is one of the vital part for the de-excitation
circuit of the rotor, and is capable of quick tripping and field energy transfer in
emergency so as to ensure safety of the generator.
The D.C. output of the rectifier is transmitted into the generator rotor via this circuit
breaker.

1.6.1.4.4

AVR
The AVR which is installed in the AVR panel is composed of the signal processing part,
the control & calculation part and the signal output part. The AVR acquires all sorts of
analogues and on-off information of the generator that are then calculated and
processed by an industrial computer for the control of the output of the large-powered
rectifier. Thus, the excitation system can be under control.
The AVR is of a fault tolerating structure with dual-channel redundancy. Moreover, it is
equipped with 2 independent sets of hardware circuits respectively composed of signal
processing, control & calculation and signal output. The two circuits operate
independently with some mutual connection.
The two channels operate in parallel in a way that one is the operating channel while
the other as the hot backup for it. Software is utilized to actualize the functions of
mutual diagnosis, real-time on-line self-diagnosis, mutual tracing, communication as
well as mutual switchover.

1.6.1.4.5

Fault Signal

Page 33 of 326

This part serves as the reference for analysis and solution for fault alarm in the
excitation system.
The sub-option of FAULT INFO beneath the menu of SYSTEM INFO, which is provided
by the man-machine interface unit, can be used to display some of the faults detected
by self-diagnosis function. In the meantime, some of the essential fault information is
transmitted through the hard relay connector to the AVR output terminal so that the
information can be used for the remote alarm system.
This situation has occurred if 1 is displayed at the position beside the fault alarm signal.
Info.
Description

Fault Description

Device Execution

Solution

PT
wire
breaking
for
channel A(B) of
AVR

The PT connected
with the regulating
channel
A(B)
comes up with wire
breaking or the
measuring board is
faulty

The
operating
channel
switches
from channel A(B) to
channel B(A). If both
of the PTs have
come up with wire
breaking,
the
regulation mode is
switched
from
Constant Voltage
To
Constant
Current

Switch to constant
current.
Perform
maintenance on the
PT circuit.

Fault of A/D of Hardware fault of The

operating Put the faulty channel
AVR channel A/D
board
of channel is switched out
of
service
A(B)
channel A(B)
from A(B) to B(A)
together
with
exchanging the A/D
board
Fault
of
channel A(B)
synchronizatio
n

Faulty
The
operating Put the faulty channel
synchronization
channel is switched out of service for
between
channel from A(B) to B(A)
prompt maintenance.
A(B) and TR. or
between
channel
A(B) and pulse
board

Pulse loss of Fault

of
pulse The
operating Put the faulty channel
channel A(B)
generation board or channel is switched out of service for
connector
of from A(B) to B(A)
prompt maintenance.
channel A(B) is
faulty
Communicatio Serial port between
n fault with 2 channels failed
Alarm
channel A(B)

check if the serial port

between the channels
is loosened.

Fault
of
channel A(B)
HMI
communication

check if the serial

connection between
the channels has
loosened.

Communication

fault
between
channel A(B) and Alarm
the
superior
computer

AVR excitation No
voltage
initiation failure established

is Cut off the power Inspect the power for

8 supply
for
initial initial
excitation

Page 34 of 326

seconds after initial excitation

excitation
command
is
issued.

circuit,
the
rotor
circuit as well as the
brush abrasion

AVR inversion The

generator Excitation CB tripped
failure
voltage output has
not dropped to
below 5% of the
rated value after
10s.

Inspect
circuit

the

Protection for
over-voltage
starting up

Alarm

Protection for
over-excitation
limitation

Alarm

Less excitation

More excitation

logic

starting up
Protection
underexcitation
limitation

for

Alarm

starting up

Protection for
V/F limitation

Alarm

Less excitation

starting up
Power
limitation
of
rectification
panel

The power panel is Inspect the faulty

faulty whose output rectification panel.
needs to be limited.

One
power One of the parallel Alarming,
blocking Inspect the faulty
panel faulty
rectification panels the pulse of the rectification panel.
is faulty.
faulty panel
Two
power Two of the parallel Alarming,
blocking Inspect the faulty
panels faulty
rectification panels the pulse of the rectification panel.
are faulty.
faulty panel, limiting
the forced excitation
Three
power Three
of
the Alarming, activating
panels faulty
parallel rectification all the power panels,
panels are faulty.
limiting the load of
them.
Stator current LCU command can Alarm
limitation
not be executed

Page 35 of 326

Inspect
the
communication circuit

effectively.

and
see
if
the
regulation setting has
gone beyond the
given authority/ been
exceeded.

Power
panel This panel is off.
1(2 or 3)

Rectification
panel is out of
operation
Power
panel Vent gate for power Cut off the pulse of
1(2 or 3)
panel 1(2 or 3) is this panel to put it
not open
out of service.
Fans
for
rectification
panel are out
of operation.

Inspect the fan circuit

and check if the vent
inlet
strainer
is
blocked.

Power
panel Pulse missing in
1(2 or 3)
rectification
of
power panel 1(2 or Alarm
Pulse loss in 3)
rectification
panel 1(2 or 3)

Inspect the pulse

transmission
circuit
as well as the pulse
amplification panel

Power
panel Thyristor for power
1(2 or 3)
panel 1(2 or 3)
carries not current
No current in
rectification
panel

Alarming,
automatically
disabling
thyristor bridge

Open
the
A.C.
disconnector and the
this D.C. disconnection to
conduct inspections
on the thyristor.

Power
panel The protective fuse
1(2 or 3)
for
thyristor
of
power panel1(2 or
Fuse blowout 3) blows out.
in rectification
panel

Alarming,
automatically
disabling
thyristor bridge

Inspect the fuse

Power
panel AVR receives no Alarm
1(2 or 3)
info. from this panel
Input
fault

module

Power
panel Command
from
1(2 or 3)
AVR can not be
Alarm
accurately
Output module executed.
fault

Page 36 of 326

this

Inspect
the
communication circuit
and the intelligent
communication
module

Inspect
the
communication circuit
and the intelligent

communication
module

De-excitation
panel

Field CB can not be

opened
as
Alarm
commanded

Inspect
the
CB
mechanism and the
control circuit.

Field CB can not be

closed
as
Alarm
commanded

Inspect
the
CB
mechanism and the
control circuit.

AVR can receive no

info. from this panel
Alarm

Inspect
the
communication circuit
and the intelligent
communication
module

Commands
from
AVR can not be
Alarm
accurately
Output module executed.
fault

Inspect
the
communication circuit
and the intelligent
communication
module

De-excitation
panel

Inspect
the
CB
mechanism and the
control circuit.

Field
CB
rejects opening
De-excitation
panel
Field
CB
rejects closing
De-excitation
panel
Input
fault

module

De-excitation
panel

Field
CB
mistakenly
opened

The field CB trips

mistakenly when it
Alarm
should not.

1.6.2

Equipment Maintenance

1.6.2.1

Overview on Maintenance
Fouls may remain in the electronic elements and in the rectification device due to the
ambient. Also, the vibration of equipment during operation may loosen the electrical
contacts. As a result, the excitation circuit which has high voltage and high current
would be shocked. Therefore, regular cleaning and maintenance seems vital for the
excitation system.

No.

Object

Every three months

Every year

Transformer for Excitation

1

Tr.
for Inspect to find out if any Sweep away the dust and sundries, check
Excitation
abnormal noises exist.
whether there are abnormal noises.

Rectifier
2

Fans

Check to see if there has

abnormal noise.

Sweep away the dust and sundries, check

whether there are abnormal noises.

Air Strainer

Sweep away the dust

Sweep away the dust.

Page 37 of 326

(the air strainer should

be frequently inspected if
the operational ambient
is dusty)
4

Radiator

External inspection

External inspection

Rectifier

Observe the current flow

Inspect the conduction of all the thyristors.

Disconnecto
r
for
Rectifier

Verify if mechanical loosening exists.

Field CB
7

Field CB

Get rid of the dust and inspect the main

contacts to see if they have come up with any
abnormal melting.

CB for Initial
Excitation

Get rid of the dust and inspect the main

contacts to see if they have come up with any
abnormal melting.

Inspect to see if any of the connection has

loosened and if erosion has occurred on the
surface.

Bus-bar
AVR
10

Hardware

External inspection

External inspections

11

Functional
Inspection

Inspection on the spare Signal examination and inspections on the

circuit
spare circuit

What is listed in the table above will be described in detail hereafter. The instructions
for inspections every 3 months and annual inspections should be executed separately
since the inspections every 3 months only involve external work while the annual
inspects requires some maintenance.
1.6.2.2

Unit Operation Every- 3 Month- maintenance

1.6.2.2.1

Excitation Transformer
Inspections should be conducted on the external of the transformer to judge by the
noises if the transformer is operating normally.

1.6.2.2.2

Rectifier
1) Inspections are necessary for the contamination on rectifier fans and noises.
Since it is impractical to supply lube oil into the fans, the faulty ones need to be
exchanged.
2) Inspect to see how the air strainer has been contaminated that is embedded in
the vent orifices on the rectifier door. Negative influence would be performed on the
ventilation and heat radiation of the panel if too much dust has deposited on the
strainer so that this strainer should be exchanged.
3) Check the contamination of the radiator.
4) If parallel operating thyristor bridges are adopted, the amperemeter of each
bridge should be read to see if the current has fluctuated.

Page 38 of 326

1.6.2.2.3

AVR
1)

External Inspections on Hardware Circuit

a

Inspections are needed to see if too much dust has deposited on the circuit
board and if oxidization by overheating has occurred.

b Inspect to see if the relay has started up with abnormal arcing and whether
the lamp is normal.
c
2)

Check if the cables and conductors have loosened.

Functional Inspections on AVR

a

Browse the alarm signals: no indication is available on the touch

for fault.

screen

Comparison on the measured values: find out the differential value between
the measured value on the display and those of other positions in order to
make sure the device indication is correct.

Testing on the spare regulative circuit: the spare regulative circuit and the
excitation current regulation channel need to be inspected to verify that
balanced tracing can be performed in channel A and channel B as well as in
the manual and auto channels.
c a AVR Switching between master/slave channel
c b Switch the AVR to constant current(manually operated).
c c Another switchover should be carried out in the constant current mode to
switch the operation of the AVR between the operating channel and the
spare one to return the AVR to the former mode.
c d Return the AVR to the auto mode.
The output of AVR before switchover and the value after switchover
should not exceed 0.5. If the switchovers have been finished smoothly,
all of the spare circuits can be regarded as normal. However, if an
distinct change has been brought by the switchover, the cause should be
found out.
Note that the current regulation channel is not capable of tracing the
voltage regulating current under the extreme working condition. Thus,
the channel should be switched to auto mode when the testing is
completed. Since the limiter can not perform its function in the mode of
constant current, diligent monitor is required for the motor operation.

d Inspection on thyristor conduction: observe the display unit on the rectifier

panel to verify that lamp FAIL and lamp BLOCK should be off but lamp ON R+ Tshould be on.
3)

Annual Maintenance
The maintenance for the excitation equipment should be finished during the
annual minus overhaul of the unit when the whole unit is shut down.
a

Excitation Transformer
External inspection involves the inspections for contaminants and abnormal
noises. Note that the external should be cleaned with a piece of dry cloth or a
vacuum cleaner or compressed air (low pressure) but no solutions should be

Page 39 of 326

used.
b

Rectifier
b.a The rectifier fans should be inspected for the existence of contaminants
and abnormal noises. The abnormal fans should be exchanged because
no lube oil can be supplied into them. In addition, the cooling fans
installed in the fan casing should be exchanged after 24000 hours
operation.
b.b Inspections are needed for the air strainer installed in the vent gate of the
rectifier door. If too much dust has deposited on the strainer, the panel
ventilation and heat radiation would be affected, as a result, the strainer
should be cleaned or exchanged.
b.c Inspections should be conducted on the radiator for fouls which should
be cleaned with a brush, a vacuum cleaner or compressed air (low
pressure) but no solutions should be used.
b.d Inspect the current distribution of the parallel rectifiers. Several groups of
data should be sampled before this inspection for analytical purpose. If
the current distribution severely fluctuates, detailed inspections should
be conducted on the bridges with abnormally decreased or increased
current output.
b.e Inspect the conduction of the thyristor bridge. Each bridge should be
connected with a low resistor for the small current ring breaking test
during which the oscillograph should be used to observe if the D.C.
output waveform is regular and if the waveform can change stably during
the regulation.
b.f Check if the load disconnector on AC and DC side of rectifier bridge is
loosen or disconnected because of vibration or fatigue.

Inspections on Internal Circuit Breakers

The external inspections are used for checking for contaminants, sundries,
any other damages as well as how the contacts look. The electric circuit
breakers that are seldom operated should be operated time to time to avoid
blocking or lagging during a real operation. Also, inspections are necessary
for contamination and contacts charring/carbonization. All of the fouls should
be cleaned with compressed air and gentle brushing.
c.a Field Circuit Breaker
Inspect how the CB has been contaminated and charred. A brush or a
piece of dry cloth should be used to clean the CB and sand paper should
be used to erase the charred matters on the contact. Moreover, all of the
sliding surfaces should be wiped with the suitable lube oil. Then, the arc
shield should be inspected and the contaminants should be cleared with
compressed air.
c.b Circuit Breaker
Inspect how the CB has been contaminated and charred.
c.c Inspect and fasten all of the bolts, the bus connectors and the supports.
c.d Inspect the contamination of the insulator and fasten the bolts.
Requirement: the bolt connection should be inspected after 1 years

Page 40 of 326

operation. After that, inspection is required for every 4 years.

d

AVR
External Inspection
d.a

Inspections are needed to see if too much dust or some contaminants

have deposited on the circuit board and the contactor, and if oxidization
by overheating has occurred. In the normal ambient conditions, no
contaminant should exist on the printed circuit board. Otherwise, a brush
and vacuum cleaner should be used to clean it but no solutions should
be used.

d.b

Inspect the relay contacts and indicators

d.c

Inspect to see if the wires have loosened and if the insulator is damaged.

d.d

Perform the functional inspection on AVR in compliance with item

3.2.5.2.3.2 before unit shutdown.

d.e

Open Ring Test with Low -Current -system

Apply generator terminal analogue voltage to AVR PANEL and set AVR
to constant voltage operating mode. Connect a resistor R to Rectifier
Bridge and do open ring test with low current, observing regulation
performance of AVR and output waveform of the rectifier bridge.

1.7

Overhaul Reference Material

GB7064-86 General Technology Condition of Turbine Generator
GB/T1029-93 Test Method of Three Phase Synchronous Machine
Reference Material: Generator Operation Rules
QFSN-315-2-20B Generator Instruction by Dongfang Electric Corporation

1.8

Lists of Generator Spare Parts (Emergency Spare Parts)

Number

Equipment

Model
specification

and Unit

Quantity

Manufacturer

Generator

1.1

Generator
brush box

1.2

Generator
electric brush

Shanghai
morgan
or
German Suker

1.3

Generator
bearing bush

Dongfang
electrical

1.4

Stabilization

Remark
Based on
technical
agreement

Page 41 of 326

Dongfang
electrical

Dongfang

bearing bush

electrical

1.5

Out-going
bushing

1.6

Bearing
sealing
insulation
parts

1.7

Hydrogen
cooler

Dongfang
electrical
Deyang

1.8

Sealing parts
(including
rubber sealing
parts)

Dongfang
electrical
Deyang

1.9

Stator
insulation
water conduit

Dongfang
electrical
Deyang

1.10

Stator water
joint thermal
detection
components

1.11

Paddle
type
fan
blade
(each end)

1.12

Water
inner
cooling stator
insulation
detector

1.13

Protection ring

Excitation
system

2.1

Thyristor
components

2.2

Fast fuse

oil

Dongfang
electrical
Deyang

Dongfang
electrical
Deyang
China

18Mn18Cr

Japan/Germa
n
Based on
technical
agreement
Switzerland
ABB

Page 42 of 326

2.3

Dedicated
software

Set

2.4

Excitation
transformer
HV CT

2.5

Excitation
transformer
LV CT

2.6

Instruments,
buttons
and
indication
lamps (10% of
total amount,
at least one
each
specification)

2.7

24V Switch
power

2.8

Rectifier
cooling fan

German RS

2.9

Fast fuse

Xian

2.10

Control circuit
fuse (twice of
total amount
each
specification)

Set

Schneider

Transformer Maintenance Handbook

2.1

Equipment overview

2.1.1

#1#2 Main technology specification of main transformer

2.1.1.1

Basic parameters of main transformer #1#2

Main Transformer #1
Model

SFPZ10-370000/150TH

Page 43 of 326

Main Transformer #2
SFPZ10-370000/150TH

Rated capacity

370000/370000

Rated voltage

15081.25%/20

Rated frequency

50

Connection type

YNd1

Phase number

No-load current

0.248

0.200

No-load loss

172.49

164.69

Short circuit loss

698.11

699.52

Impedance voltage

13.93

13.96

Cooling mode

ODAF (Forced oil guide air cooling)

Cooler quantity
Weight
of
transformer

the 181.8

181.8

Oil weight

65

65

Total weight

293.3

293.3

Upper
weight

oil

Factory
number

tank 27

27

serial 200812127

200903016

Production date

No.21st, 2009

Mar.5th, 2009

KKS Code

10BAT01

20BAT01

Manufacturer
Shandong electrical equipment company

2.1.1.2

The value of voltage and current corresponds to the tapping

switch

High voltage

Low voltage

Page 44 of 326

2.1.2

Switch
position

Current

165000

1294.7

163125

1309.5

161250

1324.8

159375

1340.4

157500

1356.3

155625

1372.7

153750

1389.4

151875

1406.5

150000

1424.1

10

148125

1442.2

11

146250

1460.6

12

144375

1479.6

13

142500

1499.1

14

140625

1519.1

15

138750

1539.6

16

136875

1560.7

17

135000

1582.4

Voltage

Voltage

Current

20000

10681

Specification list of high voltage auxiliary transformer #1, #2

Equipment

UAT #1

Model

SFF10-40000/20TH

Rated capacity

40000/25000-25000

Rated voltage

2022.5%/6.3-6.3

Rated frequency

50

Phase number

Connection type

Dyn11-yn11

Page 45 of 326

UAT #2

No-load current

0.152

0.099

No-load loss

25.6

22.04

160.67

153.5

KW
Short circuit loss

Impedance
voltage

Highlow1+low2

High
91.6(118.9)
low2(low2)

89.7(115.4)

Low1-low2

164.3

157.3

High1-low2

6.88

6.92

High
16.16(16.05)
low1(low2)

16.11(16.29)

Low1-low2

37.11

38.88

Cooling mode

ONAF

No air capacity

28000

Weight of transformer

38.8

Oil weight

14.2

Total weight

63.1

Upper oil tank weight

5.5

Factory serial number

200811119

200903017

Production date

December 23rd 2008

Mar 5th 2009

KKS Code

10BBT01

20BBT01

Manufacturer

Shandong electrical equipment company

2.1.3

Main technical specifications of HV SST

2.1.3.1

Basic parameters of HV SST

Equipment

SST

Model

SFFZ10-40000/154TH

Rated capacity

40000/25000-25000

Rated voltage

15481.25%/6.3-6.3

Rated frequency

50

Page 46 of 326

Phase number

Connection type

Ynyno-yno+d

No-load current

0.135

No-load loss

30.254

KW
Short
loss

circuit

%
Impedance
voltage

Highlow1+low2

153.74

Highlow1(low2)

Low1-low2

Highlow1+low2

8.92

Highlow1(low2)

16.93(17.10)

Low1-low2

35.01

Cooling mode

ONAN/ONAF

Plate radiator group number

Transformer weight

39.0

Oil weight

33.4

Total weight

100

Upper oil tank weight

9.4

Factory serial number

200811122

Production number

Dec. 23rd. 2008

KKS Code

00BCT01

Manufacturer

Shandong electrical equipment company

2.1.3.2

The value of voltage and current corresponds to the tapping switch

High voltage
Switch
position

Voltage

169400

Page 47 of 326

167475

165550

163625

161700

159775

157850

155925

154000

10

152075

11

150150

12

148225

13

146300

14

144375

15

142450

16

140525

17

138600

Low voltage

Voltage

Current

6300-6300

2291.1-2291.1

2.1.4

Low voltage auxiliary dry type transformer (three phase epoxy molded type)

Equipment

Unit
transform
er

ESP
transform
er

Commo
n
transfor
mer

Water
treatment
and
chemical
transformer

Circulatio
n water
transform
er

Coal
handling
transform
er

Illuminati
on
transform
er

Quantity

KKS Code

10BFT01,

10BFT04,

1BHT01, 10BHT02 10BHT04

2BHT01, 20BHT02
20BHT04

10BHT03
,

10BFT
03, 20B

10BFT02,

Page 48 of 326

20BFT01,

10BFT05

20BFT02,

20BFT04,

20BHT03

20BFT05
Model

SCB9-2000/6.3

SCB9-2
500/6.3

SCB9-1600/
6.3

SCB9-630/6.3

Rated capacity

2000

2500

1600

630

10%

8%

4.5%

Rated current
Rated voltage

6.32x2.5%/0.4kV

Rated
frequency

50

Commection
type code

Dyn11

Short
circuit 8%
impedance
Load loss
No-load loss
No-load current
Short
time
frequency
withstand
voltage
Surge impact
withstand
voltage
Insulation level
Cooling mode

Natural cooling

Protection level
Neutral
point Direct earthing
operation mode
Temperature
rise limit
Intelligent
temperature

Page 49 of 326

FT03

and
humidity
controller
Manufacturer

2.2

Shunte electrical corporation

Maintenance Period And Items Of Main Transformer And High Voltage Auxiliary
Transformer

2.2.1

Maintenance period

2.2.1.1

Overhaul period
1 After the transformer was put into operation, within 5 years, we should suspend
the shell (or transformer proper) for check or overhaul. This is because after a period
of operation, the shrink of insulating pieces and loosen of fasteners will forms some
defects that needs check and overhaul in time. Later, the check and overhaul period
like this type can been 10year. Because the transformer will have further insulation
aging, shrink and loosen, especially the transformer will suffer the shock of overvoltage and over-current for many times.
2 If the abnormal phenomenon was found in the transformer during normal
operation or the internal failure was confirmed through test, we should carry out the
overhaul ahead of schedule.
3 When the transformer bears outlet short-circuit, we should consider overhauling it
ahead of schedule.

2.2.1.2

Repair period
1

Carry out repair work one time a year

2.2.2

Maintenance items

2.2.2.1

Overhaul items
1

The test items before overhaul and analysis of transformer oil.

Suspend the core and shield to check the transformer proper.

maintenance of winding, down lead and on-load (no-load) tap changer

4 Maintenance of iron core, core bolts, and yoke frame, cross bolt and grounding
blade.
5 Maintenance of oil tank and accessories, including: sleeve, oil tank9including
silicon rubber vesicle and diaphragm) pressure release valve, and absorber etc.
6 Replace the entire sealing silica rubber layer and test the leakage of the
configuration.
7 Check and test of gas relay, protect devices, temperature measuring elements
and operation control panel.
8 Maintenance of cooler, oil pump, motor of fan, oil flow relay, valves, pipes, oil
purifier.

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Dry the insulation of transformer proper

10 Deposal of transformer oil and change the oil.

11 cleans the shell; besmear the anti-rusting paint.
12 test and trial running after overhaul.
2.2.2.2

Repair items.
1

Check and eliminate the defects witch was found in checks.

Check and tight the tie-in bolts of sleeve outlet line

3 Discharge the oil mire in the dirt collector of oil tank, check the oil level gauge,
and add oil to sleeve, transformer proper and on-load tap changer if necessary.
4

Check the entire sealing rubber pad, dispose the oil leakage.

Maintenance of cooler, oil tank, absorber and pressure release valve.

6 Check and replace of sleeve sealing and the top connecting cap. Check and
clean of porcelain.
7 Maintenance and test of various protective devices, measuring devices and
operation control panel.
8

Checks of oil valves and oil piston.

Maintenance and operation test of on-load (no-load) tap changer.

10 check the grounding system, detect shield lines of HV sleeve.

11 clean and maintenance of oil tank and its accessories,
12 carries out the measuring and test according to regulations.
2.2.3

Preparations before maintenance of transformer.

2.2.3.1

Read the technical files.

1 read the operation record of transformer, understand the failure and abnormal
during operation, especially the times and condition for transformer suffer from overvoltage and short-circuit; the load changing condition, temperature changing and the
operation condition of auxiliary equipment during transformer operation.
2Read the former maintenance report of the transformer, to understand the failure
parts, condition, disposals and efficiency, and the remained failure after former
maintenance.

2.2.3.2

Compile the overhaul engineering technical, organize the measures and plan.
1Organization of personnel and work dividing.
2Verify the maintenance items and establish construction schedule.
3 The construction precept of special items, the technical measures to insure the
safety and quality of construction, fireproofing measures on site.
4List of main construct tools, equipments and main material.
5Draw the necessary construction sketch and blue print.
6 Prepare the technical record forms, ascertain the drawings of spare parts which
should be draw and check.
7Prepare the material for overhaul.

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2.2.3.3

Take out the safety measures

1 Power off of equipments, and the nearby electrophorus equipments should be
marked with balustrade, red-white strip and warning plate. We should apprize the
electrophorus equipments to every staff.
2 Personnel safety of the working staff, including safety helmet, preventing sliding
and falling when working in a high place, preventing the substance that falling. Check
the safety appliances such as ladder, ropes and hoist equipments.
3 Supervision of visible fire operation, arrangement and check of the firefight
measures on the site.
4Security works on the site, assign some one to guard the site.

2.2.3.4

Checks of transformer before maintenance

1) The external check before maintenance. The purpose is to find the defects which
was not be found in operation monitor, and was be found during the transformer
carries voltage or load(the positions which can not be check during the transformer
carries on the voltage should be checked). Furthermore, we should check wither
there is arc-discharge trace on sleeve surface and wither there is damage situation on
porcelain sleeve; check wither the connection of electric contactor and bus-bar is
reliable or not, wither there is overheat and color change phenomenons exists; check
the sealing condition of every connection part, record the positions of seeping and
leakage point.
2) Carry out the preventive test before maintenance. The purpose is to know the
insulation conditions before maintenance, the contact (including the position of taps)
conditions of every contactor, the electric connection conditions of windings, and to
provide the data which should be gripped and the maintenance measures and
methods which should be carried out during maintenance.

2.2.4

Maintenance contents of transformer

2.2.4.1

Disassemble, hoist, transportation and assemble of transformer.

2.2.4.1.1

Disassemble maintenance and assemble sequence.

1 Transact and complete the power cut work procedure, carry out the electric test
before maintenance, carry out the comprehensive external appearance check, and
make a record.
2 dismantle the down lead and secondary circuit of transformer, dismantle sleeve,
rising seat, oil tank, cooler(including sub-emerged oil pump and fan), oil purifier, antiexplosion device, joining pipe, thermometer and gas relay after discharge the oil, set,
check and repair them respectively. Check whether the oil gauge is correct or not
when discharge the oil from oil tank. Seal the holes after dismantle the components to
avoid the dust and damp get in.
3 Discharge and filtrate the transformer oil.
4 Operation of dismantle no-load tap changer (coping of on-load tap changer),
hang the transformer proper after dismantle the bigger cover.
5 check the situation of transformer proper, hang the transformer proper after

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dismantle the bigger cover.

6 Clean and maintain iron core, winding and box shell.
7 Assemble the transformer proper, change the sealing rubber layer, maintain the
oil valve, vacuum oiling after tighten the bolts.
8 Assemble the auxiliary equipments such as cooler
9 Assemble the sleeve and internal down lead
10) Fills the transformer oil to the specified oil level
11) Leakage of oil pressure
12) Test after overhaul
2.2.4.1.2

Notes during dismantle and assemble

1) We should clean the dismantled bolts and accessories (besides the blots in the oil
tank); if we found any damage we should repair or replace it. And then keep carefully
and avoid been get lost.
2) We should dismantle the small instruments and sleeve first and then dismantle
the large iron equipments, and follow the contrary sequence to assemble.
3) We should seal the dismantled components such as cooler, anti-explosion
devices, oil purifier and oil tank; we should fill the rising seat with current with eligible
transformer oil.
4) Keep the easy damaged components (sleeve, oil gauge, thermometer) carefully
after dismantle to avoid Benn damage, we should keep the bushing vertically, and
wrap it with new plastic cloth to avoid the damp and dust.
5)

We should check the oil valve position of cooler, oil purifier and gas relay.

6) Discharge the air from the air vent on the sleeve rising seat, upper hole cover,
cooler and oil purifier top.
7) When we dismantle the operation rod of no-load tap changer, we should
remember the position of tap changer and make a mark, we should put the on-load
tap changer into settled position.
8)

Do the on site recording work carefully.

We should guarantee the guarantee of transformer accessories after assemble, and

should equip the absent accessories during the overhaul.
2.2.4.1.3

Hoist
1 We should dismantle the components which was connected to the transformer
and will affect the hoist.
2 Choose the suitable hoist tools, steel line harness and the hoist ring according to
the weight of transformer.
3) We should suspend the steel line on the hoist device of transformer, when we
start to strengthen the steel line we should recheck the suspend and colligate
conditions, after confirm we can continue to hoist.
4) When we suspend the transformer proper, the angle between lines should not
bigger than 600, otherwise the special sleeve and adjusting rope should be used to

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maintain the balance the transformer proper. The transformer proper can not hit the
box wall during hoist.
5)

we should tie the rope on the four corners and support it to maintain the balance.

6) The rise and fall speed can not be too fast during hoist, and we should master the
barycenter to avoid incline.
7) When we set the transformer, we should choose the location first, put the layers
and then set down the transformer slowly.
8) When we revert the transformer, we should cover the seal rubber layer on the box
edge and fix it with Ushape clip.
9) When we revert the transformer, we should point the transformer proper at the
position, and set down the transformer slowly, pay attentions to the distance between
transformer proper and box wall to avoid damage.
10) When the transformer proper approached the box edge, we should align the bolt
holes, screw the bolts and take out U type clamp, preventing the deformation of
sealing gaskets, when the transformer proper at its proper position we can tighten the
bolts symmetrically and evenly.
11) When we hang and assemble the bushing, its gradient should be equals to the
obliquity of bushing flange and oil tank flange, and tie it up with rope to avoid hit and
overturn.
12) The hoist work should be divided unambiguous, and sent someone to send
command, and have the uniform signal.
13) When the auto car crane was adopted, we should pay attention to the promote
angle of crane arm, the distance between gyre angle and the nearby electrified
equipments during hoist, sent someone to supervise is necessary.
14) During check process, we should not keep the transformer proper in the air for a
long time, and we should put the transformer proper reposefully during check.
15We should not put the transformer core in the air for a long time, otherwise the
vacuum zing damp proofing measures should be taken.
2.2.4.2

The maintenance technique and quality requirements of transformer proper.

2.2.4.2.1

Maintenance of transformer proper.

1 We should check the completion of transformer proper comprehensively, and to
check whether there is defects(for example overheat, arc trace, loosen, deformation
of windings, and color change of switch taps) exists, find out the reason of abnormal
conditions and carry out the maintenance work, and make record at the same time.
2 The time of transformer proper in the air(from oil extraction to oil inject):when
relative humidity65%16hours, when relative humidity75%12hours,if the
temperature of transformer proper is lower than ambient temperature, we should
heats the transformer, generally the temperature is 1010 higher.
3 When we carry out the transformer proper check, the site should be clean and
should have dust proofing measures.
4We should send someone to carry out the check, and can not carries the things

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which has no relationship with the work, and should wear the special clothes and soft
bottom shoe, and wears the clean gloves, to touch the winding and insulation layers
with hands is not allowed.
5We should maintain the cleanness of oil tank bottom, and there should not have
impurities.
6 For the forced oil cooling windings, we should check the on the lower clamp,
whether the connection is reliable or not, whether the sealing is good or not, whether
the outlet line position on the insulation panel is sealed or not.
2.2.4.2.2

Maintenance of the winding.

1 We should check the interphone insulation layers and enclose screen, to check
whether there is broken, color change, deformation and arc-discharge trace, if the
abnormal phenomenon was found, we should take the relevant measures.
2To check whether the winding surface is clean or not, and whether there is some
damage on the turn insulation or not..
3 To check whether the displacement and loosen phenomenon of winding pad is
exists or not.
4To check whether the winding oil duct was blocked by oil dirt or other substance or
not, clean it by soft brush(calico or foam) if necessary.
5 Press the winding surface by fingers, to check the insulation conditions of the
winding, to check whether there is depressed and loosen phenomenon exists on the
winding.

2.2.4.2.3

Maintenance of iron core.

1to check the surface of iron core is flat or nor, whether there is inter-slices shortcircuit or color change, and arc-discharge burnt traces, and loosen phenomenon
exists, whether there is accumulated oil dirt on the top of upper iron yoke and the
bottom of lower iron yoke. We can use calico or foam to clean it. If the segments has
cocked or unregulated parts, we can beat it by a wooden or copper hammer.
2Check the tightness and insulation conditions of iron core, upper and lower clamp,
square iron, winding end finger(including pressed iron)
3 Check the oil duct across the iron core and clamp. The oil duct should be
unblocked, the pad of oil duct should not have off and blocked phenomenon.
4Check the contact and insulating conditions of iron core grounding patch.

2.2.4.2.4

Maintenance of down lead.

1 Check the insulation tie condition of down lead and leading cone, to check
whether there is deformation, frangibility, broken, phenomenon, and whether the wire
of down lead was broken, the weld on down lead and down lead contactor is good or
not, and whether there is some overheat phenomenon.
2 Check the down lead from winding to tap changer, check the length, and
thickness of the insulation colligation, whether the weld on the tap of leading line is
good or not, whether there is overt phenomenon exists. Whether the insulation
distance from down lead to every part and fix conditions of down lead meets the

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requirements or not.
3 To check whether the insulation frame has loosen, crack and displacement, and
check the fix condition of down lead on the insulation frame.
4 Check the insulation distance between down lead and every parts.
5 Check whether the seal of sleeve cap is good or not, and check whether the
connection between sleeve and down lead is fixed or not.
2.2.4.2.5

Maintenance of oil tank and transformer proper.

1Check the cleanness inside of oil tank.
2Clean the forced oil pipes, and check the sealing conditions of forced oil pipes.
3)Check the rising seat of sleeve, generally we set a air release valve on the top of
rising seat, and for the big current sleeve, in order to avoid the vortex flow heating, we
should take the magnetism- obstruct measures between three phase..
4)the box edge of oil tank (bell glass)cover should maintain balance, the welding line
on the taps should be planish by grinding wheel to avoid concave and protruding, and
weld the round steel and square iron on the internal side on box edge to avoid the
displacement of rubber pad.
5)Check the localizing bolts.
6)Check the magnetism-obstruct and shield devices.
7)Check the intension and pressurize capability of oil tank.
8)Check the outside of oil tank and big cover, clean the rust (especially in the welding
line)if the sand hole and leakage we should mend it, and repaint the lacquer.

2.2.4.3

Maintenance technique and quality requirements of transformer accessories.

2.2.4.3.1

Maintenance of cooling devices.

A

Maintenance of common cooler(radiator).

1Clean the surface of cooler(radiator)

2 Seal the pipe tap flange with cover board, increase the pressure and test the
leakage. For the flat pipe 0.10.15Mpa10 hours.
3Cycle wash the inside of transformer with eligible transformer oil, we should use
hot oil.
4After discharged all the oil out we can install a pad for sealing.
B

Maintenance of Yf type forced oil air cooler.

1Use hot oil to wash. Leakage test: 0.250.28Mpa30 minutes.

2Clean the surface of cooler, and use compressed air(or hydraulic pressure)
0.1Mpa pressure to blow the ash, sand, gnat and grass between units.

of

3Replace the gasket of every part, maintain the butterfly valve. And get ready for
general assemble.
4 Clean the oil dirt and rust on the cooling oil pipe two sides, paint the anti-rust
lacquer and anti-corrosion surface lacquer.
C

Maintenance of oil soaking sleeve.

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1Check and clean the porcelain external.

2When we disassemble the sleeve, we should screw off the flange bolts one by one
to avoid the damage of porcelain caused by uneven force.
3Before we dismantle the sleeve, we should shake the sleeve slowly to check the
loosen conditions of sleeve.
4 Before we dismantle the guiding rod and flange bolts, we should avoid the rod
from shake to avoid the damage of porcelain.
5 To hoist the large sized sleeve we should pay attention to hang rope and hoist
angle.
6Clean the oil dirt and check the internal side of porcelain sheath.
7During assemble process, we should put the rubber gasket on position.
2.2.4.3.2

2.2.4.3.3

Maintenance of sleeve type current transformer.

1)

To check whether the indicator of down lead is complete or not.

2)

Replace the seal rubber gasket of down lead post.

3)

Carry out the volt-ampere capability test.

4)

Measuring the insulation resistance of winding.

5)

Measuring the DC resistance of winding.

Maintenance of tap changer.

1)

To check whether the components of switch is complete or not.

2) Screw off the localizing bolts on the upper part, turn the operation handle, to
check whether the dynamic contactor is flexible or not, whether the indicating position
of upper part is consistent or not.
3) To check whether the dynamic and static contactor are contacted well or not,
whether the condition of contactor surface is good or not.
4) To check whether the contactor tapping line is tighten or not, and whether the line
was loosen or not.
5)

To check whether the condition of tap changer insulating pieces is good or not.

6) Before and after dismantle and assemble the indicating position should be
consistent we can not cross-over the three phase handle and operation mechanism.
7) Check whether the contact of insulation operation rod U shape stick is good or
not.
8) If we found the switch insulation was affected with damp or was uncovered in the
air with a long time, we should dry it.
2.2.4.3.4

Maintenance of on-loading taps changer

1) Check and maintain the switch-over breaker according to the stipulated time
clearances.
2) During maintenance, the switch-over breaker proper can not be uncovered in the
air more than 10 hours, and the relative humidity can not be higher than 65%,
otherwise we should dry it.

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3)

Sample the oil for assay, if the oil is unqualified we should change it.

4)

Hang out the switch-over beaker and clean it

5) Check whether the fasteners of breaker is loosen or not, whether the main spring
and restore spring claw and clip of fast speed mechanism is deformed or ruptured or
not, whether there is some damage on intertexture soft connection of every contactor,
the burnt degree dynamic and static contactor, whether the transition resistance flat
line was broken and its resistance value is consistent with the nameplate or not,
measuring the transformer program of relative contact resistance and dynamic and
static contactor.
6)
2.2.4.3.5

Reassemble and fill the oil.

Rubber chamber type oil tank

1)

Discharge the oil in the oil tank and clean the inside of oil tank.

2)

Check the seal capacity of rubber chamber

3) Rub-up the external wall of rubber chamber with clean cloth, put the rubber
chamber into the oil tank from man hole.
4) Hang the rubber chamber on the hooks by nylon rope, connect the out leading
hole, and then tighten the man hole flange.
2.2.4.3.6

Maintenance of absorber.
1) Pour out the inside moisture absorption substance, and check the separating
cover is complete, and clean it.

2.2.4.3.7

2)

Fill the dry moisture absorber in

3)

Replace the rubber gasket

4)

Fill the oil to a proper level, and make the oil form a oil film.

Maintenance of oil purifier.

1) Pour out the silica gel(active alumina),use the clean transformer oil to clean the
internal side of oil purifier and connecting tube.
2 Check the accessories are complete and clean them, check whether the lower
filter was blocked, after cleaned it change the rubber gasket, reassemble the lower
cover board and filter, seal is complete.

2.2.4.3.8

2.2.4.3.9

Maintenance of pressure release

1)

Clean and replace the seal gasket.

2)

Upper explosion film should be complete and do not have crack.

Check of gas relay.

1) external check, check whether the vessel, glass twineow, gas release valve, oil
discharge stopper, and connection terminal box, small sleeve is complete or not, the
arrow indicator on the connection terminal and cover board is correct or not whether
there is oil leakage on the connection points.

2.2.4.3.10

2)

Clean it

3)

Check the action, insulation and flow speed are eligible.

Maintenance of butterfly valve, oil valve and stopper.

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1) Check the completion, flexible and sealing of rotary shaft, damper, replace the
seal gasket.
2) The oil valve should be dismantled and be maintained disassembly, skive and
replace the seal gland.
3) Carry out the comprehensive check to the air(oil) discharge valve and replace the
seal gasket.
2.2.4.3.11

Dismantle and maintenance of cooling fan and motor

A

Repair the cooling fan

1) To check whether the rotation of the fan is agile or not, whether the fan shield is
be scraped or not.
2)

To checks whether there is loosen phenomenon exists on connection terminals.

3)

Clean the external shell

4)

Fill the lithium lubricating grease to bearing chamber.

5)

Check whether the fasten bolts was loosen or not.

6)

Measuring the insulation resistance of stator winding.

Disassemble maintenance of cooling fan

1) Open the stopping gasket, screw off the cover type nuts, drop out the stopping
gasket. Use the special tools(triangle claw) to remove the blade impeller from the
shaft, and remove the key and wimble sheath and keep them at the same time.
2) Check the riveting conditions between blade impeller and wheel hub, If the
riveting was loosen we can use a iron hammer to rivet it.
3) Put the blade impeller on a flat, to check the install angle of blades should be
consistent, otherwise we should regulate it.
4) Dismantle the motor shield, and screw off the fixing bolts on the rear end shield,
take out the rear end shield.
5) To check whether there is some damage on the rear end shield, clean the
lubricating grease in the bearing chamber, to measuring the bearing chamber with
inner diameter caliper micrometer is bigger 0.025mm(diameter), if the corrosion is too
serious we should replace it with a new one.
2.2.4.4

The general assemble and filling of transformer.

2.2.4.4.1

General assemble
1) Before assemble, we should clean the radiator(cooler), oil storage tank, antiexplosion devices(safety air duct), oil pipe, rising seat without CT, sleeve and all the
parts and components and configurations, use the eligible transformer oil to wash the
parts and components and configurations which directly contacted with transformer.
And we should clean the auxiliary oil and water pipe lines of transformer, and make
the record.
2) Before we assemble the last section oil storage tank , we should clean the water
pipeline should be cleaned, and make record.
3)

For the parts and components with install indicator, we should assemble it

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according to the position described in install specification.

4)

We can not draw, wrest and bend the transformer download root.

5) Before we assemble the sleeve we must check whether the non-excitation tap
changer connection rod is inserted in the shaft of tap charger.
6) When we assemble the configurations, we should do it according to the
installation and use specification of manufacturer.
7) We should localize and seal the upper localization parts of oil tank top according
to the external dimension and technical specification.
8) We should replace all the seal gaskets with new one, the dimension meets the
requirements, and when it bearings the forces the compression is even, the
compression volume should better be 2/3.
9)

The vacuum oil injection technique should be use for filling the transformer.

10) Does not vacuumize the oil storage tank.

2.2.4.4.2

Vacuumize the cooler with the main body at the same time.
1) Increase the vacuum degree evenly in one hour, when it reaches to 8 104Pa,
maintain it for one hour, if no abnormal conditions was found, and then increase the
vacuum degree to 9.75104Pa gradually, and maintain it for one hour, check whether
the oil tank has deformation and abnormal conditions or not. If no abnormal
conditions were found, we can inject oil to the transformer under vacuum condition,
the oil should be degassed and dehydrated through vacuum oil filter, the oil filter and
the pipelines should be sealed. When we injecting oil to the transformer we should
maintain the vacuum degree at 9.751046.7102Pa, when the oil level reaches to
200mm of top cover, we stop to inject oil to the transformer, if the oil injecting time is
longer than 6hours, maintain this vacuum degree 6 hours, and the vacuum can be
broken.
2) Open the air release valve at the top of the oil storage tank, inject oil from the
oiling pipe of oil storage tank until the oil is overflowed from the air release valve, and
tighten the air release valve, then discharge the oil from oiling pipe, and make the oil
level a little bit higher than requested level, and then install the absorber.
3) From the end of secondary oil injection, we can put the transformer for 24 hours,
during this period, we should release the air a several times(and start up the oil
submerged pump), to check whether there is oil leakage and the oil level decrease
phenomenon.

2.3

Maintenance of Dry Type Transformer

2.3.1

Maintenance period and maintenance items.

2.3.1.1

Maintenance period of dry type transformer

2.3.1.1.1

Maintenance period of dry type transformer is along with the overhaul and repair
period of unit.

2.3.1.1.2

Every 6 months check the dry type transformer once.

2.3.1.2

Check items.

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1)

Installation conditions of transformer.

2)

Integrality of transformer shell.

3)

Check whether the ambience is suitable for operation or not.

4)

Check of transformer ventilation conditions and temperature detector.

5)

Whether the overheat phenomenon is exists on transformer.

6)

Supporting condition of transformer down lead

7)

Connection conditions of transformer parts.

8)

Conditions of sleeve and connecting board.

9)

Connection conditions of winding cover board and mat board.

10) Grounding conditions of transformer.

11) Measure the insulation resistance of winding.
12) To check whether the color of winding insulation was changed and whether there
is cracks on the winding insulation.
2.3.1.3

Maintenance item of dry type transformer.

1)

Clean the dust, dirt and moisture inside and outside of transformer.

2)

Replace and repair the easy damaged accessories.

3)

Including all the contents of check items.

4)

Carry out the electric preventive test according to period.

2.3.2

Preparations before maintenance.

2.3.2.1

Look through the technical datum.

1) Look through the operation record of transformer, know the defects and abnormal
conditions which was found during operation, especially the number and conditions
that the transformer was affected(impacted)by over voltage and short-circuit.; the load
change condition of transformer during operation, temperature rise and the operation
conditions of auxiliary parts.
2) Look through the sum-up report of all the previous maintenances, know the
defects position, condition, disposals and validity of all the previous maintenances,
and the remains defects after the last maintenance.

2.3.2.2

Compile the maintenance engineering technical, organization and measure plan.

1)

Organization of personnel and work dividing.

2)

Confirm the maintenance items and compile the construction schedule.

3) Compile the technical measures which can insure the construction safety and
quality. And the firefighting measures on site.
4)

List of main construction tools and equipments, list of main material.

5)

Draw the necessary construction sketch and blue print.

6) Prepare the technical record forms, ascertain the drawings of spare parts which
should be draw and check.
7)
2.3.2.3

Prepare the material for maintenance

Take out the safety measures

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1) Power off of equipments, and the nearby electriferous equipments should be

marked with balustrade, red-white strip and warning plate. We should apprize the
electriferous equipments to every staff.
2) Personnel safety of the working staff, including safety helmet, preventing sliding
and falling when working in a high place, preventing the substance that falling. Check
the safety appliances such as ladder, ropes and hoist equipments.
3)
2.3.2.3

Security works on the site, assign some one to guard the site.

Checks before maintenance

1) Whether the transformer was installed completely, whether there is deflection,
partial deformation and oscillation phenomenon exists.
2) Whether the shell of transformer was clean, whether the connection was loosen,
is there any damage on the box shell.
3) Whether the ambience of transformer was clean, whether there is water, water
leakage from the top and the other substances which will affect the safe operation.
4) Check the ventilation device in the power distribution room, it can ventilate
normally.
5) Whether there is partial overheat phenomenon, for example whether the color of
temperature measuring segment was changed, whether the temperature of every part
was normal, whether the temperature exceeds the rated value.
6)Whether the down lead of transformer is reliable, whether its position is normal,
whether the insulation distance surrounded the down lead was changed.
7)

Whether the bolts of transformer was loosen, whether there is abnormal sound.

8Is there any loosen and partial overheat phenomenon on the electric connection
part of sleeve and connection board, is there any broken part on the porcelain, and
then clean the dust and dirt on the ferrule.
9) Whether the cover board of winding is pressed tightly on the winding, is there any
loosen phenomenon on the mat pad.
10) Whether the transformer was grounded reliably.
11) measuring the insulation resistance of winding.
12) There is no holes and gaps that an let the small animals in and do some harm to
the transformer.
2.3.3

Quality requirements of maintenance.

2.3.3.1

Carry out the maintenance according to the check contents before maintenance

2.3.3.2

We should clean the dismantled bolts and accessories by clean agent, repair and
replace it if any damages were found, and then keep it properly to avoid get lost and
damage.

2.3.3.3

Dismantle the small instruments and sleeves first and then dismantle the big iron
parts, during dismantle, and the sequence of assemble is contrary.

2.3.3.4

Check the integrality of transformer proper, whether there is any defects(for example
overheat, arc trace, loosen, deformation on winding, the color of tap was changed)

Page 62 of 326

exists. Check the reason and maintain the abnormal conditions, make record at the
same time.
2.3.3.5

Check the interphase isolating board and surround screen, to check whether there is
broken, color change, deformation and arc-discharge phenomenon, if any abnormal
was found, we should take the relevant measures.

2.3.3.6

Whether the winding surface is clean, is there any damage on the insulation.

2.3.3.7

Check whether there is any displacement or loosen phenomenon on the winding pad.

2.3.3.8

To check whether the ventilation duct of winding was blocked by oil dirt or the other
substance, if necessary we can use soft brush(calico or foam) to clean it.

2.3.3.9

To check the surface of iron core is flat or nor, whether there is interslices short-circuit
or color change, and arc-discharge burnt traces, and loosen phenomenon exists,
whether there is accumulated oil dirt on the top of upper iron yoke and the bottom of
lower iron yoke. We can use calico or foam to clean it. If the segments has cocked or
unregulated parts, we can beat it by a wooden or copper hammer.

2.3.3.10

Check the tightness and insulation conditions of iron core, upper and lower clamp,
square iron, winding end finger(including pressed iron)

2.3.3.11

checks the air duct across the iron core and clamp. The pad of air duct should not
have off and blocked phenomenon.

2.3.3.12

Checks the contact and insulating conditions of iron core grounding patch.

2.3.3.13

check the insulation tie condition of down lead and, to check whether there is
deformation, frangibility, broken, phenomenon, and whether the wire of down lead
was broken, the weld on down lead and down lead contactor is good or not, and
whether there is some overheat phenomenon.

2.3.3.14

To check whether the down lead was connected well, is there any overheat
phenomenon. Whether the insulation distance from down to every part and the fix
condition of down lead meets the requirements.

2.3.3.15

To check whether the insulation frame has loosen, crack and displacement, and
check the fix condition of down lead on the insulation frame.

2.3.3.16

Checks the insulation distance between down lead and every parts.

2.3.3.17

Use the electric blower or compressed air to blow the inside and outside or
transformer until there is no dust blow out; the flow speed of air can not be too fast to
avoid to blow the condensate to transformer. We can use clean agent to clean the
naked part of down leads, sleeve, connection board, and shell.

2.3.3.18

Replaces or repairs the easy damaged components, for example insulator,

connection board and connecting wires.

2.3.3.19

Electric preventive test.

2.4

Handover and Acceptance after Transformer Overhaul.

After the overhaul of transformer was finished, we should clean up the site, tidy up the
record, datum and drawings, count and give back the remained material, check and

Page 63 of 326

calculate and hand over the finish and acceptance report, and invite the relevant
departments to organize relevant unit, maintenance department, HV test, oil assay,
relay protection, operation and measure units to accept the site.
2.4.1

Offer the relevant datum for acceptance.

2.4.1.1

Maintenance record.
Check items

Techinic requirements

Hang
the
(1)the time for transformer
shield(core)
proper uncovered in the air:
and check
when the 65, is 16 hours,
when the relative humidity
is lower than 75 ,
is12hours

Disposals

Checke
d by

Environment for hang the

shield(core),
weather
inside and outside of door.
Temperature
transformer proper

of

Ambient temperature:

(2) The environment should

be good, otherwise the relative humidity is
protect measures should be
take out.
start to eject the oil: day
hour minutes
start to inject the oil: day
hour minutes
(1) There is no deformation,
slope, displacements of Results of check
winding,
no
radiation
conductor sringing out; no
damage
of
interturn
insulation.
(2)
The
interphase
clapboard is complete.
(3) The surround screen is
pressed tightly, clean and
have
no
arc-discharge
trace.
(4)
There
is
no
displacement and loosen
phenomenon of bushes,
and arranged in order.
(5) The oil
duct
is
unblocked by oil dirt and
the other sundries.
(6) No loosen of impact

Page 64 of 326

mechanism.
(7) No heating and off weld
phenomenon of conductor
taps.
(8) The surface is clean and
without oil dirt.
Down lead

(1) The downleads were

arranged in order
(2) There is no broken of
multidown lead.
(3) The downlead taps are
welded well, the surface is
smooth and clean and
without burrs
(4) We should change the
tin weld of cross cable fetch
tap and down lead into
phosphor braze or silver
welding
(5) The connection between
down lead and sleeve
conductive rod is fixed.
(6) The outside package
insulation thickness meets
the requirements, and the
tie is good, there is no
deformation, off, brittleness
(7) Mat the insulation paper
board on the fixed position
of down lead and insulation
frame, there is no damage
of downlead insulation
(8) The distance between
downlead and the distance
between downlead and
ground
meets
the
requirements.
(9) The surface is clean
(10) The calico tie of cross
cable downlead inside of
sleeve part of is complete.

Page 65 of 326

Insulation
frame

(1) The insulation frame

has enough mechanism
rigidity
(2) There is no damage,
crack, bend, deformation
and burnt trace, otherwise it
should be replaced.
(3) The fasten bolts of
insulation frame is fixed,
and have locknuts.
(4) The surface is clean

Iron core and (1) The iron core surface is

clamp
flat and do not have cocked
segments, and no serious
wavilness

Insulation resistance M
Insulation resistance M
Insulation resistance M

(2)There
is
no
inter- Insulation resistance M
segments
short
circuit,
Insulation resistance M
heat, and no color change
Insulation resistance M
and burnt trace.
(3) The insulation lacquer
does not fall off
(4)Insulation to ground is
perfect, 200M under
normal temperature.
(5) Insulation between iron
core and square iron
(6) Insulation between iron
core and clamp
(7) Insulation between iron
core and drawstring
(8) Insulation between iron
core and core bolt.
(9) The oil duct of iron core
and clamp was unblocked,
the oil duct pad is in good
order.
(10) The insulation of iron
core and the positioning pin
is perfect.
(11) The matted wood of
iron core feet was fixed and

Page 66 of 326

have no loosen.
(12) There is no heating
trace
on
grounding
segments, and was fixed
good.
(13) Grounding of iron core
electric field shield out
going line is perfect
(14) The iron core surface is
clean, without oil dirt and
sundries.
Cover board (1) The cover board does
and cross bolt not
have
serious
eccentricity
(2) The insulation of steel
cover board and cross bolt
is good, and was been well
connected with clamp by
grounding segment.
(3) The cross bolt and
metal seat is tighten and
without suspend.
(4) The lock bolt of cross
bolt is tighten.
Non-excitation
tap changer,

(1) The insulation canister

and protection board is
complete and has no burnt
trace.
(2) There is no heat and
burnt trace on dynamic and
stationary contactor, and
the connection is good, the
contact resistance is less
than 500(every phase,
every position)
(3) The connection of metal
rotary shaft in the breaker
and the metal rod of
operation rod is good and
without
suspend,
if
necessary we can add a
spring patch.

Page 67 of 326

(4) The breaker is fixed

well.
(5) Indication of breaker
position is correct(can be
regulated
according
to
manufacturers
specification)
Switch-over
the switch

(1) Pressure measuring of

contactors.
(2) The burnt value of every
contactor can not be bigger
than 3mm, otherwise we
should
replace
the
contactor.

Burnt value of contactor

mm
Switch-over time ms
bridge connect time ms
Three phase synchronize
error ms

(3) The action sequence transition resistance value

meets the specification of
manufacturer, use the DC
wave indication method to
measuring the switch-over
time.
The bridge connect time of
arc contactor is 35ms
Three phase synchronize
error can not be longer than
3ms
(4) There is no broken and
damage
on
transition
resistance. measuring the
resistance value is less
than10
(5) There is no oil leakage
between
breaker
oil
chamber and transformer
proper.
(6) Fill the eligible oil into oil
chamber after maintenance
(7) The contact resistance
of every pair of contactor is
less than500
Commutator
(1) There is no burnt and
and
select heat trace on dynamic and
switch
stationary contactor, and

Page 68 of 326

the contact is good.

(2) The cation of rotating
parts is agile.
(3) There is no damage and
deformation
or
arcdischarge
trace
on
insulation frame.
(4) Connected well with
tapping down-lead, the
bolts are tighten and have
locknuts.
(5) The distance between
contactor ,electric part and
tapping downlead meets
the requirements.
(6) The connection is good.
Commutator
(1) There is no deformation
and
select and broken of main spring,
switch
restoration spring and paw.
(2) The
tighten.

locknuts

are

(3) There is no serious

wear, scrape, damage and
block on action part.
Fast
mechanism

(1) The mechanism rotary

part is agile, the gear box is
sealed
well.
and
the
lubricating
grease
is
enough.
(2) The connection of
electric circuit is correct and
no loosens.
(3) There is no serious rust
corrosion on the contactor
of relay.
(4) The position indication
is correct.
(5) The action of electric
sequence switch, position
limit
switch,
and
mechanism position limit is

Page 69 of 326

reliable.
(6) The seal of box is good.
(7) The insulation of control
circuit is good.
Commissionin (1) The action cycle meets
g
after the
specification
of
assemble.
manufacturer.
(2) The measured DC
resistance of transformer
three phase positions meets
the standard.
Oil
tank(including
sleeve
and
rising seat)

(1) Inside of oil tank should

be clean without rust
corrosion, orts and oil dirt,
the lacquer film should be
complete.
(2) Clean the sundries in
the forced oil cooling pipes,
and seal it, there is no
leakage of forced oil cooling
pipes
(3)The
magnetic(electric)shield
devices was fixed reliable,
there is no loosen and
overheat phenomenon, and
been grounded well.
(4) The box wedge is
smooth without protruding
and concave, there is block
cycle on the inside of box
wedge to preventing the
rubber
pad
from
displacement.
(5) The rigidity of oil tank is
enough, and the seal is
good, if the leakage was
found we should mend it
and repaint the lacquer.
(6) Replace all the seal
rubber bushings.
(7) Withdraw the insulation

Page 70 of 326

of iron core positioning bolt

on the box wall or on the
top and the iron core.
(8) The lacquer film outside
of oil tank was painted
evenly,
nacreous
and
without lacquer knurl.
(9) The outgoing grounding
sleeve of iron core(clamp)is
complete.
Oil
tank.

storage (1) There is no oil dirt and

rust corrosion on the
external
and
internal
surfaces, we paint the
insulating paint on the
internal side, and paint the
lacquer on the external
side. The lacquer should be
smooth and nacreous.
(2) The rubber bursa or the
diaphragm does not aged
and chap, and does not
leaked under the pressure
of 0.02 0.03Mpa within
30min.
(3) The indication of oil
level indicator is correct.
(4) The remains gas in the
oil storage tank was been
discharged out, the fake oil
level was been eliminated.
(5) The moisture absorber,
air discharger, oil injection
pipe should be unblocked.
(6) Replace the seal gasket,
and there should be no
leakage.

Pressure
release
valve(safety
gas duct)

(1) The internal side should

be clean and without rust
corrosion and oil dirt.
(2) Sealed well and no
leakage.

Page 71 of 326

(3) Connect the upper part

of safety gas duct to oil
storage tank.
(4) Pressure release valve
was checked and was
eligible.
Moisture
absorber

(1) Internal and external

sides are clean, replace the
disabled absorber.
(2) The breathing pipes are
unblocked.
(3) Sealing oil
normal position.

Oil purifier

level

at

(1) Clean the internal side

and external side, and paint
the lacquer.
(2) Replace the disabled
absorber.
(3) We must replace the
metal strainer.
(4) The relevant valves was
been maintained, and the
valves does not leaked.
(5) Replaced the rubber
gasket and it seals good.

Gas relay

(1) Internal side and

external side is clean and
without oil dirt.
(2) Seals
leakage.

good

without

Flow speed

ms

Insulation resistance M

(3) Check the flow speed is

eligible, and insulation is
good.
(4) Rain proofing shield was
installed reliable.
(5) Gas relay maintain the
horizontal position, there is
a rising grade of 11.5
from connection pipe to oil
storage tank direction.
Temperature

(1) Check the thermometer

Page 72 of 326

measuring
elements

is eligible, the action of

alarm contactor is correct.
(2)
Inside
of
the
temperature
measuring
spile is clean and full of oil.
Screw on the end seat after
the temperature element
was inserted in, the spile
was sealed and no leakage.

Valves
piston

and (1) Open and close of

proper and accessories and
valves are agile, the
indication is correct.
(2) Replace the rubber
gasket, it should be sealed
good and without leakage.

Cooling
devices

(1) Clean the inside with oil

(2) Clean the outside.
(3) Replace the rubber
gasket, and no oil leakage.
(4) The pressure leakage
test is eligible.

Pressure for leakage test

MPa
H no leakage.

(5) Painting.
Oil pump

According to maintenance
technique of oil pump.

Fans

According to maintenance
technique of fans

Sleeve

(1)
The
external
of
porcelain should be clean
and without crack, broken
and arc-discharging trace.
(2) Replace the changeable
rubber
gasket
of
oil
discharge hole, it should be
Whether
it
was
sealed well and without
disassembled dry or not.
leakage.
Attach the construction
(3) Oil level of capacitor
record and test report.
sleeve and oil filled sleeve
should
be
normal,
if
necessary add oil or
replace oil.

Page 73 of 326

(4) When the tg exceeded

the standard or when the
tg has serious defects we
should disassemble and dry
it.
(5) Test the sleeve and oil is
eligible.
Dry of proper

(1) We should dry it when

the insulation of proper was
decreased or affected with
damp.
(2) Dry and construction
record is complete.

Oil treatment

(1) Oil straining and oil

replace

Attach the oil test report.

(2)
The
oil
type,
predigestion of oil quality,
pressure
withstand,
moisture and chromatogram
analysis of injected oil
should
meets
the
requirements in GB2536
90 <transformer oil>
Overhaul
preventive test

(1) It should be carries out

according to <preventive
test specification of electric
equipments

Attach the overhaul hand

over and accept report.

(2) Attach the test results

and record to this report
2.4.1.2

HV insulation test report, predigestion and chromatogram test list of oil, the calibrating
report of thermometer, test report of gas relay and transformers.

2.4.2

Check items before test running.

2.4.2.1

There are no defects and oil dirt on transformer proper, cooler and all the
accessories.

2.4.2.2

The fix device of wheel was fasten.

2.4.2.3

The lacquer was complete and grounded reliable.

2.4.2.4

There are no remained sundries on the transformer top cover.

2.4.2.5

The oil valves on the oil systems such as oil storage tank, cooler and oil purifier was
at open positon.

2.4.2.6

Ground the ground small sleeve of HV sleeve, the seal capacity of the cap on the top

Page 74 of 326

of sleeve is good. And the connection to outside downlead is good.

2.4.2.7

The oil level of oil storage tank and oil filled sleeve of transformer is normal, there is
no gas in the gas collection box of diaphragm type oil storage tank, the oil
conservator level of on-load tap changer is normal.

2.4.2.8

Discharge the gas from rising seats,

2.4.2.9

The moisture absorber in the absorber is enough, and does not been affected with
damp, the oil seal is good, and can performance the normal absorb function.

2.4.2.10

The position of no-load tap changer should meet the operation requirements, the
action of on-loading operation is correct, the action of interlock device is correct, the
tapping position of control panel, operation mechanism box and top cover are
consistent.

2.4.2.11

The indication of thermometer is correct.

2.4.2.12

The commissioning of cooling device is normal, start-up all the submerged oil pump
to circulating the forced oil device for a long time and discharge the air for several
times.

2.4.2.13

Carry out the automatic operation test of standby cooling device, and carry out the
failure shut down test of operating cooler.

2.4.2.14

After the commissioning and calibrating the action of relay protection device is
correct.

2.4.3

The running of transformer

2.4.3.1

All he protection device should be put into operation during the operation of
transformer, the gas relay of transformer proper should be put into operation, the
heavy gas should be at outlet trip position.

2.4.3.2

The impact test under rated voltage(3 times for replace the winding, and 2 times for
overhaul), should not have abnormal conditions, the excitation flow can not cause the
action of protection devices.

2.4.3.3

After the first energize the maintained time should not be less than 10 minutes, and
the transformer should not have abnormal conditions.

2.4.3.4

After energize, check all the weld line and contact surface of transformer and cooler,
there should not have oil leakage, and the transformer should not have abnormal
oscillation and arc discharge sound.

2.4.3.5

Analyze and compare the chromatogram datum of oil before and after operation, the
chromatogram datum of oil before and after operation should not have obvious
changes.

2.5

Spare parts
Not available now

The Maintenance Technical Manual of Motor

3.1

The technical specification of AC high/low voltage motor

3.1.1

The technical specification of 6.3KV motor

Page 75 of 326

Equipment

Model

(KW)

(KV)

Capacit
y

Voltag
e

Suction fan YKK710-6THW

motor

2150

990

2+2

FD
motor

fan YKK450-4THW

500

1490

2+2

PA
motor

fan YKK630-4THW

1700

1490

2+2

Medium
YHP560-6
speed coal
pulverizer
motor

520

982

5+5

Condensate YLKK500-4
pump motor

1000

1500

2+2

CWP motor

1900

2+2

Closed
KK4002-4TH
circulation
cooling
water pump
motor

355

2+2

Main feed YKS 710-4 TH

pump motor

3300

Instrument
air
compressor
motor

200

Fire fighting
pump motor

250

Sea water
booster
pump motor

160

2+2

Coal
crusher
motor

550

Y355-2

Curren
t

Page 76 of 326

Rotar
y
speed

1493

Wirin
g

Insulatio
n level

Quantit
y

1+1

C-01A belt
conveyor
motor

250

C-04A belt
conveyor
motor

200

C-05A belt
conveyor

400

C-03A belt
conveyor

250

C-02A belt
conveyor
motor

160

C-07A belt
conveyor
motor

160

3.1.2
Equipment

Technical specifications of 380KV main motor

Model

Capacity

Voltage

Current

Wiring
Rotary
speed

Quantity

Water ring Y-355L-12

vavuum
pump motor

110

0.38

Condenser
water
chamber
vacuum
pump motor

7.5

0.38

1+1

Fiber
ball 1LA7
conveying
pump motor

0.38

2+2

Condensat
Y160M1-2
e
pump
make-up
water pump

11

0.38

1+1

Y132M-4

500

Insulation
level

Page 77 of 326

2+2

Startup
water
feeding
pump motor

Y250M-2

55

0.38

1+1

Sea water Y2-355M1-4

booster
pump motor

110

0.38

2+2

Feed pump YB801-2

turbine oil
suppy
device
exhaust fan
motor

0.75

0.38

2+2

Feed pump YB160L-2

turbine oil
supply
device main
oil
pump
motor

18.5

0.38

2+2

Feed pump YB160L-2,

turbine oil
supply
device
standby
emergency
oil
pump
motor

18.5

0.38

2+2

Seal steam Y160M2-2

exhaust fan
motor

19

0.38

Jacking
YB250M-4
device antiexplosion
motor

55

0.38

1+1

Startup
boiler
house FD
fan motor

110

0.38

2920

Page 78 of 326

2+2

Turning
gear motor

22

0.38

730

Electric
YB280S-2centrifugal
TH
oil supply
pump antiexplosion
motor

75

0.38

Electric
YB160L-2centrifugal
TH
oil
unloading
pump antiexplosion
motor

13.6

0.38

Truck
YB160M-4electric oil TH
unloading
pump antiexplosion
motor

15

0.38

ID
fan
cooling fan
motor

1+1

4+4

Sealing fan Y315L1-6

motor

110

0.38

Electronic
SA77 /TJ
weighing
coal feeder
motor

2.2

0.38

Steam feed Y315M-4

pump prepump motor

132

0.38

AC lube oil YB200L-4

motor

55

0.38

1+1

Main
tank
fume

0.38

2+2

oil YB11ZM-2
oil

960

2+2

5+5

1480

Page 79 of 326

2+2

exhaust fan
motor
AC
oil Y132M2-6
pump
conveying
pump motor

5.5

0.38

2+2

Electronic
SA57 /TJ
weighing
coal feeder
cleaning
chain motor

0.37

0.38

5+5

Air heater Y315M-2

alkali
cleaning
pump motor

132

0.38

Intermittent
blowdown
water pump
motor

15

0.38

2+2

3.1.3
Equipment

DC motor technical specifications

Model

Main
equipment
DC lube oil
pump

Rated
power

Rated
voltage

17

220

7.5

220

Rated
current

Rated
rotary
speed

Air
side
sealing oil
pump
Feed pump Z2-42
turbine oil
supply
device DC
emergency
oil
pump

Page 80 of 326

Excitation
mode

Rated
excitation
current

Quantity

motor

3.2

Maintenance Period and Maintenance Items

3.2.1

Maintenance period

3.2.1.1

High voltage motor should be overhauled at the same time as unit overhaul, generally
the overhaul period is three years, and repair period is 2 times a year

3.2.1.2

For the high voltage motor which installed in the clear areas in the room or the full
closed high voltage motor, its maintenance period can be shorten or prolonged
according to the actual operation hours and preventive insulation test conditions
every.

3.2.1.3

If the overhaul is carries out to the unit, the repair of high voltage is unnecessary to
carries out

3.2.1.4

If the problem is found in operation and preventive test and repair, it should be
changed into overhaul.

3.2.2

Maintenance items

3.2.2.1

Repair items

3.2.2.1.1

The high voltage motor should be blow out and flushed; the general check should be
carries out.

3.2.2.1.2

Check and deal with the partial insulation of the windings, and carries out the
mending
works. Fix and bind up the winding and lead partially.

3.2.2.1.3

Measure the gas gap between the stator and rotor (when the condition is allowable)

3.2.2.1.4

Check the bearings and bearing house, cleaning the bearings, check the bearings, or
change the lubricating oil if necessary.

3.2.2.1.5

Fasten the bolts and the grounding devices of motor

3.2.2.1.6

Adjusting the fans of rotor, ventilation duct, fan shield

3.2.2.1.7

To check if the insulation resistance meets the requirements or not.

3.2.2.1.8

for the rolling bearings, the insulation of the bearing block and soleplate.

3.2.2.2

Overhaul items

3.2.2.2.1

Repair items contents of whole repair items

3.2.2.2.2

Check the motor disassembly, clearing and clean the motor stator, rotor, frame,
undercarriage and junction box, cleanout the oil dirt and accumulated dust.

3.2.2.2.3

Check and clean the front and rear bearings, change the lubricating oil, replace the
bearings is necessary.

Page 81 of 326

3.2.2.2.4

Rescrape the bearing bush, repair the bearing bush and mend the bearing bush,
replace the insulation bushing of the sliding bearing if necessary.(this item should be
carries out by the boiler ,steam turbine maintenance staff)

3.2.2.2.5

Check the stator winding, replace the winding partially, strengthen and mend winding
insulation. Dispose and replace the loosen slot wedge, strengthen the insulation of
the winding end and leading wires, over lines. Reinforce and replace the colligation
line of winding ends.

3.2.2.2.6

Check or replace rotor squirrel cage failure such as bar broken, loosen, sealing-off
and so on, reinforce and welding it.

3.2.2.2.7

If the squirrel cage bar of the motor rotor has changed or welded, the dynamic
balance test should be carries out.

3.2.2.2.8

If the winding was totally aged, we should contact with the manufacturer to replace
the whole windings.

3.2.2.2.9

The motor is dry.

3.2.2.2.10

measuring of DC resistance, insulation resistance and current leakage and AC

voltage withstand test.

3.2.2.2.11

no-load and loading test of the motor

3.3

Maintenance Technique Requests for High Voltage Motor.

3.3.1

The preparations before maintenance and security measurements

3.3.1.1

Prepare the needed equipments and spare parts for motor maintenance

3.3.1.2

Prepare all the power off permit for the equipment exit the standby condition, and
through site check and verified that the start up devices of this equipment is already
exit the standby condition. Breaker and the disconnecting link is already open, and
carries out short-circuit grounding measurements, and hang the alarm plate of
working, forbid to connecting, verified the safety measurements is complete; then the
maintenance group can enter the site.

3.3.1.3

Before work, the measuring work of initial data should carries out, and makes
records.

3.3.1.4

To dismantle the inlet power cable of the motor, the phase should be marked with
color; three phases short-circuit and ground the connection link.

3.3.1.5

Clean the maintenance site

3.3.1.6

Check working reliability of all the lifting devices.

3.3.1.7

Prepare the tool for dismantle the bearings, and the equipments and material to dry
and heating the motor.

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3.3.2

The maintenance items of the high voltage motor and working process and the
requirements

3.3.2.1

Checks and flush before maintenance

3.3.2.1.1

Cleanout the motor surface. Motor surface should not have dust dirt, oil dirt, and other
dunghills.

3.3.2.1.2

To check that the end shields of motor sides are complete and has no damage, no
crack, and the motor fans has no damage and deformation.

3.3.2.1.3

There is no accumulated dust, loosen inside the junction box and high voltage
connection porcelain bottle, there is overheating phenomenon on connection bolt,
and there is no arc-discharging crack phenomenon exists on HV connection
porcelain.

3.3.2.1.4

When dismantle the inlet cable of the motor, we should avoid damaging the HV
porcelain and the other accessories

3.3.2.2

Disassembly maintenance of the motor

3.3.2.2.1

Dismantle the motor coupler

1) Install the jack which is used for dismantle the coupler, hang the coupler on the
gourd hanger, put the jack on the position where can bearing the force, heat the
coupler by the means of oxygen-ethine flame to 250300 (we can put a tin bar on
the coupler surface to measuring the temperature, if the bar melted in a short time it
shows that the temperature of the coupler reaches to250 300 ),then we can add
force by jack, and pull out the coupler
2) When the whole coupler leaves off the rotor, hang it by gourd hanger, and put it
on the ground where the passenger comes by, and cool it, we can not use water to
cool it in the short time to avoid the coupler deform and explode.

3.3.2.2.2

Dismantle the end shields of stator two sides

1) Prepare the dismantle tools and lifting devices.
2) Dismantle the two positioning pin on the lower end shields horizontal line
3) Dismantle all the bolts on the end shields (put them in the box and do not loss
them)
4) Tie up the end shields with steel line hang it with crane hanger, but do not put
force on it
5) Screw the two dismantled end shield bolts on the jack hole, rotate the screws
slowly to the end shield jack out surface, and then put two crowbars in the line of jack
out surface, on the two side of end shield, and crow it out side slowly, and the hoist
should move at the same time, when the end shield leaves off the bearing house, he
hoist should hoist the end shield tightly, and then hang off the stator slow, put it on the

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crosstie reposefully. The end shield should be put upwards for check and clean.
3.3.2.2.3

Pull the motor rotor

A

Works before pulling the rotor

1) For the motor which adopts sliding bearings, before pulling out the rotor the
bushes of the bearings should be dismantle first ,before dismantle the bearing bushes
the gaps between the bearings should be measured and the data should be recorded.
Because this work belongs to mechanical work, so the mechanical stuff should be
contacted for cooperate
2) When the bearing is pulled out, it needs be cleaned and take good care
3) The lower insulation layer of the sliding bearings should be complete and has no
damages, when it is installed again the insulation layer should be put in position
4) Before pulling out the rotor of the motor the gas gap between of stator and rotor
should be measured by feeler
5) The gas gap should be measured at the two sides of the iron core respectively,
before measuring we should make four measure datum marks on the upper, lower,
left and right side of the motor. We should turn the rotor for many times and then we
can educe the data.
6) The asymmetry value of any side of iron core gas gap should not be bigger than
510%. The measured gas gap value differences of iron core should not be bigger
then 15% of the average value
B

Take out the rotor of the motor

1) When we take out the rotor, it should be carries out at the area where the crane
can move, when we take out the rotor of large sized motor, the crane should be 5 ton
at least. We can adopt multi-hanging point and prolonged shaft method to take the
rotor out of the chamber. After dismantle, we should put the rotor on frame or crosstie
for check and clean.
2) In the whole process to pulling out the rotor, a person should command the
group, and take good cooperation with the crane group. Especially to take out the
rotor of large sized motor, properly air gap between rotor and stator should be
maintained to avoid scrape the stator iron core and end winding.
3) Before install the prolonged shaft we should protect the bearing journal.
3.3.2.2.4

Check of the motor rotor.

A

Check of the motor iron core

1) Iron core of rotor should have no trace of attrition and damage, if the traces are
exists, the reason should be check out and the position of attrition and damage
should be disposed.

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2) Rotor iron core should not have loosen phenomenon, if the iron core was loosen,
we should fasten it, or fill it with epoxy
B

Check of squirrel cage bar

The weld points on the rotor squirrel cage bar and end rings should not have changed
color, overheated, loosen, weld cracking and bad contact phenomenon. During the
operation before the maintenance, if the start torque decreased, stator temperature
increases sharply, stator current is higher than normal operation, unit oscillation is
bigger than normal operation, yawp increases, the pointer of three phase ampere
meter has periodical vibration when the unit carries load, the squirrel cage bar should
be checked carefully.
The squirrel cage bar can be checked by different methods
Take out the rotor and observe the squirrel cage bar, and beat every with a small
hammer, if the bar is broken, the noise is big and hoarseness.
4) If we can not affirm the squirrel cage bar failure point, we can adopt the big
current test method. Use one set of big current generator of 220/124 voltage and
capacity of 15---20kVA, connect the secondary voltage to the two sides end rings of
squirrel cage bar, adjusting the secondary voltage between 300---1500A, at this time
rotor surface will produce a magnetic field. then splash the iron powder on the rotor,
and the iron powder will distributed in order and clearly along the direction of the bars,
if some part has little iron powder or has no powder, it shows that the broken bar is
exist.
5) If the broken bars are found, the bar should be taking out, and check whether the
broken bar is caused by mechanical damage or big current burnt the bar. And then
check if the unequal burr or iron core protruding pad are exists in the cage bar slot,
and dispose them in time, and at the same time machining the new eligible bars
according to the original bars dimension and type, and bore the eligible holes on two
sides end rings, make the meld point tidy and even. The end rings should be melded
by the engineer with rich experiences.
6) The squirrel cage bar should be well fixed in the rotor slot; we should press its
upper and lower side on the bottom and notch of the slot. When we replace the
squirrel cage bar, the parallel connection of several conductors shall not be used to
instead one bar. If the bar was loosen in the slot, the can be used to fix it.
7) We should make the welding point of replaced bars smooth and even, after the
bar of rotor was changed, we should carry out the balance test of rotor.
3.3.2.2.5

Maintenance of motor stator

A

Check of stator iron core

1) The iron core teeth should be pressed and no loosen phenomenon exists; there
is no red powder and yellow powder on the core surface, no broken blades of the

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teeth. And no partial overheat and color-change phenomenon on the surface lacquer.
2) There is no contusion, burr concave and protruding points and burnt short-circuit
conditions on the core.
3) There are no oil dirt and metal substances inside the core.
4) The pressing screw and rod of two sides of the iron core is fixed, and no partial
overheat and crack phenomenon the
5) Ventilation slot is unblocked, and there is no accumulated ash, oil dirt, eye winker
and partial blocked phenomenon.
6) When we check the iron core, we can use a hammer to beat the teeth parts and
teeth board of two sides of the core, if the core was loosen, it will gives out hoarse
sound, and the rust pieces and dust will spurt. If the core relaxation was found, tuck
some mica pieces or insulation layers in the relaxation parts, and fix these parts with
epoxy.
7) If some eye winker such as metal powder or were found inside the core, we
should check out the reason. If the burr and short-circuit points were found, we should
eliminate the burr and chisel out the short-circuit points, and paint the epoxy
insulation lacquer.
8) Use the clear and dry air to blow out the ventilation holes and slots one by one,
until the ventilation holes was unblocked.
B

Check of stator winding.

1) winding coil surface should be clear and has no dirt, the winding coil has no
overheat, deformation and damage phenomenon
2) The connection line and leading line between windings has no deformation, the
interphase distance is even, and has enough creepage distance, the arrangement is
in order.
3) There is no aged, loosen, off and broken line phenomenon occurs on insulation
block and tie of the end, the insulation block is fixed and reliable.
4) The slot wedge should be tight and not broken, if the slot wedge was loosen and
damaged, we must tuck it in or replace it again.
5) We can use the carbon tetrachloride or electrified cleaning agent to clean the
winding surface.
6) If the insulation layers have aged, crack, exuviate and bed phenomenon, we
should check out the reason.
7) If the winding become flexible or the insulation part is damaged, it should be
colligated again.
3.3.2.3

Assemble the HV motor

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3.3.2.3.1

Maintenance and preparation works before assemble

1) We should clean the dust and dirt on the rotor surface, and clean it with clean
cotton cloth.
2) Clean out the inside eye winker and the lacquer burl which remain by lacquer
soaking. Especially for the lacquer burl and dust and dirt on the frame and end shield
stop surface, we should use a scraper to clean it, otherwise the installation quality will
be influenced.
3) To check whether the slot wedge, teeth press board, end colligation of the
winding and insulation tucked block are loosen and off or not, the slot wedge and the
insulation layers and binding lines of bind hole can not be higher than core surface.
4) We should clean out the ventilation duct of the core, it can not be blocked.
5) Insulation of winding, leading line and outlet box should be complete, and has no
damage.
6) Insulation resistance value can not be lower than the value before maintenance
or lower than the lowest allowable value in the regulation.

3.3.2.3.2

Assemble the bearing.

A

Check and replace the bearing.

Because the coordinative surface of bearing journal will be damaged and the
coordinative intensity will be debased during dismantle the rolling bearings, so the
bearing s can not be dismantled voluntarily, if these following conditions were met
during the maintenance, we should think about to dismantle the rolling bearings:
1) Replace the failure bearings.
2) The normal abrasion of bearing reaches to the allowable value of technical
standard, and we should replace it by a new one.
3) Only after dismantled the bearings the other component can be changed, for
example: change the shaft, and lathe the shaft.
4) The assemble quality of bearing is not good, it need to assemble again.
B

Dismantle the rolling bearings

1) When we dismantle the bearings, the force bearing points should be even and
correct. When we dismantle the bearings from the motor shaft, the inside track of the
bearing should bear the even forces. And if we dismantle the bearings from the end
shields bearing housing, the outside track should bear the even forces.
2) We should use special tools to dismantle the bearings.
3) When we span the dismantle tolls, we should make the length of every tension
rod equal, and the distance to main screw should be equal, and the claw should not

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be deflexed, and should hook the bearings straightly. in order to protect the center
hole of the rotor shaft end, we can not put the puller on the center hole directly, put a
piece metal board or a rolling ball to protect it.
4) When we tighten the main screw and take out the bearings, the force should be
even. The forces on every hook should be equal. And the actions should be uniform,
and we can not hitch it.
5) During dismantle, do not damage the of the rotor shaft bearing journal.
6)
For the shrink-fit bearings, to use cold dismantle methods is not allowed.
Because if we use this method, not only the dismantle is difficult, but also the
coordinative surface precision was damaged, and the bearing noise was increased,
so the hot dismantle method can be used, the process are

Span the dismantle tolls, and clean out the bearing lubricating grease.

Wrap the rotor shaft surface besides the bearing with asbestos cloth or anti-oil rubber
to avoid the hot oil pour on the surface and the shaft and bearing inside track
expanded in the same time, and its every difficult to dismantle.

Heat the hot oil(wasted transformer oil) to about 110 , and then use oil pot or oil
scoop pour the hot oil on the bearing inside track, it will expands, after expands, the
force between bearing journal and bearing inside track decreased, then we can use
dismantle tools to dismantle the bearings easily.

This operation need several peoples cooperation, wearing the gloves to avoid been
burnt.
C

Clean the rolling bearings.

1) It does not matter whether the bearing is newly use or just dismantled from the
bearing journal, first it should be cleaned and then we can assemble and use it.
2) For a eligible bearing, its rotation should be balance, the rotating speed should be
even, and has no cacophony.
3) The inside and out side surface of the bearings should not have rust spot sand
nicks, bearing rolling ball clamp has not deformation, and the rolling ball proper has
no wear marks.
4) We should choose the lubricating grease of rolling bearing according to the type
standard and use site in table 2. The specified lubricating grease should be used but
not the lubricating oil of any type.

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5) If the full closed bearing is adopted, we can not use hot oil to heat it, we can
adopt electric heating method to heat the bearing evenly and then put it inside of the
bearing.
6) According to the actual conditions of the site, we can use the following methods
to clean the rolling bearing.

High pressure steam and high pressure air methods blow it clear and use benzine to
wash it for two times.

If the lubricating oil is already concreted, we can use 105 hot oil to wash it, and
clean it, then use benzine to clean it for two times, this method is convenient and
quick. But we should take the fire fighting safety measures and before we clean the
bearings.(we can use wasted transformer oil as the oil for washing, when boiling the
oil we should sent someone to take care of the oil, and this person can not leaves the
site.)
7If the bearing is not use after clean, we can clean it with clear calico and wrap it
carefully to avoid the dust drops on it.
D Before assemble of the bearings, we should use benzine to clean the bearing
housing, front and rear end shields of the bearing and component and accessories of
the bearing journal. And make sure that there is no damage and burr on the bearing
journal, and after the benzine was volatile we can assemble it.
E before we assemble the bearings, first we should put the inner cover in, and then
use hot oil(wasted transformer oil) heat the bearing to 110maintain this condition
about 58 minutes, after the inner track was expanded use a isolated tool and lifting
the bearing,(we must put the side with letter forth and the side without letters entad )
and put the bearing on the bearing journal quickly, and push it the bearing positions,
after the bearing is cooled and the inner track is fastened, we can carry out the next
works.
F chose and paint the proper lubricating grease in side the bearing lodgement and
in front and rear oil cover of the bearing, generally the oil amount of front and rear
bearing is about 2/3 of the bearing capacity. And then rotate the bearing to make the
redundant grease in the bearing lodgement flow out, scrape the redundant grease,
fasten the front and rear end shields , and waiting for the installation after put the rotor
in position.
3.3.2.3.3

Install the motor rotor

1)Before installation, check that the accessories and fittings should be
eligible and complete.

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2)Use compressed air about 0.10.3Mpa to blow the dust on motor core and
winding.
3)The sequence of install the motor rotor is contrary to dismantle.
4)When we install the rotor, we should pay attention to maintain the gas
gap distance between rotor stator. And do not damage the stator winding
and winding end coil.
5)If necessary, we should carry out this work with the cooperation of the
crane staff.
3.3.2.3.4

Install the end shields of HV motor.

1) Before install, we should check that there is no damage and crack trace on end
shields, and there is no burr and protruding blocks on en shield stop surface.
2) Air guiding board of the end shields does not loosen, and every screw is
fastened, no dunghill and dust and dirt exists.
3) When we assemble the end shield, in order to avoid the uneven gas gap caused
by stop surface abrasion which will cause the failure of stator and rotor, we should
maintain the even gas gap of stator and rotor is even, assemble the end shield
according to the marks mark during dismantle, In order to guarantee the assemble
quality; we can take the following measures for assembly and adjusting.
a) Use two jacks to support the end shields.
b) Lift the en shields on position by crane, do not fasten the end shield screw at this
time, regulating the jack and at the same time detect the gas gap value between
stator and rotor.
c)

3.3.2.3.5

After the gas gap is regulated to even, fasten the end shield screw symmetrically

Install the coupler.

1) Before install, check that the coupler does not have deformation and crack, and
there is no burr and protruding block in the sleeve hole.
2) Before assemble, we should check that the key and key groove was tied in, not
high and lower, the surface is smooth and do not have burr.
3) Before assemble the coupler, we should clean and wash the bearing journal
surface, after we confirm that the bearing surface is smooth and do not have burr we
can install the coupler.
4) Before installation, use crane to lift the coupler by steel line.
5) Adopt shrink-fit method to heat the coupler to 250---300 by oxygen-ethine
flame and we can install it.

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3.3.2.4 Dry the HV motor (when the motor was affected with damp)
1) We can use the following methods to dry the HV motor according to the actual
situation if necessary.
2) Stator iron loss heating method, this method is used for the motor at dismantle
situation. The method is, reel some insulated conductor on stator iron core, and
connect 380V AC voltage, heat and dry the motor winding by the vortex loss produce
by stator core.
3) Stator copper loss heating method: this method is used for the motor at
assembled situation. The method is to connect the stator winding with working
connection methods, and then connect the stator winding with 10 15% rated
voltage(three phase working frequency AC voltage), stator voltage reaches to 50
70% of its rated value. Use the copper loss heat of motor winding proper to heat and
dry the motor winding.
4) When the insulation resistance value and absorbptance R60/R15 were
increased and reaches to required value, under the same condition, if this value is
maintained in 5 hours, this process can be stopped.
3.3.3

Test of HV motor after maintenance.

This test shall be carries out only the insulation resistance value and absorbptance
has reached the required value. The test items, technical specifications after HV
motor maintenance shall be carries out according to electric preventive test
regulations.

3.3.4

Trial running of HV motor after maintenance.

3.3.4.1

Checks before trial running

1) The accessories and components of motor proper should be complete; the inner
and outside surface should be clean.
2) During the electric test, every item meets the requirements, to check that the
initial record and test datum should be complete and correct.
3) If the sliding bearings are adopted, the oil system of bearing should be
unblocked, and there is no leakage phenomenon
4)To check that the control and protect system of HV motor should be complete, and
meets the start requests, and after interlock test the open and close breaker control is
normal.
5)Prepare the trial running working permit, after the operation control staff check it is
eligible, it can be energized and carries out the non-load trial running.

3.3.4.2

Trial running check

1) After start up the motor, the oscillation of every part and axial displacements

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should in the rated range,

2) After 12 hours non-load operation we should check that the operation of every
part should be normal, and the current should be stable, and has no big swing and
changes, generally the bearing temperature is 3550the highest value is lower
than 75.for the rolling bearings the temperature is 50 60the highest value
is lower than 85.
3) After shut-down, we should check whether the abnormal phenomenon is occurs
on the motor or not.
4) After operation is check out, fill the acceptance list and the relevant information
and submit it to the governing body for acceptance,
3.4

Maintenance Techniques of LV Three Phase Asynchronous Motor

3.4.1

Maintenance items and technique

3.4.1.1

Preparation before LV motor maintenance,

1) Before dismantle the motor we should do some preparation and prepare the
necessary tools.
2) Chose dismantle working site of motor, and clean the site.
3) Separate the motor and dragging parts, when we suspending and moving the
motor, we need to take care of the earth foot bushings, number them and record the
number and thickness, do not make mistake so that we can install it easily.
4) Before maintenance we should check whether there is cracks on the end shields
or not, every screw shall not have tripping phenomenon, the fans should no have
deformation and damage. The shell and radiator of motor should not have crack and
damage.
5) Before maintenance we should carry out tests and make record, know the defects
of the motor.

3.4.1.2

Dismantle, check and maintenance of LV motor.

3.4.1.2.1

Dismantle the coupler

1) We should use puller to dismantle the coupler, generally, for the coupler of 50KW
below motor, if its diameter is between 80180cm we can machine he special tools
by ourselves.
2) The puller hook should hitch the rim of coupler, and bearing the even forces. In
order to avoid the excursion during dismantle, the puller main screw and the rotation
shaft center line should be equal.
3) During dismantle, we should maintain balance and even, put the force step by

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step and take out the coupler.

4) If the coupler is too tighten, we can use oxygen to heat it, we can determine the
heating time and temperature according to the size of the coupler. Generally we can
easily take out the coupler at 150250
3.4.1.2.2

Dismantle the external fan.

1) Screw off the four screws on the fan shield, remove the fan shield, and screw off
the pressed screws or fixed screws on the shaft.
2) Use the special tools to dismantle the fan, we can not use crowbar or other tools
to draw, prize, beat the fan to avoid deformation and broken.
3) If the fan is made by plastic ethylene material, we can heat the fan with low
temperature produced by hot air generator, and remove the fan.

3.4.1.2.3

Dismantle the end shield of LV motor

A

Check and preparations before dismantle

1) There is no break and damage on the end shield

2) The connection between end shield and frame surface can not be too loosen or
too tight.
3) The accessories and fittings should be complete and meets the uniform standard
B

Technique and notes during dismantle

1) To avoid the fasteners (small screws, gaskets and bushes) remains in the motor
when we assemble the motor after maintenance, before dismantle the end shield, we
should check whether all the fasteners are complete and put the defects conditions in
the record,
2) Before dismantle the end shields we should dismantle the bearing end shields at
two sides first, we should put the dismantled accessories (small screws, gaskets and
bushes etc.)In the box to avoid been lost.
3) Before we dismantle the end shield, we should mark the end shield of frame two
sides and frame cooperate line with different marks, and then screw off the bolts, and
then jack out the end shield by jack bolt hole until the end shield get off the frame, if
there is no jack bolt hole, and the cooperation of stop surface is not so tight, we can
insert a crowbar in the cooperation line of end shield and frame, beat the end shield
use a hammer, or use a screwdriver or a small crowbar crow the protuberance on the
end shield, and let the end shield off the frame stop surface, if the stop surface
cooperation is too tight, we can take the efficient measures to dismantle the end
shield without any damage, to acts recklessly is not allowed.
4) For the motor with roller bearings as its load end, we should dismantle the nonload end first.

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5) The end shield of the large sized motor above 50KW is very heavy, when we
dismantle it, for seek of safety we should use electric pulley; we can not use our
shoulder and hands.
3.4.1.2.4

For check and replace the rolling bearings, please consults dismantle and assemble
method of HV motor bearings.

3.4.1.2.5

Take out motor rotor

A Do not damage stator iron core, colligate wires of stator winding end coil and slot
wedges, when we taking out the motor rotor.
B When we take out the rotor of LV motor, we can determine the working method
according to the idiographic configuration, rotor weight and the lifting devices.
1) For the motor below 350KW, the weight of its rotor is about 35 45kg, we can
cover a steel pipe on the shaft journal, which little is bigger tan motor shaft, and take
out the rotor at one time.
2) For the small motor, we can dismantle the front end shield, and then screw off
four screws on the rear end shield, and use a wood hammer to beat the front shaft,
and the rear end shield will leave the stop surface, and then we can pull out the rear
end shield and rotor at one time.
3) When we pull out the rotor for the motor above 50KW, we should sent some to
send commands, if necessary, we can ask the lifting staff to work together, at the
whole process, we should maintain the gas gap between rotor and stator, to avoid the
damage on stator and end winding.

3.4.1.2.6

Check and repair the motor winding

1) Stator winding is not affected with damp, and insulation resistance is eligible.
2) There is no powder, oil dirt and chemical corrosion trace and phenomenon on the
winding surface and in the gap. if the dust and dirt, oil dirt(for example, the oil leakage
of bearings made the winding full of oil dirt) is exists on stator winding, we should use
clean agent to clean it, carbon tetrachloride and benzine are also can be used, but
first we should take some safety measures. After clean, no matter whether the
insulation resistance is eligible or not, wed better dry it, and if the insulation
resistance can maintained for 4hours and does not change, then we can assemble
the motor.
3) The changed color, overheat and damage phenomenon should not exists on
stator winding end coil and insulation. There is no copper oxide on winding conductor.
If the insulation damage is found on stator winding, we can repaint the insulation
lacquer and dry the winding.
4) There should not have overheat and color change on connection wire and leading
line of winding end. The colligation is fixed, and the colligate line has no loosen and
broken phenomenon. If the loosen and broken was found it should be colligated

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again.
5) For the motor affected by damp, first we should clean it by air, an then put it in the
dry room to dry it and furbish the insulation resistance. If the condition is not allowed,
we can use iodine-tungsten light to heat it.
6)When the stator winding slot wedge was loosen, we should check out the resin, and
we must reinforce it again or replace it.
7) Check and repair the motor iron core.
a) To check whether the stator iron core is pressed tightly, if the iron core was
loosen, we should take measures. For the iron core which used screws to tense it, we
need to tense the screws, tighten the screws evenly and symmetrically, tense the iron
core. If it is just Light partial iron core loosen and end two side loosen, first we should
clean the rust and oil dirt, use benzine or clean agent to clean it and dry. Wedge the
blades into loosen core chips, Wedge mica or insulation layers in, and then paint the
insulation lacquer or fix it with epoxy.
b) To check whether there is partial wear, the color changes to blue because of heat
on stator or not, if the wear and heating phenomenon was found, we should check out
the reason and do some dispose work.
3.4.1.3

Assemble the LV motor.

1) Before assemble, we should clean the dust dirt on inner and outside surface of
stator and rotor. and then clean it with benzine and calico. For the rotation rotor or the
stator and rotor iron core with ventilation duct, the ventilation duct should be
unblocked and clean.
2) To check that the stator slot wedge, teeth board, colligation of winding end and
insulation pad should not be loosen and off from the position, the slot wedge and
colligate wire should not be higher than core surface, no lacquer knurl that caused by
lacquer soaking is remains.
3) The winding insulation, leading line insulation and outlet box insulation is
complete and has no damage.
4) Clean the lacquer soaking lacquer knurl, especially for the lacquer knurl and dust
dirt on frame and end shield stop surface, we need to clean it by scoop and knife,
otherwise it will influence the assemble quality.
5) The surface should be clean and do not have eye winkers, every accessories and
components should be complete.
6)The insulation resistance value should not be lower than prescriptive value.
7) After check that the insulation between wingding and shell is eligible, we can
assemble the rotor at contrary sequence of dismantle the rotor.
8) When we assemble the rotor, we should add lubricating oil on front and rear

Page 95 of 326

bearings. For the notes and quantity to add lubricating oil, we can consult the notes
and quantity of HV motor bearing lubricating oil.
9) When assemble the rotor, we should be careful and do not damage the stator
winding and iron core.
10) After assemble, we should check the insulation resistance of motor again, the
value should be equal with the value before assemble.
3.4.2

Trial running after assembles of LV motor after maintenance.

3.4.2.1

Before trial running, the maintenance group should put the maintenance tools and
test equipments in order, clean the sanitation and the other eye winkers on the site
and check the following items:
1) The insulation resistance should be eligible; it should not be lower than the value
before maintenance obviously.
2) Connection of the leads of the motor and the cable should be reliable and correct.
3) The fasten conditions of all the motor mechanism parts should be good, and
every screws should be tighten.
4) Hold the shaft end by hand and try to run it, to check if the rotor is balance and
light or not, there should be no abnormal sounds in the bearings and motor.
5) The whole protective circuit, measuring circuit, control circuit and signal circuit
should be complete, and to check that it is in normal condition.

3.4.2.2

Prepare the trial running permit, after the operation staff checked it is eligible; we can
energize it and do the trial running.

3.4.2.3

Checks after start-up

1) The rotating direction of motor should meet the rotating direction request of
driving machine.
2) During start and operation, the oscillation value of motor should not exceed the
prescriptive value.
3) During no-load and loading test of motor, its three phase current should be
balance, and the discrepancy should not bigger than 5%.
4) No-load test time of motor should no less than I hour, the temperature increase of
iron core and bearing temperature should be normal.

3.5

Maintenance of DC motor.

3.5.1

Maintenance period and maintenance items.

3.5.1.1

Maintenance period of DC motor Overhaul with the unit,, or overhaul under failure

Page 96 of 326

condition and special conditions, arrange 12 check and repair works every year.
3.5.1.2

Check items of repair

1Check the wear conditions of carbon brush and rectifier segments
2Clean the cumulated dust and oil dirt inside and outside of the motor tighten the
screws of every component.
3Replace the incompetent carbon brushes and bearing lubricating grease.
4Measuring the insulation value of every winding

3.5.1.3

Check items of overhaul

1Including all the repair items.
2Dismantle and check of DC motor
3Measuring the insulation resistance and direct resistance of main magnetic pole,
direction change magnetic pole, and compensation magnetic pole winding.
4Measuring the inter-segments DC resistance and insulation resistance of rectifier
segments.
5Adjust, check and clean the carbon brush and brush holder.
6Proofread whether the center line of main magnetic pole and geometry center line
is equal or not.
7Tight the bolts of main magnetic pole and direction change magnetic pole,
8 Strengthen the winding insulation of every magnetic pole (paint the insulation
lacquer), replace the coil of every magnetic pole if necessary.
9Test of DC motor.

3.5.2

Maintenance items and technique requests.

3.5.2.1

Dismantle the DC motor

3.5.2.1.1

Checks before dismantle

1Before dismantle we should mark the winding of every pole.
2Bind up the rectifying direction change segments, do not damage them.
3Test the insulation resistance of every magnetic pole, and make record.
4Check there is no deformation and crack on end shield and fan.

3.5.2.1.2

Technique and notes for dismantle the DC motor

1We should dismantle the rear end shield (the direction change end) first when we
dismantle the end shields.

Page 97 of 326

2Take out the carbon brush from brush holder, if we need to dismantle the electric
brushes from the frame, we should number the brush, and then dismantle the
connection wire from brush rod.
3 Screw off the bolts on the rear end shield; use the tools to prize the end shield
along with the end shield edge evenly. made the stop surface of out cover leave the
frame and bearing out track, remove the rear end shield. Before we remove the rear
end shield, we should wrap the rotor rectifier, preventing to damage the rectifier when
we dismantle the rear end shield.
4Dismantle the front end shield: after screw off the bolts of front end shield, take out
the rotor which is connected with the stator carefully. During this process, do not
touch the windings and direction exchanger, put the rotor on frame or crosstie at a
certain height after it was been pulled out.
5Screw off the bearing bolts on end shield, remove the bearing external cover and
end shield.
6 We can check the internal fan of the rotor, and carry out the general clean
according to check situation, it is no need to dismantle it. if the failure occurs in end
winding or the check quality can not be guaranteed because the dirt on end winding is
too much, we can dismantle the fan.
3.5.2.2

Maintenance of DC motor bearing.

We can consult the knowledge in HV motor part to dismantle and replace the bearing
of DC motor

3.5.2.3

Check of stator magnetic pole winding

1The connecting bolts of magnetic poles and shell should be tighten
2 The shell should be clean and does not have crack, rust and paint fall off
phenomenon.
3The magnetic poles and winding should be clean and should not have dirt. There
is no burnt, color change, crack and overheat phenomenon of magnetic poles and
insulation material.
4 Use 500V megger to measuring that the insulation resistance should be bigger
than 1.
5All the connecting wire should be fixed cleanly and reliably. And there is no crack,
and off of weld point, overheat and loosen phenomenon.
6When we clean the stator winding coil, we should use calico, clean agent to clean
it tardily.
7We should dry the winding coil after wash and clean.

3.5.2.4

Check of rotor winding and direction change segments

Page 98 of 326

1 The armature winding should be clean and without dust dirt, the surface is
smooth, and there is no damage and overheat phenomenon on insulation.
2There is no off, loosen and overheat phenomenon on weld of winding and rectifier.
3The surface of rectifier should be clean without dust dirt, smooth without spots.
4the mica duct should be clean without dust and dirt, and it should be 1 1.5mm
lower than copper segments. The duct shape forms a right angle, and the measured
DC resistance difference between segments no more than 10%
5there should not be concave and protruding phenomenon on rectifier, the highest
and lowest parts should not exceed 0.5mm when it was exceeded we should lathe
it. After lathe, the diameter of rectifier segments can not be 10mm smaller than the
initial value.
6 The fan should be clean without dust dirt, and there is no damage and loosen
phenomenon on the blades
3.5.2.5

Check of electric brush and brush frame.

1 Brush holder and brush frame should be clean without dirt ,damage and loosen
phenomenon, the brush holder should be smooth, brush frame insulating pad should
be clean without dirt and disrepair, use 1000V megger to measuring the insulation
resistance should be bigger than 30M.
2The distance between brush holder lower end surface and rectifier surface should
be in the range of 23mm.
3 The brush frame leading line should be clean without dirt, insulation without
expansion and burnt phenomenon, connecting surface without overheat and weld off
phenomenon.
4 There should be a gap of 0.1 0.2mm between brush and brush holder, it can
move smoothly.
5The connection between electric brush and copper braid should be tighten without
loosen.
6 The electric brush surface should be smooth, and should be inosculate with
rectifier contact surface, at least reaches to 70%.

3.5.2.6

Re-assemble the DC motor.

1 Before assemble the DC motor, we should clean the end shields and bearings.
After we cleaned the winding, brush holder, brush frame, and direction exchanger, we
can assemble the motor at the contrary sequence of dismantle.
2 When we assemble the armature, do not damage the magnetic poles, armature
and direction exchanger, if the armature was overweighed, the lifting devices should
be used.

Page 99 of 326

3Lubrication oil in the bearings should meet the requirements of the manufacturer.
4The leading line should be clean, the insulation is perfect, without broken, no dirt
on contactor, the screws was pressed tightly, the connection is reliable, the indicate of
leading line is evident.
5The insulation of every circuit should not less than 0.5 M
3.5.2.7

Re-assemble and adjust the brush and brush frame.

1 The shop sign of electric brush should be unified, use the stated type and
standard as you can. Use spring counter to adjust the electric pressure evenly. The
pressure which the brush bears is related to the types and the speed of electric brush.
For the hard brush it is 0.020.03MPa/cm2, and for the soft brush it is 0.0150.02
MPa/cm2, the pressure differences of every brush on the same frame should not
exceed 50%.
2Before we assemble the brush, we should put the brush into the brush holder and
check if the brush can move smoothly, if the brush is too tight, we can use emery
cloth to polish it gently, after it meet the requirement we can connect and fix it.
3 The electric brush surface should be smooth, and should be inosculate with
rectifier contact surface, at least reaches to 70%. If necessary we can skive it.
4The skiving method of brush and rectifier contact surface: wed better foist the #0
coarse emery cloth between brush and direction exchanger, the emery cloth surface
faces the brush, then vellicate the it along the direction of direction exchanger, when
we vellicate the vellicate, it should close to the exchanger.
5We should seek the center line of brush frame according to the sign made during
dismantle.
6adjusting method of brush center line: connect a milli-volt meter between bear by
two electric brush, and connect the current of 5 10%Ie, adjust the position of brush
frame, disconnect the disconnecting switch, if the swing value of milli-volt is the
smallest at this time, the position is the center line position of electric brush.

3.5.2.8

Check the polarity

Connect the voltage of 6 12 volt to magnetic pole winding, use a compass to
measuring it step by step, if the compass changes by turns, it shows that the polarity
is correct, if the bear by two poles point at south or north, it shows that the connection
is wrong, we should change the taps of this winding two sides.

3.5.2.9

Check the DC resistance between commutator segments

Use an electric bridge to measure the DC resistance difference between commutator
segments can not be bigger than 10%of average value.

3.5.3

Test running of DC motor after maintenance.

Page 100 of 326

3.5.3.1

Complete the test running procedure, stop all the maintenance work of motor, put the
operate power supply and motor drive power supply.

3.5.3.2

Start up the motor; detect the rotating direction of motor and the indication of ampere
meter.

3.5.3.3

There is no park occurs on commutator during operation.

3.5.3.4

There is no abnormal sounds in the motor, there is no oscillation and overheat

phenomenon on the bearings, the oscillation standard (double oscillation value)
should meet the requirements.

3.5.3.5

The abnormal phenomenon should not occur during 1 hours no-load operation.

3.5.3.6

after checked there is no abnormal occurs on the motor, shut down the motor, and
restore the safety measures of maintenance, assemble the coupler, and put it into
standby operation.

3.6

Attached-tables

3.6.1

Table 1

3.6.2

measuring of insulation resistance of asynchronous motor.

Insulation grade of Megger type

motor

Eligible value
insulation
resistance

of

380V

500V

0.5M

>1.3

6KV

2.5KV

10M

>1.3

absorptance

Table 2 capability, use and choose of motor lubricating grease

name

code
name

drop
point

Penetration main use

degree
25 150g
(1/10mm)

calcium
base ZG2
lubricating
ZG3
grease GB491 ZG4
65
ZG---5

80

265295

85

220250

90

175205

95

130160

Natrium
base ZN---2
lubricating
ZN3

140

265295

140

220250

Page 101 of 326

It can be used to lubricate the

bearings
of
industrial,
agriculture and traffic machine,
for
which the working
temperature is below 55
60, especially use for the
wet area and water area, and it
can also be used for lubricate
the oil handling devices such
as oil ring and dry oil wheel
use for lubricate the bearing of
various mechanism devices,

grease GB491 ZN4

65

150

175205

which working temperature are

at the range of115 145,
this kind of grease has the
intolerance of water(or wet),
the working temperature is: ZN
2 lower than 150 , ZN---3
lower than135 , ZN4 lower
than145

calcium
& ZGN---2
natrium
base ZGN---3
lubricating
grease SYB14
0362

120

250290

135

200240

to lubricate the machine use in

wet and water environment
with 80 100 working
temperature

Grease
for ZGN69
rolling
2
bearing SY151
465

120

250 290(- lubricate the rolling bearings of

4020)
motor or the other machine

#2aeroZL45---2
lubricating
grease SY150
865

170

285315

to lubricate the rolling bearings

with
large
temperature
changing range.

compound
ZFU1
aluminium base ZFU2
lub. Grease.
ZFU---3

180

310350

200

270300

220

230250

can be used to lubricate the

high
temperature
wet
equipments, and can be used
to replace the calcium base
lubricating grease, calcium &
natrium
base
lubricating
grease,
and
compound
calcium
base
lubricating
grease.

compound
ZFU---1
calcium
base ZFU---2
lubricating
ZFU---3
grease.

180

310350

200

270300

220

230250

molybdenum
3
bisulphite
lub.
grease

220

240280

Page 102 of 326

can be used to lubricate the

high
temperature
wet
equipments,#1and #2 can be
use for centralized lubrication,
its replacements is compound
aluminium base lub. Grease.
To
lubricate
the
rolling
bearings
of rotating speed
below
40

1401500r/min,and the load

below
107Pa(4000kgf/cm2),
for example: to lubricate the

rolling bearings for large sized

motor, high temperature axial
flow fan, high pressure forced
draft fan and air compressor.
molybdenum
bisulphite
compound
calcium
base
lub. grease
3.6.1

ZFG--1E

180

310350

ZFG--2E

200

260300

ZFG--3G 220

210250

ZFG--4G 240

160200

Table 3 oscillation limited value table of motor

Rated rotating
turn/ minute

speed, 3000

Oscillation value(double 005

swing),millimeter
3.6.2

3.7

to
lubricate
the
high
temperature and high load
mechanism equipments.

1500

1000

Below 750

0085

01

012

Table 4 the permitted largest abrasion value of rolling bearing radial gap.
internal diameter of radial gap
bearing
new ball bearing

new roller bearing

permitted
largest
abrasion value

2030

0.010.02

0.030.05

0.10

3550

0.010.02

0.030.07

0.20

5580

0.010.02

0.060.08

0.25

85120

0.020.04

0.080.10

0.30

130--150

0.020.05

0.100.12

0.35

Name

standard and type

Unit

NO.

bearing

Used for motor of

different type

set

2 for each

Piece

10 for each

Spare parts

Copper connection Used for motor of

link
different type

4 Maintenance Technology of Distribution Device

Page 103 of 326

4.1

150 KV GIS

4.1.1

Technical regulations of 150kV GIS equipment

4.1.2

GIS maintenance interval and items of

4.1.2.1

Maintenance division of SF6 switchgear

Category

Interval

Patrol
inspect

Every
months

Description

Items

3 Inspect the outlook Equipment

of the GIS during appearance
operation. Check if
there is abnormal
condition on the
equipment

Contents
If the indicator and indicating light are
normal or not.
If there is abnormal sound or odour
If there is overheat or discoloring on the
terminal
If the grounding conductor or bracket is
corroded or damaged.
Check the indication of pressure gauge.

Regular

Specific

Every
year

12 years

3-6 The aim of regular

maintaining is to
ensure the long-time
good performance
of the GIM. If the
deenergizing
is
required within a
short time, the gas
is
not
recycled.
Check the outside of
equipment
for
abnormity. Carry out
such maintenance
as dust removing,
adding lube oil, etc.

Operating test

Indication state.
Check the reading on SF6 pressure
gauge before and after operating. Check
if there is any sound of gas leaking

Operating
Check if there is damp, rust or dirt inside
device
and the control box and control panel
control panel
Add lube oil and clean it up.
Tighten the conductor in the LV circuit.
Others

Same as patrol inspect.

When the opening Operating

1The spring is eroded and deformed.
and closing time device
and Repair the damaged components.
reaches
the control panel
2Adjust the stroke.
stipulation
(see
3) Check if each pin in the connecting
sheet 2), if the
section is normal.
equipment requires
4) Lubrication
to be power off for a
5 Check and repair the auxiliary
long time. In order
switch.
to keep the good
6 Regulate the oil buffer. Change the
performance of the
oil.
equipment,
check
7 Change the components according
the
components
to the stipulation.
thoroughly
for

Page 104 of 326

Category

Interval

Description

Items

damage
or
abnormity. Conduct
the
inspection
based
on
instruction, working
method
and
environment
conditions of the
breaker.

Disconnecting Inspect
closely
and
repair
the
unit
and disconnecting unit & isolating unit.
isolating unit
Change the corresponding components.

Measuring
test

Contents

1 Test on activation time (OPEN &

CLOSE under rated atmospheric
pressure and voltage, measure the 3phase
activation
time
and
asynchronisation)
2 Measure the activation
minimal working voltage.

under

3Free trip test

4Pressure switch test
5 Inspection and test on pressure
gauge1
Specific

12 years

When the opening

and closing time
reaches
the
stipulation
(see
sheet 2), if the
equipment requires
to be power off for a
long time. In order
to keep the good
performance of the
equipment,
check
the
components
thoroughly
for
damage
or
abnormity. Conduct
the
inspection
based
on
instruction, working
method
and

Operating
1The spring is eroded and deformed.
device
and Repair the damaged components.
control panel
2Adjust the stroke.
3) Check if each pin in the connecting
section is normal.
4) Lubrication
5 Check and repair the auxiliary
switch.
6 Regulate the oil buffer. Change the
oil.
7 Change the components according
to the stipulation.
Disconnecting Inspect
closely
and
repair
the
unit
and disconnecting unit & isolating unit.
isolating unit
Change the corresponding components.

Page 105 of 326

Category

Interval

Description

Items

environment
conditions of
breaker.

Contents

Measuring
the test

1 Test on activation time (OPEN &

CLOSE under rated atmospheric
pressure and voltage, measure the 3phase
activation
time
and
asynchronisation)
2 Measure the activation
minimal working voltage.

under

3Free trip test

4Pressure switch test
5 Inspection and test on pressure
gauge
4.1.2.2 Maintaining items of breaker
No.
1

Body

Position

Items

Remark

Outside

Foundation
tightness.

bolt Conduct
checking
terminal interior

Grounding
tightness.

Inside

while
the

Abnormal sound.

Rust.

Check
disconnecting
components.

the

Change the sorbent.

2

SF6
System
The system

Close and open SF6 Check

the
check
valve
for components under
tightness checking.
maintenance

of

wiring

Check blind cover of

gas filling port.
Operating
device panel

Working pressure of
SF6
temperature
compensation pressure
switch.
Working
state
operating counter
Tightness
terminal

of

Page 106 of 326

No.

Position

Items

Remark

Measurement
of 2M
insulation resistant of
control circuit

Inspection of auxiliary Inspection

switch contact
contacts

of

If it works normally
or not.

If the wiring of the If it works normally

heater is opened or or not.
not.

Inspection
connecting
disconnecting coil

of
&

Check clearance G2, Disconnecting

G3 of electromagnetic G2=0.8-1.2(see
iron core.
Fig. 3)
Connecting
G3=2.0-3.5(see
Fig. 3)
Change
damaged

it

if

Check if there is Change

dewing or corrosion damaged
inside the panel and
panel seal.

it

if

Rubber strip on the

door

Tightness of bolts in
each section

Damage
damper.

to

rubber

G1(=1.40.3)

Page 107 of 326

No.

Position

Items

Remark

Operation
mechanism

Check if the tightening

detent ring for the G1(=1.40.3)
connection and each
bolt is in place or not.
Apply the lubrication
grease
to
the
components
and
connecting pieces.
Measure clearance G
between cam and roller

If it is normal.

Operation

Remark: a. Patrol inspect b. Regular inspect

should be carried out.
4.1.2.3

c. scrutinous inspect

Markon the items which

Overhaul plan for isolation switch and faults-connecting grounding switch:

No.

Item

Content

After
installation
before
activation

Corrosion

In the corroded place,

derusting, painting and
antirust oil painting is
conducted.

Wiring state

Keep
the
wirings
of
terminal plate and all the
other components and
tighten the bolts of all the
terminals.

Fastener

Tighten all the binding

bolts, screws and nuts.
Tight and lock the binding
bolts in the regulating
place.

& Check if the indicating of

opening & closing on the
plate is correct

Closed
tripped

Page 108 of 326

Patrol
& inspection

Regular
inspection

Check if the U-typed slot is

corresponding
to
the
needle (the pointer tip is
positioned within range of
slot).

If there is any deviation,

use the adjusting screw in
the positioner to adjust
5

Manual
operation
opening
closing

Normal activation

Operate under the rated

value of controlling voltage
and voltage of the motor
and 85% of rated value
and the activation is
normal. The activation and
switching
of
electrical
components is normal.

of
&

Motor driven
operation of
opening
&
closing

Inspection
Inspect and test based on
and test on the related clauses in the
interlock
specification

Insulation
test

Use the megameter of

500V to measure the
insulation resistance. The
insulation
resistance
between controlling circuit,
motor, heater and the
circuit of the heater and the
pedestal is no less than
2M

Cleaning

Clean the dust and dirt

inside and outside the
panel

10

Lubrication

Pa Paint lithium base

grgrease on friction part

4.1.2.4

Maintenance plan for grounding switch for maintenance

1) Patrol inspection

Page 109 of 326

2)

No.

Items

Inspect and maintain the

operation
mechanism
and
its
connecting
pieces.
Outlook
If
the
component
is Remove the corrosion
corroded.
and make the anticorrosion treatment
Check the nuts Check if the bolts for Tighten
again
if
and bolts
equipping,
terminal necessary
tightening bolts, detent ring
and pin are loose.

Checking position and key

points
Connecting
or Make sure the opening and
disconnecting
closing indicator works
correctly.

Solutions

Regular inspection

3)

No.

Items

Contect

Procedure

Operating test

Operating state Check if operating with Per year

of
connecting handle is normal
and
disconnecting

Clean and
refilling

State of conductor Conductor and Check if the bolts of the Every

and terminal
terminal strip
terminal strip is loose three
and if the conductor is years
damaged

Insulation
resistant

Otherpatrolling
items

oil Rubbing
connection
section

Meaurement
insulation
resistant

Cycle

and Remove the dust and Per year

paint the lubrication
grease

of Measure using 500V Every

meter, indicating that three
controlling
circuit years
grounding resistant is
greater than 2M
Every
three
years

Temperary inspection and maintenance

No.

Maintaining conditions

Contents

When
problems
are
discovered
furing
patrolling inspeciton
When
abnormal
conditions are discovered
during operating
Other precautions

Inspect, repair and regulate

the faulted parts

Inspect, repair and regulate

the faulted parts
Inspect, repair and regulate
the faulted parts
Page 110 of 326

Remark

4.1.3

Maintaining technology and procedure of GIS

4.1.3.1

Cleaning

4.1.3.1.1

Applicable range
This section is applicable to insulator casing and metal components cleaning. The
insulator surface must be clean. In addition, all the metal components must be
cleaned thoroughly without dust and other particles.

4.1.3.1.2

Cleaning solvent
Ethanol and acetone are allowed for cleaning the insulator surface.
Note: Do not breathe in the vaporized solvent while operating.

4.1.3.1.3

Consumable
Use the wiping paper or dacron cloth to clean up the surface of the cast insulator.
Use the white dacron cloth to clean up metal components
When cleaning the pouring insulator and metal components, dip these required
consumables into the cleaning solvent to make sure the surface of the components is
cleaned up.
Use the dry cloth instead of the dirty cloth for the final cleaning of the components.

4.1.3.1.4

Cleaning inside the gas pipeline

Fill the hith-purity nitrogen into gas pipeline from the both ends for romoving the dirt
inside the pipeline.

4.1.3.2

Air sealing

4.1.3.2.1

Acppication range
This section states the details on the operation procedure of sealing the SF6 with O
ring and air sealing glue for SF6 equipment.

4.1.3.2.2

O ring location (see Fig.5)

Sealing surface

Sealign ring

Sealing groove

Fig. 5 O ring location

4.1.3.2.2.1 Clean the sealing groove and the sealing surface. Check if there is scratching trace or
dust.
Use the cleaning cloth or smooth paper with alcohol while cleaning.
4.1.3.2.2.2 In the sealing groove, place the O ring which meets the requirement on size and
material reliably.

Page 111 of 326

4.1.3.2.2.3 When fix the flanges, make sure the O ring is in place.
4.1.3.2.3

Air sealing gel is used (seen Fig. 6)

Air side

Air
glue

Gas side

sealing

Fig. 6 Painting sealing glue

4.1.3.2.3.1

Using method of air sealing glue

(1) Generally speaking, the air sealing glue is not used on SF 6 side (used for the
whole circle of the O ring with the diameter of less than40)
(2) Apply a thin layer of air sealing glue on the whole outside surface of flange on air
side to prevent rain and corrosion.
(3) Finish assembling before the air sealing glue becomes hard (it will be harden by
1mm in at least 1h)
(4) Make sure there is no solvent sediment on the flange surface before air sealing
glue is applied.
(5) Check if the O ring and its tightness slot is clean without damage.

4.1.3.2.3.2

Other precautions
(1) Do not mix the grease and air sealing glue.
(2) Remove the residual air sealing glue after assembling
(3) Screw on the cover of the air sealing glue tube immediately after usage.

4.1.3.2.4

Using procedure of air sealing glue

Page 112 of 326

No.

Procedure

Cut the attached inclined nozzle

in a proper position for applying
it to narrow zone. Make the glue
can be squeezed out smoothly.

Reove the dirt in the sealing

grooves.

Paint the air sealing glue (zone

a) on the side of the external air
with the nozzle

Flatten the air sealing glue

smooth and paint it on zone a
with fingers

54

Set O ringFlatten the air sealing

glue smooth and paint it on
zone a with fingers

655

Use the nozzle to paint the air

sealing glue on zone b.Set O
ring

Picture

765

766

876

877

flatten the air sealing glue

smooth and paint it on zone b
with fingersUse the nozzle to
paint the air sealing glue on
zone b.
Use the nozzle to paint the air
sealing glue on zone b.

Swear the air sealing glue with

fingers in the zone b to make it
cover all the flanges on the air
side.flatten the air sealing Page
glue113 of 326
smooth and paint it on zone b
with fingers

4.1.3.3

SF6 filling

4.1.3.3.1

Application range
This section is applicable to SF6 filling into equipment after equipment installation or
maintenance. The process of SF6 filling includes extraction, leakage inspection and
SF6 filling (see Fig.7)

4.1.3.3.2

Process of evacuation

5.3.2.1

Connect the pipeline of vacuum pump with air inlet of equipment. It is required that all
the air pipes and vacuum pump should be be consistent with the capactity of the
equipment needed to be extracted.

4.1.3.3.2.2 Check if the rotating direction of vacuum pump is correct. Start up the pump.
4.1.3.3.2.3 After the vacuum reaches 133P, keep extraction for 30 mins.
4.1.3.2.4

If the vacuum pump stops running, close the valve of the vacuum pump and check if
the oil flows in reverse direction.

4.1.3.3.3

Vacuum leakage inspection

4.1.3.3.3.1 After extraction, close the air inlet valve and measure the pressure of the air chamber.
4.1.3.3.3.2 Conduct the leakage test. It is required that within 4 hours, It is required that the
difference between initial pressure and final pressure does not exceed 133P.
4.1.3.3.3.3 If the pressure increasing is approximately 133P, continue extracting until the vacuum
reaches 133P. Keep it for 30m. Repeat the leakage test to see whether there is
leakage or moisture venting.
4.1.3.3.4

SF6 filling process

4.1.3.3.4.1 Connect the pipeline from vacuum pump to SF6 bottle

4.1.3.4.2

Use SF6 to discharge the air in the pipeline. Fill SF6 to the equipment until it reaches
the rated value.
The rated pressure of the breaker is 0.5MPa. The maximum pressure is: 0.52MPa
The rated pressure of other air chamber is 0.4MPa. The maximum pressure is
0.42MP.

4.1.3.3.4.3 After filling, dismount the pipeline, cover the self-sealing joint.
Notes: (1) At the beginning of filling, open the valve of the SF6 bottle gradually for
filling slowly.
(2) For reserving and transporting the product which do not need to be disassembled,
fill the SF6 until the pressure reaces 0.02-0.05MPa. When install the equipment on
site, if there is no air leaking through checking, extraction and leak inspection are not
required. Fill the SF6 according to the instruction book.
4.1.3.4

Refill SF6

4.1.3.4.1

Application range
This section is applicable to refill of SF6 switchgear which is running (when the
pressure of various gas of decrease).

4.1.3.4.2

Procedure of SF6 refilling

4.1.3.4.2.1 Remove the blank cover of the SF6 bottle and the protective cover at the inlet of the

Page 114 of 326

filling chamber with the spanner.

4.1.3.4.2.2 Connect air inlet and valve of the air container with the hose with the diameter of 1/4
inch through a safety valve, pressure regulator and joints A & B. (the self-sealing joint
is used at air inlet. In normal operation, this connector is self sealed. SF6 pipeline can
be connected after the joint is forced to open and the pipeline are connected.
4.1.3.4.2.3 Release a certain amount of SF6 from the air container to blow out the air inside air
pipes and pressure regulator.
4.1.3.4.2.4 Tighten joints A & B.Ensure reliability of pipeline connection.
4.1.3.4.2.5 Open the valve of the SF6 bottle and the valve of the pressure regulator.
4.1.3.4.2.6 Raise the pressure of the SF6 chamber to rated pressure. But keep it lower than the
rated value 0.2Kg/cm20.02MPa.
4.1.3.4.2.7 After refilling, tighten the blank cover of the SF6 bottle and the cover of the selfsealing joints to prevent leaking. It takes a long time to gasify SF6 through latent heat.
Do not accelerate the gasification with flame.

7 SF6

Page 115 of 326

a6 refilling port of SF6

Blank cover B

Self-sealing joint

Connector A
O ring
Safety valve
Relief valve

Rubber pipe

Check valve

SF6 container
joint B

4.1.3.5

Application and changing of the sorbent

4.1.3.5.1

Precautions

4.1.3.5.1.1 Do not change the the sorbent during raining or the moisture content is larger than
80%.
4.1.3.5.1.2 The time for taking the sorbent from the sealing device and putting it inside can not
exceed 30 mins.
4.1.3.5.1.3 After assembling the sorbent, extract the equipment as soon as possible.
4.1.3.5.2

Procedure

Page 116 of 326

No

Procedure

Picture

Dismount the cover with

sorbent
from
the
air
insulation equipment

Dismount the box of

sorbent on the cover plate.
Change the sorbent

After covering the box of

sorbent with the plate, use
bolts to fix the box on the
plate.

Clean out the flanges of the

cover and the sealing
surface of the covering
plate. Install O ring and
covering plate.

4.1.3.6

Installation of the control cable and cable gland disposal

4.1.3.6.1

Application range
This section is applicable to installation of the control cable and cable gland disposal
connected with switchgear.

4.1.3.6.2

Installation of controlcable

4.1.3.6.2.1 All the cables in the switchgear are layed on the wire conduit or cable support.
4.1.3.6.2.2 After installing the cable in the control box, regulate it properly.

Page 117 of 326

Make sure the

terminal does not bear mechanical stress.

4.1.3.6.2.3 After connecting all the cables, use the electric bell or multimeter to check if all the
core wire are connected correctly and reliably.
4.1.3.6.2.4 When moving and operating, check the connecting bolts and clamp which may be
loose.
4.1.3.6.2.5 After checking the connecting parts, use the sealing glue to seal the conductor pipe
port.
4.1.3.6.3

Cable gland disposal

4.1.3.6.3.1 Open the cable, its coat should be longer than the wiring terminal.
4.1.3.6.3.2 Peel off the metallic layer and the ethene coat.
4.1.3.6.3.3 Connect the grounding wire to the metallic layer by tin weling or clamp.
4.1.3.6.3.4 Use the insulation belt (e.g.FB insulation belt) to twine the end of the cover, metallic
layer and ethene coat forming two films around them. If the cable insulation requires
water proofing, paint silica gel (water repellent) on both ends of the cable before
winding the insulation belt.
4.1.3.6.3.5 Remember that connect the grounding wire to the grounding terminal in the
mechanism box.
4.1.3.7

Maintenance of circuit breaker

4.1.3.7.1

Precautions for maintenance:

4.1.3.7.1.1 Cut off the operating power supply.

4.1.3.7.1.2 When checking the interior or the components, confirm the closing pin and prevent
disconnecting pin from being inserted. After the maintenance is finished, make sure
that both pins are pulled out.
4.1.3.7.1.3 If it is necessary to check the inside of CB, cut off the main circuit. After two ends of
the breaker are grounded, extract thoroughly the SF6, keep ventilation in good
condition. Then, the maintenance work can be carried out.
4.1.3.7.1.4 Use the designated lubrication grease (see the section 4.6.2) but do not paint it on the
insulator.
4.1.3.7.1.5 Take down the O ring. Install the new one according to the stipulaton.
4.1.3.7.1.6 The liquid sealing glue is painted on O ring and exterior of the air sealing surface. (Oring sealing slot and O-ring contact surface)
4.1.3.7.1.7 Do not disassemble the seal of shaft driven directly
4.1.3.7.1.8 After the internal maintenance is finished, change the sorbent. Carry out the
extraction timely.
4.1.3.7.1.9 For all the disassembled sealing link, carry out air leaking test on them.
4.1.3.7.1.10 Confirm that all the technic parameters are not changed dramatically before and after
the maintenance.
4.1.3.7.2

Maintenance on arc extinguishing chamber

Figs 8 and 9 shows the maintenance procedure of the arc extinguishing chamber

4.1.3.7.2.1 Confirm the SF6 is recycled completely. Dismount the galvanized bolts. Check the

Page 118 of 326

covering plate.
4.1.3.7.2.2 Dismount the M12 hexagonal bolts. Take out both fixed contact b7 and fixed arc
contact b12 at this time. If the fixed contact is slightly abraded, reinstall the contact.
4.1.3.7.2.3 Insert the remover e1 for the nozzle and disassemble nozzle b14.
4.1.3.7.2.4 Insert the remover e2 for movable contact. Dismount the movable contact b15.

Hexagon bolt

Support
conductor
of
fixed contact b7

fixed contact b12

Chart8 Maintenance of arc distinguishing charmber

Remark:
Reinstallation should be carried out in inverse sequence shown in Fig. 8. The
precautions are as follows:
(1) Compare the wearing of the component with the content in the section 4.3, if it has
reached the level for changing, change it for a new one.
(2) If the component is slightly worn,use a crocus paper to polish it for reusing.
(3) Clean the contact and paint the dedicated lubrication grease on the contact
components.
(4) When reassembling the arc extinguishing chamber, the nozzle will be tightened
until the nozzle become loose. Once the nozzle is loose, do not increase the moment
and keep the nozzle clean during assembling and operation.
(5) After maintenance on components inside the arc extinguishing chamber, clean it
thoroughly.

Page 119 of 326

remover e1 for
the nozzle

b14
nozzle

Remover
e2
for
movable
arc
extinguishing contact

Movable
arc
extinguishing contact
b15

Fig. 9 Maintenance of arc distinguishing

charmber

4.1.3.7.3

Change the sorbent

After the internal maintennace, change the sorbent inside the shell. For detains, see
section 5.6.

4.1.3.7.4

Inspect the working pressure of the SF6 pressure switch (SF6 density switch) see Fig.
10.
Inspect the working pressure in the following order

Page 120 of 326

4.1.3.7.4.1 Close the SF6 controlling valve (a2) and dismount blind cover A (a5).
4.1.3.7.4.2 Slowly open the vent valve F of SF6 (a3) and use a buzzer or tester to check the
releasing pressure of the switch while observing pressure gauge of SF6.
4.1.3.7.4.2 Slowly open and close the vent valve F (3) of SF6 and open the controlling valve E
(a2) and check the releasing pressure in the same way as that mentioned in
section4.1.3.7.4.2.
4.1.3.7.4.4 When connected, the working pressure that is in the following range is normal.
= 4.50.3kg/cm20.450.03MPa

20

SF6 working pressure in the coming direction

= 4.50.3kg/cm20.450.03MPa
2

= 4.00.3kg/cm 0.400.03MPa

When the temperature is 20

20

Working pressure when operating interlock (63GL)

= 4.00.3kg/cm20.400.03MPa

When the temperature is 20

=63GA63GL+0.1~0.5kg/cm20.01~0.05MPa
Releasing pressure (63GA63GL)
= Working pressure63GA63GL+0.1-0.5kg/cm20.01-0.05MPa
When the blank cover A (a5) recovers, slightly open the vent valve (a3) to vent the air
in the pipe. After tightening the blank cover, use the suds to inspect if there is air
leaking in the disassembled part. Besides, make sure the contro
lling valve E (a2) is open after the test.

a4 temperature makeup pressure

switch (SF6 pressure gauge)

a5 blind cover A
O tank

Tank downside
breaker
a2 controlling valve E

Fig.10 Inspection of working pressure of temperature makeup pressure switch

Page 121 of 326

a3
vent
valve F

4.1.3.7.5

Filling and refilling of SF6 (see in section5.3 and section5.4)

4.1.3.7.6

Air sealing inspection

4.1.3.7.6.1 Use the soap water to inspect the leakage

When inspecting the leakage, paint the subs on the part to be inspected and check if
there is bubbling (observe for more than 30 seconds)
4.1.3.7.6.2 Vacuum leaking inspection
(1) Evacuation inside the breaker
(2) Close the check valve of the vacuum pump and the valve of the breaker. Keep
them in closed state for hours.
(3) After closing the valves for hours, open the check valve of the vacuum pump and
extract the equipment for 1-2 min.
(4) Stop extraction. Open the valve of the breaker and check if there is variation (over
1mmHg) in the vacuum pressure guage.
4.1.3.7.6.3 Use to leak detector to inspect
Compare the results of inspecting according to methods mentioned in section 5.7.6.1
and section 5.7.6.2, and the following high-accuracy inspection is conducted in the
following methods,
(1) Fill SF6 of 5kg/cm20.5MPainto the breaker.
(2) Use the plastic film to twine and cover the parts requiring inspection and keep it in
that state for 4 hours, then use the leak detector to inspect.
4.1.4

Precautions for GIS Maintenance

In the SF6 CB, working in the cover is unnecessary. But it is reqired there is
inadequate oxygen. Working principles are listed as follows:

4.1.4.1

The work should be carried out under the guidance of the personnel who is in charge
of WORKING UNDER OXYGEN LACKING

4.1.4.2

Confirm the number of the personnel before and after the work.

4.1.4.3

Check the oxygen densimeter, ventilation equipment and protective devices.

4.1.4.4

The non-related personnel is not allowed to enter.

4.1.4.5

Ventilate the air CB. Make the record on the oxygen density.

4.1.4.6

Start working under the conditions that the oxygen density is over 18%, the oxygen
density is not lower than 18% when the ventilator is in service.

4.1.4.7

The duty personnel should be on site in the whole process of maintenance. In

addition, more than two persons should be working.

4.1.4.8

Move the SF6 bottle from the CB. Hang the sign plate DO NOT OPEN OR CLOSE.

4.2

6kV Auxiliary Power System

4.2.1

Technic regulations on equipment in 6kV auxiliary power system

4.2.1.1

6.3KV circuit breaker

Description of 6.3KV
power
circuit breaker
incoming feeder

supply Specification and ZN12A-12

circuit model

Page 122 of 326

breaker
Rated voltage

10kV

Working voltage

Rated current

1250A

Rated
current

Phase number

3-phase

Rated frequency

6.3KV

breaking 40kA

Mechanical
service life

Electrical service
life

Mode
of Spring energy type
operation
mechanism

Voltage
operation
supply

50Hz

of DC 110V
power

Manufactory
4.2.1.2

6.3KV power supply incoming and outgoing line switchgear

Specification and KYN18C-12TH Drawout Type AC Metal-enclosed switchgear

model
Rated voltage
Rated
current
Rated
current

10kV

busbar 3150A
breaking 40kA

Working voltage

6.3 kV

Rated frequency

50 Hz

Rated
thermal
stability time

Bus model and Rectangle copper Cooling mode

material
busbar
current
transformer

LZZBJ9-10

Overvoltage
protection
implement

Zero
sequence LXKB-120
transformer
Circuit
breaker
state
intelligent
controller

Manufactory
4.2.1.3

Natural cooling

Beijing Beikai Electric Co., Ltd.

6.3KV feeder switchgear

Specification and KYN18C-12TH Drawout type AC metal-enclosed switchgear

model
Rated voltage

10kV

Working voltage

6.3 kV

Rated bus current

1250A

Rated frequency

50 Hz

Rated
current

breaking 40kA

Rated
thermal
stability time

Bus model and Rectangle copper Cooling mode

material
busbar
current
transformer

LZZBJ9-10

Overvoltage

YH series of Xian Circuit

Natural cooling

Zero
sequence LXKB-120
transformer
breaker

Page 123 of 326

protection device

Shendian

state
intelligent
controller

Manufactory

Beijing Beikai Electric Co., Ltd.

4.2.2

Maintenance interval and items of 6kV auxiliary power system

4.2.2.1

Maintenance frequency

4.2.2.1.1

Maintenance frequency of circuit breaker is one time for every year

4.2.2.1.2

If has overhaul in that year, it will be taken along with unit overhaul.

4.2.2.2

Maintenance item of circuit breaker

4.2.2.2.1

Clean up the dust

4.2.2.2.2

Adding lubricating oil to the rotation part

4.2.2.2.3

Check regularly

4.2.3.

Maintenance content and notes of6.3KV circuit breaker

4.2.3.1

Clean up of circuit breaker

1 Periodically clean up of circuit breaker can ensure the cleanliness of insulating
component and conductor surface; prolong the service life of circuit breaker.
2Transact maintenance working permit, clean up after safety measure has finished
and be permitted.
3Use electric cleaner and dry brush when cleaning
4 Clean up of circuit breaker should be carry out when circuit breaker main and
auxiliary loop with no electricity.

4.2.3.2

Adding lubricating oil to the rotation part of circuit breaker

1 Adding lubricating oil to the rotation part of circuit breaker can make sure the
operating mechanism of circuit breaker agile and reliable, without unsmooth blockage
phenomenon.
2Transact maintenance working permit, clean up after safety measure has finished
and be permitted.
3Main parts should be lubricated includes:
a)Every transmission part of circuit breaker including operating mechanism
b)Transmission part related to the installation part of circuit breaker, such as:
interlocking transmission part between circuit breaker and other parts in switchgear
cabinet.
c)Primary isolation pin of circuit breaker should be cleaned and painted with new
petroleum jelly.

4.2.3.3

Check of circuit breaker appearance

1)Insulating support should with no crack, disrepair and loosen phenomenon. Change
if necessary.
2)No fall-away and asymmetry for every shaft and pin. Or should be complement or
regulate.
3)Tighten all fasten with spanner, tighten again when loosen.

Page 124 of 326

4.2.3..4

Operation check of circuit breaker

1)Operation check should be done after transact the working permit and circuit
breaker main and auxiliary loop with no electricity.
2)Before operation, every indicator on circuit breaker panel should be check whether
in normal location. Circuit breaker should in the state of switch on and spring with no
energy saving, main loop switch off before checking.
3)Check according to the following procedure:
a)Shake the manual energy saving crank according to the direction clued on the
operation panel and undertake energy saving operation. Check whether circuit
breaker energy saving complete and whether energy saving indication on
observational panel after operation finish.
b)Use manual energy saving switch on button to switch on. Check whether circuit
breaker in normal switch on state, whether action of circuit breaker switch on
indicator,switch on and switch off counter is right or not after operation finish.
c)Use manual switch off button to switching off. Check whether circuit breaker in
normal switch off state and whether action of circuit breaker switch off indicator is right
or not after operation finish.

4.2.3..5

Test and check of circuit breaker mechanical parameter

1)Test the following data of circuit breaker with appropriative switch mechanical
characteristic tester.
a)Contactor distance: it means that the total gap between circuit breaker one side
dynamic and static contactor position. Test contactor opening distance of three
phases separately. Test method is as the drawing. Measuring result should accord
with the parameter scope when leave the factory.

Page 125 of 326

b)Contact travel: moving distance of component after dynamic and static contactor
contacts and produces closing force. This circuit breaker adopts the method of
indirect measuring contactor spring compressing quantity to test the contact travel of
contactor. Test contact travel of three phase separately. Test method is as the above
drawing. Measuring result should accord with the parameter scope when leave the
factory.
c)Contactor bouncing time: interval between contactor close and dynamic and static
contactor flick again when circuit breaker switch on. Test the contactor flick time of
three phases separately. Measuring result should accord with the parameter scope
when leave the factory.
d)Three phase switch off synchronization: time difference between earliest separating
phase contactor and latest separating phase contactor when circuit breaker breaking.
Measuring result should accord with the parameter scope when leave the factory.
e)Switch off time: interval between the moment that circuit breaker receive the
breaking signal and the moment that all phase contactors separate. This value should
be measured separately during circuit breaker rated voltage, lowest operation voltage
and highest operation voltage.
f)Switch on time: interval between the moments that circuit breaker receives closing
signal and all phase contactor contact.
4.2.3..6

Test and check of circuit breaker loop resistance

1)This test need appropriative DC resistance tester. Test resistance for main loop of
circuit breaker three phase separately.
2)Connect 100A DC current by appropriative DC resistance tester to main loop on one
side upper and lower terminal. Loop resistance value of this phase loop can be got by
calculation.

4.2.3..7

Test and check of circuit breaker insulating level

1)Measure the primary and secondary loop voltage value according to the working
frequency pressure resistance value prescribed by electric preventive test regulation
so as to check the insulating level of circuit breaker.
2)This test can only be done after circuit breaker remote test insulating resistance by
2500V megger.
3)Working frequency and pressure resistance test of primary loop should take
pressure resistance test between phase, terminal pressure resistance test and phase
to ground pressure resistance test separately.

4.2.4

Precautions for maintenance of 6kV auxiliary power system

4.2.4.1

Usually the circuit breaker installs in the manufacture by standard clamping fixture
and all the cooperation relation is ensured by clamping fixture. Do not do much
disassembly and installation during maintenance process. Because circuit breaker
maybe can not reaches the basic performance requirement after disassembly and
installation, even worse than before disassembly.

4.2.4.2

For the components that require to disassemble, method, procedure and position

Page 126 of 326

method should be designed before disassemble so as to make sure the correctness

for next assembly.
4.2.4.3

For those have been disassembled and can not reach the standard requirement after
installation and checking, contact the manufacture for repair. Operation of equipment
with failure is forbidden.

4.3

0.4kV Auxiliary Power System

4.3.1

Technological regulations on the equipment in 0.4kV auxiliary power system

4.3.1.1

0.4KV circuit breaker 1

Description
0.4KV power supply Specification
of
circuit incoming line circuit and model
breaker
breaker and the above
motor of 75KW
Rated
voltage

400V

Working voltage

Rated
current
Phase
number

400V

Rated breaking 50KA

current
3-phase

Rated
frequency

50Hz

Manufactory
Manufactory

4.3.1.2

Zhongshan Ming Yang Electric Co.,Ltd.

0.4KV circuit breaker 2

Description of Outgoing
line
circuit Specification and Schnaid
circuit breaker
breaker of motor with model
series
capacity
below
0.4KV
75KW
Rated voltage

400V

Working voltage

Rated current

See drawing

Rated
current

Phase number

3-phase

Rated frequency

Manufactory

Zhongshan Ming Yang Electric Co.,Ltd.

400V

breaking 42KA
50Hz

4.3.2

Maintenance interval and items of 0.4kV auxiliary power system

4.3.2.1

Maintenance frequency

4.3.2.1.1

Maintenance frequency of circuit breaker is one time for every year

4.3.2.1.2

If has overhaul in that year, it will be taken along with unit overhaul.

4.3.2.2

Maintenance item of circuit breaker

4.3.2.2.1

Clean up the dust

4.3.2.2.2

Adding lubricating oil to the rotation part

Page 127 of 326

NS

4.3.2.2.3

Check regularly

4.3.3

Maintenance content and notes of 0.4KV circuit breaker

4.3.3.1

Clean up of circuit breaker

1)Periodically clean up of circuit breaker can ensure the cleanliness of insulating
component and conductor surface; prolong the service life of circuit breaker.
2)Transact maintenance working permit, clean up after safety measure has finished
and be permitted.
3)Use electric cleaner and dry brush when cleaning
4)Clean up of circuit breaker should be carry out when circuit breaker main and
auxiliary loop with no electricity.

4.3.3.2

Adding lubricating oil to the rotation part of circuit breaker

1)Adding lubricating oil to the rotation part of circuit breaker can sure the Operating
mechanism of circuit breaker agile and reliable, without phenomenon.
2)Transact maintenance working permit, clean up after safety measure has finished
and be permitted.
3)Main parts should be lubricated includes:
a)Every transmission part of circuit breaker including operating mechanism
b)Transmission part related to the installation part of circuit breaker, such as:
interlocking transmission part between circuit breaker and other parts in switchgear
cabinet.
c)Primary isolation pin of circuit breaker should be cleaned and painted with new
petroleum jelly.

4.3.3.3

Check of circuit breaker appearance

1)Insulating support should with no crack, disrepair and loosen phenomenon. Change
if necessary.
2)No displacement and asymmetry for every shaft and pin. Or should be complement
or regulate.
3)Tighten all fasten with spanner, tighten again when loosen.

4.3.3.4

Check and parameter inspection of circuit breaker

1)Main contactor and Arc extinction contactor surface should unknit, no burn and
accidented phenomenon. If the thickness of contactor silver & tungsten alloy layer
<1mm, contactor must be changed.
0.5MM
2)Regulate the spring. Make sure no overheated, distortion and tiredness
phenomenon. Contact resistance of three phase contactor100asynchronization
of contactor contacting0.5MM
3)Good contacting of every conductive part, no overheated and burn phenomenon.
Contacting part between switch and bus bar, cable should be opened for checking
when overhaul, cleanup the oxidative membrane again, paint with folium conductive
cream. Then, install and tighten it.

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4)No rust and distortion phenomenon for electromagnet. Agile iron core without
unsmooth blockage and displacement. Active iron core and static iron core contacts
closely.Break time gap meets the requirement.
5)Arc extinction device is good and arc extinction bar should be cleaned with firm
installation and correct location. Contactor should not touch the arc extinction cover
when close the switch manually with certain distance.
6)Agile Operating mechanism. No unsmooth blockage, abrasion and distortion for
every active parts and components; good springiness of spring; adding oil to rotary
shaft part.
7)It should closed reliably after energy saving (under pressure trip must close).
Energy saving spring should in shortest position after switch closed. Pressure
"separate" Button manually and the switch can be open reliably.
8 Good insulation and agile rotation of energy saving motor. Check entirely when
overhaul.
9Energy releasing electromagnet coil is good. DC resistance meets the requirement
of nameplate data and with tightness connection.Suitable adjustment of switch on
mechanism which can switch on reliably and working voltage meets the
requirement85110%Ue.
10 Good insulation of switch off coil. DC resistance meets the requirement of
nameplate data and with tightness connection. Suitable adjustment of switch off
mechanism which can switch off reliably and operation voltage meets the
requirement3570%Ue.
11Operating fuse is good. Fuse rated current is qualified and with good contacting.
12 Firm installation of auxiliary contact with good contacting, no burn, good
insulating condition, and gap meets the requirement and suitable regulation of on-off
time. Check whether its on-off location is suitable Manually and motor driven, switch
off and switch on.
13 Primary overcurrent mechanism is good. Regulation of overcurrent meets the
requirement and can switch off reliably.Dismantle it when nonuse and fixup it to avoid
misoperation
14Good insulation of secondary loop, terminal block is clean and with clearly marks.
15Pedestal is good and firm with vertical installation.
16 Inspection methods for brainpower controller protection characteristic setting
value are as following:
a)For L25X type controller: contact CW2 appropriative tester, press "selection" Button
convert to the setting value that will be checked. If want to change the setting value,
rotated the code board and regulate every setting value.
b)For M25M26L26 type controller: press "setting" Button, protection characteristic
setting value will displayed on LED screen. If want to change the setting value, press
/ to regulate every setting value and press "save" Button to save the chang ing
value.

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c)Test method is as following: L25 controller

Rotate "test" code board button and choose suitable test current.
Finish step 1 press Trip button after 2S. Controller will enters test state and
circuit breaker switch off according to protective curve .
Press "setting" Button and choose suitable test current by press /. Press trip
button and take trip test or press non-trip button and take non-trip test.
Controller enters test state when testing light lights. Enters the three sections
protective action scope according to the size of test current. Circuit breaker switch
off according to protective curve.
4.3.4.1

Usually the circuit breaker installs in the manufacture by standard clamping fixture
and all the cooperation relation is ensured by clamping fixture. Do not do much
disassembly and installation during maintenance process. Because circuit breaker
maybe can not reaches the basic performance requirement after disassembly and
installation, even worse than before disassembly.

4.3.4.2

For the components that require to disassemble, method, procedure and position
method should be designed before disassemble so as to make sure the correctness
for next assembly.

4.3.4.3

For those have been disassembled and can not reach the standard requirement after
installation and checking, contact the manufacture for repair. Operation of equipment
with failure is forbidden.

4.4

Transformer

4.4.1

Technological regulation on transformer

4.4.2

Transformer maintenance interval and items

4.2.2.1

Maintenance interval

4.4.2.1.1

Conduct the minor overhaul every 1-3 years, the preventive test should also be done.
Lessen the minor overhaul interval for the transformer that is running in the poor
environment.

4.4.2.1.2

During the overhaul, whether the transformer needs to be maintained depends on the
transformer preventive test result, on-line monitoring result of transformer in service,
and the all-round analysis.

4.4.2.1.3

Conduct the temporary maintenance timely if the serious defects are found during the
operation.

4.4.2.2

Transformer maintenance items

4.4.2.2.1

Minor overhaul items

4.4.2.2.1.1 Oil immersed transformer

1) External inspection and cleaning
2) Inspection of the maintenance of expander, oil reservoir and breather.
3) Inspection of tightness of primary and secondary lead connection elements..

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4) Solution for leaking

5) Inspection of tightness of fuse-panel CT, end-panel grounding place of PT and the
grounding place of end N (X) of the PT.
6) If necessary, repire and replace the components.
7) If necessary, relulate the oil level or nitrogen pressure
8) If necessary, repaint the CB.
9) If necessary, add the metal expander for better seal.
10) If necessary, remove the gas in insulation oil.
4.4.2.2.1.2 Solid insulation transformer
1) External inspection and cleaning.
2) Inspection of tightness of primary and secondary lead connection pieces.
3) Check the iron core and clamps
4) If necessary, re-paint CB.
4.4.2.2.1.3 Capacitive PT
1) External inspection and cleaning
2) Inspection of tightness of primary and secondary wiring connectors.
3) Leak disposal of the electromagnetic unit and refill the oil necessarily
4) Necessary paint refilling
4.4.2.2.2

Overhaul items

4.4.2.2.2.1 Oil immersed transformer

1) External inspection and test before overhaul
2) Check the metal expander
3) Discharge insulation oil
4)Disassemble porcelain bushing of primary and secondary lead
maintenance.
5Hoist the porcelain bushing for checking.
6) Change all the rubber gaskets.
7) Clean the oil tan. Remove the rust.
8) Inspection and test on pressure releasing device
9) Disposal or changing of insulation oil
10) Inspect the breather. Change the dryer.
11) If necessary, dry the transformer.
13) Entire installation
13) Fill oil under vacuum condition.
14) Sealing test
15) Insulation oil test and electrical test
16) Painting
4.4.2.2.2.2 Capacitive PT

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poles for

1) External inspection and test before overhaul

2) Check the capacitive bushing, and measure the capacitance and the medium loss
factor
3) Check the electromagnet unit
4) Electromagnetic unit insulation drying (when necessary)
5) Disposal of insulation oil in electromagnetic unit
6) Change the rubber gaskets.
7) Assemble the electromagnetic unit
8) Oil filling or nitrogen filling of electromagnetic unit
9) Electrical test
10) Painting
4.4.3

Transformer maintaining technological regulations and procedure

4.4.3.1

Maintaining technics and quality standard of components of oil impregnation

transformer are as follows:

No.

Items

Maintenance technology

Quality criteria

Inspection 1) Check if there is leaking from the beading

of
metal welding joint of the expander. If weld joint
expander
has cracks or the expander deforms
permanently, change it. If there is partial
leaking in the mounting barrel, reweld it
again.

1) The expander is
sealed reliably without
leaking and permanent
deformation.

3) Check if oil indicating unit and the oil

temperature pressure indicator mechanism is
in good condition and reliable. Repair them if
they are blocked.

indication unit indicate

smoothly and correctly.

2) There is no residual
gas in the gas releasing
2) Check if there is gas inside the gas valve
releasing valve of the expander, if any, 3)
The
oil
level
ascertain the cause, discharge the residual indication unit or the oil
gas.
temperature pressure

4)
The
pressure
releasing device of the
4) Check if the pressure releasing device of box expander is good
the box expander is good. If the releasing 5) The top cover and
plate has cracks, ascertain the cause and the coat of the rippling
replace it.
expander
are
5) Check if all the connecting bolts of the top
cover of the corrugated expander are
complete and eroded. If any,complete the
bolts and remove the erosion on the top
cover and coat.

connected reliably and

prevent corrosion and
blockage. Ensure that
the top cover can be
jacked up when the
6) Check if the paint coating peels off in the pressure inside the
expander is extremely
coat, repaint it.

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increased.
6) The paint coating is
good
2

1) Check the oil indicator to ascertain if there

Check the is leaking. If there is, tighten the bolts,
change the broken glass pipe of the oil
oil tank
indicator or the glass plate and change the
aged disabled sealing ring for a new one.

1) Oil indicator is good

without leaking, the oil
level
indication
is
correct and there is no
false oil level.

2) Check if the rubber membrane inside the 2) The septum is good

oil tank for cracks or aging. If any, replace it. without damaging
3) Check if the glass cover of silica gel
moisture absorber for cracks. If any, change
it for a new one. If the silica gel discolors
after absorbing moisture, change it for a dry
one. Clean the moisture absorber when it is
dirty and refill the oil when it is lack of oil.
4) Check the tightness of
connection of the primary lead.

the

3) The moisture is
good, silica gel is try,
the oil in the oil cup is
pure and the oil content
is normal.

4)
Primary
lead
wiring connection is reliable.

5) The paint coating is

5) Check the paint coating outside, if the good
paint coating peels off or is corroded, remove
the corrosion and repaint it.
3

Porcelain
bushing
inspection

1) Remove the dirt on the surface of the 1) The surface of the

porcelain bushing. Do not damage the porcelain
is
clean
porcelain.
without dirt
2) Use the epoxy resin to repair skirt
wearout, or use the super glue (such as 502)
to splice the knocked-off porcelain. If there is
obvious cracks along the radial direction, the
damaged surface exceeds 10% of single
skirt, or over two of the skirts are damaged
along the same direction.

2) The surface of the

porcelain is completed
and
the
repairing
surface of one skirt
does not exceed the
stipulations listed in the
left sheet

3) In the dirty place, if the creepage distance

is inadequate, paint the pollution-proof
flashover or add the silico gel to increase
creepage distance.

3) The hydrophobicity
of the coating and silico
gel creepage skirt is
good.

4) Check the hydrophobicity of the stainrepellent layer, if it falis, clean it and paint
again. Change the creepage if it fails.
4

Inspection 1) Inspect and complete tne name plate and 1) The name plate and
of oil tank indication plates.
the indication plates are
ans
all in place
2) Remove the dirt and corrosion outside
pedestal

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3) Open the cover of the secondary junction 2) The surface is clean

box. Check and clean up slightly the without dirt or corrosion
secondary wiring terminal and wiring board.
3) The secondary wiring
4) Clean slightly the minor porcelain bushing board and the terminal
at the N end of PT, end panel of CT and sealing is good without
monitor the minor porcelain bushing
leaking, no oxidation or
discharging sign.
5) Inspect the pressure releasing device
4) Keep the porcelain
7) Inspect the paint coating in the surface. If bushing clean without
leaking
or
paint coating is detached or corroded, dirt,
discharging sign.
remove the corrosion and repaint it.
6) Inspect the oil releasing valve

5) The membrane of
the pressure releasing
device is good and
sealed reliably
6) The tighness of the
oil releasing valve is
good without leaking
7) Paint coating is good

4.4.3.2

Maintenance technology and quality criteria of the solid insulation transformer

are as follows:

No.

Item

Inspection
solid
insulation
surface

Maintenance technology
of 1) Remove the dust and dirt in the
insulation surface using abluent if
necessary, then clean the surface using
clean water and wipe it.
2) If there is any sign of discharging on the
insulation surface, abrade the carburized
layer using a crocus paper. After seeing the
normal resin insulation surface, clean it
with the acetone solution, paint it again
with the resin of the same type.
3) If there are cracks on the insulation
surface, inspect that if the cracks have
extended along the primary direction. If it is
only a partial fault, abrase the flawed parts
and repaint the resin of the same type. If
the crack is throughout, replace the
transducer.
4) When the silica powder of resin casting

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Quality criteria
1) The surface of the
solid insulator is clean
without dirt and dust.
2) There is no sign of
discharging or crack
on the surface of the
porcelain insulator
3) There is no crack
on the surface of the
resin insulator
4) The paint coating
on the surface of the
resin is good
5)
The
semiconductive coat
on the resin surface is
in good condition.

body is exposed, repaint the resin of same

type after cleaning
5) If paint coating of the semiconductor on
the the resin insulation surface is
detached,
repaint
it
with
the
semiconductive paint of same type after
cleaning.
2

Inspection of 1) Check if there is overheating in the

primary wiring wiring terminal. If there is oxidized layer
connection
due to overheat, disassemble the primary
wiring, remove the rust, swear the
conductive paste and reassemble it

1)
There
is
no
oxidation in contacting
surface of primary
wiring terminal and
the fastener are all in
2) Check if the primary wiring fastener is place and connected
tightened based on the requirements and reliably
complete the bolts washer.
2) Primary wiring is
connected reliably.

Check if the Remove the oxidized layer of the The lugs of the end
equipotential
contacting part. Tighten the bolts on the wiring
of
the
line of busbar lugs of the tightening wiring.
equipotential line and
CT is reliably
primary current bas
connected
are
tightened,
contacting reliably

Check
the 1) Make sure all the marking on the wiring 1) All the markings on
name plate in terminals are complete and clear. Make a the wiring terminals
the checker
new marking if there is lacking or damage. are complete and
2) The name plate is good and contact the clear.
manufacturer if there is lacking or damage.

2) The name plate is

good

Check the iron 1) Make sure the clamps are tightened

core
and reliably. Complete them if they are
clamp
inadequate. Tighten reliably the iron sheets
after smoothing if they are loose

1) The iron core is

smooth, the clamps
are all adequate and
they are all reliably
2) Keep the paint coating on the surface of tightened
the iron core and clamps in good condition. 2) The paint coating of
Remove the corrosion and repaint them if the iron core and
there is any corrosion.
clamp
are
good
without corrosion

4.4.4

Precautions for transformer maintenance

4.4.4.1

For Primary and secondary circuit operatioin of the transformer, issue the
working permit and operating permit according to the related regulations and
stipulations. take safety measures.

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4.4.4.2

Precautions for stopping PT

1) Changing the operating mode based on the related stipulation of relay
protection and automatic device. Prevent the malfunction of the relay.
2) Open the main fuse of the secondary circuit or automatic switch to prevent
back energization.

4.4.4.3

It is required that working in secondary circuit of the energized CT is in

accordance with the safety stipulation. If the unit of protecton and the
measurement share the same secondary winding, when the meter is working
in circuit, short circuit the meter first to prevent tripping of the CT and misdeactivation of the protective device.

4.4.4.4

After the capacitive PT is deenergized and before it contacting the capacitive

divider, have the tapping capacitive units discharge to ground until there is no
spark or sound discharing, then connect them to ground reliably.

4.5

Spare List and Attachment for Oil Standard (Unavailable for Interim)

5 Maintenance technology manual of cable

5.1

Generals
The cable of our plant electrical specialty can be classified as power cable and control
cable. The control cable can not be damaged easily for its section area and its
passage current both are smaller, so only household inspection is enough in the daily
maintenance; the passage current is larger in the operation of power cable and easily
causes faults of heat and so on, so this manual focus on the maintenance and
inspection of power cable

5.2

Technical Parameters and Characteristics of Cable

5.2.1

Technical parameters of cable

5.2.1.1

Technical parameters of power cable

5.2.1.2

Model

Rated voltage

Mode of insulation

Insulation
resistance

ZRC-YJV-10-1240

10 KV

Cross linked PVC

1000

ZRC-YJV-7.2/12-3185

12 KV

Cross linked PVC

1000

ZRC-YJV-7.2/12-3150

12 KV

Cross linked PVC

1000

ZRC-YJV-7.2/12-3120

12 KV

Cross linked PVC

1000

ZRC-YJV-0.6/1

0.6 KV

Cross linked PVC

1000

Technical parameters of control cable

Page 136 of 326

Model

Rated voltage

ZRC-KVVP

0.6 KV

Mode of insulation

Insulation
resistance
1000

PVC
ZRC-DJYVPV

0.6 KV

PVC

1000

ZRC-KVV

0.6 KV

PVC

1000

5.2.2

Characteristic of cables of different type

5.2.2.1

The full name of ZRC-YJV type cable is cross linked polythene insulation polyvinyl
chloride conduit fire retardant power cable, and it is used for places in need of
relevant fire retardance such as indoors, tunnels, and cable trenches and so on.

5.2.2.2

It has a fire retardant performance and can control the fire spread in certain bound
when the cable burns, so serious accidents caused by the firing cable can be avoided,
and then the fire protection level of cable line can be improved

5.2.2.3

Fit for high fall and vertical run

5.3

Maintenance Period of Cable

5.3.1

Most of power cable is laid in the cable tunnel frame, and the patrol and inspection of
cable in cable tunnels and risers should be carried out once a month

5.3.2

The clearing work of cable should be done once a year

5.3.3

When the newly-installed cable line has been put into operation for 3 12 months, a
DC withstand voltage test should usually be done and the electrical preventive test
should be done once a year after that

5.4

Maintenance Content of Cable

5.4.1

After the cable line was power off and before it was been put into operation again, we
should check that the insulation of cable is good. For the cable that power off time is
longer than one week but not enough for 1month, we should measuring the insulation
resistance of the cable conductor to ground with megger, if we have any doubt we
must test it with DC voltage which is lower than the voltage used for conventional DC
voltage withstand test, test it for 1minFor the cable that power off time is longer than
one month but not enough for one year, we must carry out the DC withstand voltage
test 50% specified test voltage value, test it for 1min for the cable that power off
time is longer than one year we should carry out the conventional DC withstand
voltage test.

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5.4.2

The cable patrol and inspection is done monthly, it is mainly to check whether there is
phenomenon of overheating with cable and connectors and whether there is
phenomenon of chap or distortion with polyvinyl chloride conduit. Whether there is
detrimental accumulation of dust and ash, whether the fire fighting and blocking
facility is complete, whether the fir alarm device equipment can be started up
normally, where the cable tunnel lighting is perfect; and there should also be complete
records of the cable patrol and inspection.

5.4.3

Content of the yearly electrical preventive test

5.4.3.1

Insulation resistance of cable main insulation

The 0.6/1kV cable is by megohm meter of 1000V; the cable above 0.6/1kV is
measured by megger of 2500V, and the insulation resistance should be no less than
1M/1kV

5.4.3.2

Insulation resistance of cable external shield

The insulation resistance of cable external shieldUse a megger of 500V to measuring
the insulation resistance, the eligible value of insulation resistance of every kilometer
is not less than 0.5M, when the insulation resistance of every kilometer is lower than
0.5M, we should analyze and judge whether the water is getting into the external
shield, if judged that the water is getting into the external shield cut the power at once
and dispose it.

5.4.3.3

Insulation resistance of cable internal conduit

The insulation resistance of cable internal shieldUse a megger of 500V to measuring
the insulation resistance, the eligible value of insulation resistance of every kilometer
is not less than 0.5M, when the insulation resistance of every kilometer is lower than
0.5M, when the insulation resistance of every kilometer is lower than 0.5M, we
should analyze and judge whether the water is getting into the external shield, if
judged that the water is getting into the external shield cut the power at once and
dispose it.

5.4.3.4

DC withstand voltage test of cable main insulation

5.4.3.4.1

The test voltage value should be tested according to 2.5 times of rated voltage value,

5.4.3.4.2

The leakage current of 5 minutes voltage withstand time should be no more than the
leakage current of 1 minute voltage withstand time

5.4.4

Precaution items in doing the electrical preventive test

5.4.4.1

Before and after telemetering the insulation resistance, the testing cable must be
discharged fully, and only then test personnel can touch it with hand

5.4.4.2

When the DC withstand voltage test is done to the main insulation of cable or the
insulation resistance is

5.4.4.3

The test result is abnormal, but according to synthesized judgments it is allowed to

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continue operating cable line under the monitoring condition, the test cycle should be
shorten, if within no less than 6 months, after more than 3 times continuous tests, the
test result does not go bad, then it can be tested according to its normal cycle
5.4.4.4

After the withstand voltage test, only when the current limiting resistor of about
80k/KV repeats discharging several times until there is no spark in discharging of
conductor, then the direct earthing discharge can be started.

5.4.4.5

During the DC withstand voltage test, we should measure the leakage current when 1
minute later after the test voltage is reaches to specified value and when the add
voltage time reaches to the specified time. The leakage current value and imbalance
coefficient (ratio of maximum and minimum value) can be used as reference to judge
the insulation conditions but not to judge whether we can put it into operation or not. If
we found the leakage current compared with the last tested value has big change, or
the leakage current is unstable, it means it increased sharply along the increase of
test voltage or add voltage time, we should find out the reason. If it caused by the
leakage current of terminal tap surface or to-ground stray current, we should eliminate
it, if we doubt that the insulation of cable line is not good, we can increase the test
voltage(or prolong the test time,(dont exceed the leave manufacturer test voltage in
standard )to confirm whether it can operating continuously or not.

5.4.4.6

Before and after time of the cable DC withstand voltage test, it is necessary to
measure the insulation resistance of cable with megohm meter, and the twice
measuring values of insulation resistance should not differentiate largely. Or else,
check out the problem and solve it

5.5

Fabricating Cable Connectors

5.5.1

Fabricating craftwork of XLPE cable connector ends

5.5.1.1

The size of cross linked cable connector ends should refer to the basic size
requirement, and if the section are of cable is very large in fabricating, the size can
aptly be broadened according to the practical conditions of cable pyrocondensation
accessories

5.5.1.2

In fabricating pyrocondensation cable, each phase should be installed strictly

according to the size

5.5.1.3

Set two cable wires to be connected right against and 200---300mm in superposition,
and make sure the joint center of the two cable wires

5.5.1.4

Measure the size according to the requirement and shuck off the external sheath,
colligate the armor 50mm apart from the fracture with line, and shuck off all others

5.5.1.5

Keep the 20mm internal sheath, shuck off all other insulation and the stuffing

5.5.1.6

Strip off the external shield insulation of two cable that ready for connection, align the
centre wire of cable, and saw it off from the centre point.

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5.5.1.7

the distance from centre point to two sides is300mm for every cable Strip off the
external shield layer, keep down 20mm of semi-conductive layer, clean the semiconductive substance on insulation layer.

5.5.1.8

Cover the stress pipe on the phases of the two side cables, cover it for 20mm, heat
and fix it.

5.5.1.9

Cover the longer side of stripped cable with end socket, sealing socket and protection
sheath, cover every phase wire with 2insulation sleeves, 2semi-conductive
tubes and copper wire, and Cover the cable short side with end socket and sealing
sleeve.

5.5.1.10

crimp connect the connection tube of centre taps, measure 1/2 of cable wire and
connect the tube of 5mm length, cut off the insulation layer, measure the insulation
layer for 35mm from the breaking, and cut it to a cone of 30mm length, keep 5mm
semi-conductive layer, clean the oxide film of crimp connect tube, clean it with alcohol
and paint the conductive grease, choose the compression mold according to section
of cable wires, and crimp connect every phase, we can crimp the crimp connect cycle
for 4---5 rings, when we crimp connect every cycle, after it was finished we should
waiting for half a minute and then take off the compression mold, we should pay
attention that the taps after crimp connection should without obvious edges and
corners, of necessary we can mend it by file.

5.5.1.11

After crimp connection, tie the semi-conductor layers on the phases of centre crimp
connected tube, and join it with the semi-conductor of two sides.

5.5.1.12

Wrap stuffing glue between the cones of two ends, and the thickness should be no
less than 3mm

5.5.1.13

Fixing the internal insulation conduit: set the internal insulation conduit between the
bushing of ends and fix it by heating from the midst

5.5.1.14

Fixing the external insulation conduit: set the external insulation conduit at the central
position of the internal insulation conduit, heat and fix it, while heating it follows the
sequence from the midst to the two ends

5.5.1.15

Fixing the semi-conductor conduit: cover two semi-conductive pipes on the insulation
pipe, cover 50mm copper shield on two sides, heat and fix it from the centre to two
sides.

5.5.1.16

Install the shield and ground line, connect the two side copper screen layers tie up the
ends and weld it, cycle and tie up the cable wire, weld the two sides on the shield
layers, and weld it on the screen layers at two sides.

5.5.1.17

Fixing the metal sheath: set the external insulation conduit at the central position of
the internal insulation conduit, heat and fix it, while heating it follows the sequence
from the midst to the two ends

5.5.1.18

Cover the seal sleeve on the end of protection shield, cover the two ends with 100mm

Page 140 of 326

tube and cable external shield, then heat and fix it from the centre to two ends, during
the heating process of sealing sleeve, the temperature can not be too high, heat
along the cable cycle in sequence, and can not heat the cable at will, make the
sealing sleeve close to the cable tightly, check whether there is overheat crack
phenomenon exists after heating, thereby the whole technique of pyrocondensation
for the cable was completed.
5.5.2

6KV three-core and single core cable gland technology

The structure and size of lower part of the outdoor end of the 6kv cable are the same
as that of the indoor end. But the rain-proof cover is set up on the outdoor end.

5.5.2.1

Sheath disassembly
horizontally place the cable (see Fig. 1).the sheath to be stripped is classified two
sections:one is 750mm in length measured out door;the other one is 550mm in length
measured indoor.

5.5.2.2

Armor stripping
Coat the outside protective bushing of 30mm in length from fracture end with metal.
Then bind it. Remove the left protective bushing.

5.5.2.3

Inner protective liner stripping

Save 20mm in length of the armor between the sripped cable above,the remains of
armor should be clear out.

5.5.2.4

Split core wire

Take out the filling. Split the core wires.

5.5.2.5

Welding grounding
Polish the jointing part of the armor grounding. Use the grounding wire to connect
(divided into three parts) each-phase copper shield layer and the armor. Weld them
firmly.

5.5.2.6

Wrap the filling gel

Bind the filling gel on the Y-shaped root. The maximal diameter is 15mm higher than
outer diameter of the cable.

5.5.2.7

Glove fixing
Sleeve the Y-shaped root with the glove. Heat both ends for better fixing with fingers.

5.5.2.8

Copper shield removing

Keep copper shield of 55mm from the finger tip of the glove. Remove the rest copper
shield. Clean up the insulation surface.

5.5.2.9

Stress pipe fixing

Page 141 of 326

Sleeve the stress pipe according to Fig. 2. Connect it with copper shield of 20mm in
thickness. Heat it for fixing.
5.5.2.10

Terminal connection
Deepen the hole of wiring terminal by 5mm. Strip off the insulation on wire core,
sharpten the end. Connect the terminal through pressing. Bind the filling gel on the
sharp end. Overlap the terminal by 10mm.

5.5.2.11

Insulation bushing fixing

Sleeve the insulation bushing until it reaches Y-shped root (the insulation bushing is
10mm higher than the filling gel). Heat the insulation bushing on Y-shaped root for
better fixing.

5.5.2.12

Phase indicating seal tube fixing

Sleeve the phase indicating seal tube on terminal connection pipe. Preheat the
terminal. Heat the phase indicating seal tube from the top end for fixing. The
installation of the indoor end is finished.

5.5.2.13

3-hole rain-proof cover fixing

Sleeve the end out door with the 3-hole rainproof skirt according to Fig. 3. Heat the
neck for better fixing.

5.5.2.14

Single-hole rain-proof cover fixing

Coat it with the single-hole rain-proof cover according to Fig. 3. Heat the neck for
better fixing.

5.5.2.15

Seal tube fixing

Sleeve the seal bushing on terminal connection part. Preheat the terminal. Heat the
seal tupbe from the top end for fixing.

5.5.2.16

Phase indicating tube fixing

Sleeve the phase indicating tube on the seal pipe. Heat it for fixing. the outdoor end
installation is finished.
For the end size to be cut for installation is attached dehind.

5.5.3

Additional insulation materials commonly in fabricating cable connectors

5.5.3.1

Transparent PVC strip: its specification is 0.23mm in thickness and 25mm in width, it
is used for the protection of usually-temporary casing or cable external package

5.5.3.2

Standard for the irradiated high pressure polyethylene layer: thickness 0.1mmwidth:
25mmuse for the insulation of centre tap of cross linking polyethylene cable below
35KV and indoor terminal. irradiated high pressure polyethylene layer was been
reheat and stretched during manufacturing (stretched 30% under 100 )and then it
was been cooled and cut and packed, after it was been packed, if we heat it it will

Page 142 of 326

rebound, (heat is not crosslinking process) and in-turn compress the gas between
layers and increase the discharge voltage.
5.5.3.3

PVC stickiness strip: its specification is 0.12mm in thickness and 10 to 25mm in width,
it is used for commonly airproofing cable connectors of 10KV voltage grade below but
not used for the long-term sealing

5.5.3.4

Black PVC strip: its specification is 0.25mm in thickness and 30mm in width, and it is
used for the furthest outer layer protection for cable connectors and connection ends
of the plastic. This kind of plastic strip has a superior withstand ageing performance to
common PVC strip

5.5.3.5

Polyvinyl tetrachloride strip: its specification is 0.1mm in thickness and 25mm in width,
it withstands a high temperature (about 300 ) and has a excellent insulation
strength. It produces extremely-toxic gas in burning, so do not burn it at will. While in
fabricating XLPE cable connectors, it is only used for de-module usage not for
insulation materials

5.5.3.6

Implements commonly in fabricating cable connectors

5.5.3.6.1

A piece of 2500V megohmmeter

5.5.3.6.2

Petrol blowtorch 0.5kg22.5kg

1 each model

5.5.3.6.3

Electrical searing-iron 220V 300W

1 pair

5.5.3.6.4

Electric heating air blower (portable/400W) 2 pairs

5.5.3.6.5

Clamp

5.5.3.6.6

Cable cutting tools

5.5.3.6.7

Electrician tools

5.6

Spare parts

1
1 set
1 set

Description

Specification
model

Copper winding nose

Specification
power cable

and Unit
of

all

Quantity
Each 10

10KV
cross
linked
cable 240mm2
accessories (end connection)

Set

10KV
cross
linked
cable 185mm2
accessories (end connection)

Set

10KV
cross
linked
cable 150mm2
accessories (end connection)

Set

cable 120mm2

Set

10KV

cross

linked

Page 143 of 326

accessories (end connection)

DC System Maintenance Manual

6.1

Arrangement, specification and requirements of DC system

Reference
SUPER FM GFM valve control type seal lead-acid batteryspecification.
PS48300/1800power supply system equipmentsspecification.
JZ-22020Btye high frequency switch power supply modulespecification.
HJZ-MC-type monitoring devicespecification.
JZ-IPD-type intellective grounding walk down devicespecification

6.1.1

The DC system includes unit DC system (control and dynamic), switchyard DC system
and coal handling DC system.

6.1.1.1

Unit DC system
The unit DC system consists of following parts:

6.1.1.1.1

Unit dynamic 220V DC system

This DC system is used to power DC motor, emergency illumination and UPS. It uses
single busbar connection mode, and each unit consists of following equipment:
One set of valve control lead acid sealing batteries of 1800Ah220V;

6.1.1.1.2

a)

One set of high frequency switch charging device of 240A ;

b)

DC in-coming panel and feeder panel;

c)

Connective conductor and accessories;

d)

Other two units are equipped with one set of common charging device which is
respectively connected to DC busbar and dynamic batteries of two units via two
mutual interlock switches.

Unit control 110V DC system

This DC system is used to power loads like control and relay protection. It uses single
busbar connection mode and each unit consists of following parts:
a)

Two sets of valve control lead acid sealing batteries of 500Ah,110V;

b)

Three sets of high frequency charging devices of 140A;

c)

DC in-coming panel and feeder panel;

d)

Connective conduct and accessories.

All DC equipment above used for two units are arranged in 0m level and UPS room
of CCR.

Page 144 of 326

6.1.1.2

Switchyard DC system
This DC system is used to supply power to loads like control, relay protection and
emergency illumination in 150KV relay room. It used single busbar sectional
connection mode and main consists of following equipment:

6.1.1.3

a)

One set of valve control lead acid batteries of 400Ah,110V;

b)

Two sets of high frequency switch charging devices of 120A;

c)

DC in-coming panel and feeder panel;

d)

Connective conductor and accessories.

e)

DC system equipment of switchyard are all arranged in 150KV relay room.

Auxiliary plant DC system

The auxiliary plant coal handling system is equipped with a set of 110V 100Ah DC system
which includes 60A charger, DC incoming panel and feeder panel. All equipment are
arranged in coal handling relay room.

6.1.2

Main equipments of DC system

SUPER FM GFM valve control type seal lead-acid batteryis
JZ-22020Btye high frequency switch power supply module
JZ-11020Btype high frequency switch power supply module
HJZ-MC-type monitoring device
JZ-IPD-type intellective grounding walk down device

6.1.3

SUPER FM GFM valve control type seal lead-acid batteries

6.1.3.1

Technical specification

Type

Rated
voltage

Weight

Length

Width

Tall

Total
height

GFM-100

100

64

170

325

350

GFM-400

400

157

175

330

340

22.0

GFM-500

500

244

175

330

341

34.0

1800

490

350

340

350

140.0

GFM-1800 2
6.1.3.2

10H
ratio Exterior dimension
capacity

Electric performance
Charging performance: charging method: current limiting----voltage stable
Initial charging current: 0.1C

Page 145 of 326

8.5

Later charging method: charging under controlled voltage

Floating charging voltage: 2.24V(25 )
Saturated floating charging current: 1-2mA/AH
Equal charging voltage: 2.35V
Discharge performance: the maximum discharging current of SUPER FM GFM small
sized seal battery is 15 time ratio, the maximum discharging current of stationary seal
battery is 6 time ratio, the most effective discharging current range is 0.05CA-1.0CA
The discharging basic parameters and electric performance of SUPER FM GFM seal
battery.
Types of
battery
Ratio discharge of every hour
10 hours ratio

5 hours ratio

3 hours ratio

1hour ratio

Final
1.8V
A

voltage Final
1.8V
AH
A

voltage Final
1.8V
AH
A

voltage Final
1.75V
AH
A

voltage

GFM-100

10

100

18

90

25

81

55

60

GFM-400

40

400

72

360

100

324

220

240

GFM-500

50

500

90

450

125

360

275

300

1800

324

1620

450

1458

990

1080

GFM-1800 180

6.1.4

JZ-22020B \JZ-11020Btype high frequency switch power supply module

6.1.4.1

Technique specifications
Working ambient temperature 1045
Working ambient humidity: 90PH
Working ambient height 2000m from sea level
AC in-put voltage 380V20
AC in-put frequency502HZ
Setted out-put voltage 243VDC
Out-put voltage range180V300VDC
Setted out-put current20ADC
Out-put current range 220ADC
Voltage stabilize precision0.2%
Current stabilize precision0.2%
Texture and wave coefficient : 0.2%

Page 146 of 326

AH

Synchronize odds current degree: 5%

In-put under-voltage protection:3042VAC
In-put over-voltage protection: 4562VAC
Out-put over-voltage protection: 3002VAC
Out-put limit current protection: 202.2A
Module overheat protection : 855
Efficiency: 90%
Cooling mode: temperature control air cooled
6.1.5

HJZ-MC- type monitoring device

6.1.5.1

Using condition
The altitude can not higher than 2000m;
Ambient temperature :-10 T40 ;
The maximum ambient relative humidity is no more than 90%,, no dewing(relative to
the ambient temperature is 205 )
Used in the area where there is no conductive or explode dust, and there is no gas
can corrupt and damage the insulation
There is no serious shake and shock on the used location.

6.1.5.2

Technique specification
Voltage of power supply:220V10%(AC/DC)
Frequency of power grid :5010%HZ
Control out-put voltage :-6.56.5V
DC in-put :0V5V,025MA,050MA, 0100MA,8 way
Grounding in-put:
Alarm range of grounding resistance:099K
Define rate of grounding resistance:1 K
Voltage error of bus : 1.5%
Error of bus grounding resistance: 15%
Error of branch grounding resistance: 20%
Test way number:0 96
Operation mode: continuous operation and automatic walking down
The biggest power cost: 50VA
Test bus section number: two section bus
Current in-put
Voltage measuring range: voltage of single battery is 0 18V; of battery bank is 0
300V

Page 147 of 326

The measuring range of current :01000A(we can select a sensor)

Measuring range of temperature:-25125
Error: voltage 0.5% current 0.5% temperature 2
Walk down period :45S
Test quantities: 108ways
Operation mode: Continuous operations, automatic walk down
The biggest power cost: 50VA
AC in-put: three phase four lines: phase voltage is about220V, and phase voltage is
less than 5A
Protection grade: IP20
Display: 320240 lattice LCD.
Operate mode: keyboard
Communicate interface: RS-485
6.1.6

JZ-IPD- type intellective grounding walk down device

6.1.6.1

Used conditions
Ambient temperature :-1050
Relative humidity: highest 90%
Atmospheric pressure:86106Kpa
In-put power supply:220V10%
Exterior dimension :630350138

6.1.6.2

Technique parameters.
Frequency of power grid:501HZ
Alarm range of grounding resistance: 099K
Define rate of grounding resistance:1 K
Voltage error of bus: less than 1%
Error of bus grounding resistance: 15%
Error of branch grounding resistance: less than 20%
Test ways nnumber:0 128 way(the summation of two sections)
Operation mode: continuous operation, automatic walks down.
Biggest power cost: 50VA
Test bus section number: two section of bus

Page 148 of 326

Display: 320240 lattice LCD

Communicate interface: RS-485
6.2

Maintenance of the Equipments in DC System.

6.2.1

Maintenance of SUPER FM GFM valve control type sealed lead acid battery

6.2.1.1

For the GFM-150, GFM-300, GFM-1500 valve control type sealed lead acid battery,
its charging mode is continuous floating charge, and its charging method is limit
current-stable voltage, during stable voltage charging, the current of battery
decreases step by step, and finally, it will be stable, if the current decreases under
0.01C, and this condition maintains 3-5 and does not changed, it shows the charging
of battery was finished, and the battery can be put into floating operation.

6.2.1.2

The battery can be used at -20+50 , the efficient working temperature is 5

35 , if we want to realize the best use life, it should be used under 15 25.

6.2.1.3

If the transport, storage and installation of battery costs a lot of time, some of the
capacity of the battery will loss, if no need to check the capacity of battery, when
voltage of the open circuit end of battery is higher than 2.13V, we can put it into
floating operation directly, if the voltage of the open circuit end of battery is lower than
2.13V, we should stable charging the battery first, and then put it into floating
operation, if needed we can check the capacity.

6.2.1.4

We should discharging the batteries according to the actual load every year, we
should maintain the stability of current, discharge out 30 of the rated
capacity(0.IC/hour for three hours),during discharging we should measuring the
voltage, discharging current and temperature every one hour(for individual battery and
battery bank), after discharge we should equal charge the battery and put it into
floating operation.

6.2.1.5

We should measuring the individual voltage and the terminal voltage every month,
cheek whether there is exterior deformation and heating, and keep the completed
operation record, the total floating voltage should reaches to 2.24V, and maintain it
within l

6.2.1.6

We should check whether the connected conductor is fixed or not, and whether there
is corrosion, if the loosen phenomenon was found we should tight it to prescribed
torque, and replace the corrosion one in time.

6.2.1.7

Do not increase or decrease the load of the individual battery in same battery bank, it
will cause the imbalance of individual battery capacity and the inhomogeneity of
charging, and shorten the using time of the battery, if we take out some batteries for
the other usage, or they are not in the same group when we charging the batteries,
we should put them together during discharging.

6.2.1.8

Equal charging is no need during normal floating operation, we should equal charge
the battery if the following conditions were found:

Page 149 of 326

The voltage error exceeds 0.IV during normal floating charging.

Individual battery voltage was lower than 2.18V
The battery was laid up more than three months after power cut.
Can not meet the requirements of floating charge for a long time, equal charge the
battery every half a year.
Does not charge the battery in time after discharged 24hours.
Small current deep discharge for a long time.
Over-current discharging(the current is 20 higher than the rated value ). Overvoltage discharging(the voltage of individual battery is lower than1 5V )sub-overelectric quantity discharging(exceeds 10% of rated capacity).
Equal charging the batteries at once.
6.2.1.9

Best storage temperature of battery are 5-20 Storage place should clean,
ventilation and not wet. Battery more than three months should balanced charge.

6.2.1.10

Charge and discharge with big current usually will shorten the service life.

6.2.1.11

Floating charge when capacity of 12V are 50100A. Service lives are three years. 2V
is for floating charge and the service life are ten years.

6.2.2

JZ-MC- Intelligence Monitor Equipments (V4.01)

6.3

Searching of DC System Equipment Failure Part

6.3.1

Storage battery normal failure and countermeasure.

No

Failure

Failure result

Floating
charge Large
water
operation voltage over consumption,
high(more than 2.30v/)
temperature increases,
battery
leakage,
shorten service life

Voltage control over Same as above but Regulate

voltage
high when balanced more than them
control value
charge or compensate
charge

Floating charge voltage vitriol

salting,
too low(less than 2.20v) capacity

Current over high when Large

Page 150 of 326

countermeasure
Regulate
voltage
control value, or
change the failure
voltage
control
component

low Regulate
voltage
control
value,
balanced charge
water Decrease

charge

charging(more
0.2CA)

than consumption,
current, shut down
temperature increase, and
repair
the
battery distortion
equipment

Average
environment Too mach water loss by Strengthen
temperature over high
evaporation,
floating ventilation or use air
charge
current condition
increases,
corrosion
quickens,
shorten
service life

Charge can not be Large

water Shut
disconnected on time
consumption,
repair
temperature increases,
battery will be damaged
if continue for a long
term

Charge interrupted for a vitriol salting ,quicken

long
term(or
not discharge of battery,
enough)
deep discharge and
vitriol,
voltage
unevenness

Battery didn't use for a Self-discharge,

vitriol Charge,
includes
long time after leave salting
,voltage balanced charge and
factory
unevenness
then floating charge

Deep discharge

10

Deep
discharge Shorten the service life
frequency(such as once
for every month)

Avoid this,
battery with
capacity

11

After discharge lay the vitriol salting

battery and without
charging for 24 hours in
open circuit condition

Charge immediately,
balanced
charge
carefully.

12

High AC pulse current

that
result
in
temperature
increase
about 5

vitriol, capacity drops

For
charge,
charge
work

down

and

necessary
balanced
by manual

Balanced charge, or
charge with large
electricity
than
normal
install
larger

The floating charge Check relay, reduce

voltage
decreased AC component
especially
for
discharged batteries, if

Page 151 of 326

this conditions happens

very often the battery
will been damaged
13

Short circuit of whole Terminal is melt down Avoid this, check the
battery group or single that damage battery connect lead with
battery
group or battery
insulating equipment

14

Reverse connection of Reverse polarity charge

part battery group or will damage the battery,
battery.
maybe damage rectifier
and electric equipment,
effect as short circuit

15

New battery and old Charge

voltage
is
battery operates on the unevenness,
shorten New battery and old
same line
the service life
battery
can
not
operate in same
battery
group
in
series.

16

Loosen of the bolt

Burned by spark, lead

Clean and blow all
or battery glow, even the components and
fire.
then tighten them

17

Safety valve leakage

Reduce the electro Remove the electro

analysis solution
analysis solution in
time, tighten the
safety valve and
change it if serious.

18

Acid
leakage
terminals

Avoid this, change

the battery polarity
immediately
when
find out

on Corrupt the connecting Change

component
connecting

battery

6.3.2

Trouble shooting of JZ-22020B type high frequency switch power supply module

6.3.2.1

Incorrect of module output voltage: regulate the voltage through the potentiometer on
the board in front of the module panel to correct output voltage value.
Over-voltage protection after module electrify: regulate output voltage exceeds the
overpressure protection value manually or module control output voltage regulation
terminal input voltage over high.

6.3.2.2

Unstable of output voltage: check whether fluctuation of output voltage over the
permissive scope or load fluctuate continuously and seriously.

6.3.2.3

No output current of module: check whether DC output line is turnoff or not, output

Page 152 of 326

fuse melt down or not, or no input voltage of the module.

6.4

Spare Parts of DC System Equipment

symbol

Name

Type

Technical
character

Number

FU3

Fuse

RT18-32X/3P

6A

Q1

Plastic
shell DZ20J 225/3300
circuit breaker

180A

2FL

General splitter

M1-M8

High
frequency Jz5.99.001
second type 20A

EP1

Current module

Kt-500A

B2

DC voltage

FPD-1-A9-PD2030-75mV/4

20mA

QA1

Isolating switch

QAS-400/2

2H4

Indicator light

AD11-22/RAC380V

1T

Temperature
sensor

FU4

Minitype
breaker

HAU

buzzer

FL29-300A/75Mv

circuit GMN20R 6A

24V(DISCONTINU
OUS TYPE)24V

Page 153 of 326

BS

DC
voltage T-UD-D-201
transmitter

Brainpower
JZ5.997.705
monitoring total
conversion
and
connection board

M9-M13

High
frequency JZ5.99.001
second type 20A

WJ

Monitoring
module-
horizontal

220V

type

1S

Button

LA38-11S/209B

1H

Indicator light

AD11-22/21-8GZ

B3

DC
voltage FPD-1-V13-PD2-03
transmitter

B1

DC
voltage FPD-1-A9-PD2-03
transmitter

QF1-3

Minitype
breaker

PA1

Ammeter

AC/DC220V

circuit GMN20R 6A

PA19511000A/75
mV

Page 154 of 326

350V/4
20mA

PV1-2

Voltmeter

PZ195U-300V

0-75Mv/4 2
20mA

EP2-3

Current module

KT-500A

S1-S2

Striker

RX-1000A

F1-F2

Fuse

NT4-1000A

1FL

General splitter

FL-29/1000A-75mV

Q2

Plastic
shell GM225H-2320R
circuit breaker

QA2

Isolating switch

QPS-1000/2P

3H

Isolating switch

AD11-22/21-8GZ

1-7Z

Minitype
breaker

8-16Z
29,31Z

19,29Z
26Z

200A

AC/DC220V

circuit GM225M-23228R

25A

Minitype
breaker

circuit GM225M-23228R

32A

18

23- Minitype
breaker

circuit GM225M-23228R

10A

32Z

Minitype
breaker

circuit GM225M-23228R

10A

21,22Z
27,28,30Z

Minitype
breaker

circuit GM225M-23228R

16A

17-18Z

Page 155 of 326

33Z

Minitype
breaker

circuit GM225M-23228R

63A

34Z

Minitype
breaker

circuit GM225M-23228R

100A

18

35Z

Minitype
breaker

circuit GM225M-23228R

315A

36Z

Minitype
breaker

circuit GM225M-23228R

180A

Appendix:
JZ-MC- Intelligence Monitor Equipments (V4.01)
INSTRUCTION

HARBIN JIUZHOU ELECTRIC CO., LTD.

Page 156 of 326

Table of contents
1Summarization
2Technique Indexes
3Usage Conditions
4Basic Methods For Operating Intelligence Monitor Equipment
5Charge Management
6Computer Communication
7Definition And specification Of Interface

157

JZ-MC- Intelligence Monitor Equipments (V4.01)

INSTRUCTION
I.

Summarization
HJZ-MC- intelligence monitor equipment belongs to industry intelligence inspection
instruments whose main part is a singlechip. With the artificial intelligence technique and
the intangibly-control method, it monitors the running state and parameters of powersupply system, and shows them on the LCD screen. At the same time, it sends these data
information to the remote control end and accepts data/work parameters and statements
sent by operators or previous computer through the communication interface RS-232 and
RS422/485 so that it keeps the power-supply system running under the given state and
perform its tasks of measuring, communicating, controlling and modulating remotely.
Gather Charge Management of being automaticallyItinerant Ground-InspectionItinerant
battery-inspection with Various function togetherachieve so gather
perform its tasks of alarming overlimit or belowlimit voltage, as well as AC cutting and
restarting automatically, etc.
This equipment is mainly used to monitor GZDW PEDW DC power-supply series
produced by Jiuzhou Co. Moreover it also can monitor this companys rectifier modules
and power-supply and Battery products of other companies through changing the control
program according to the consumers need.

Technical Index
Voltage of Power-supply: 220V10% (AC or DC)
Frequency of Electric network: 50Hz10%
Output voltage of Control Uo: -6.5V+6.5V0V5V
DC Input: 0V5V or 025mA or 050mA or 0100mA, 8 loops (2 loop for spare)
Ground input
1.Ground alarm range:

0~99K

2.Resolution of ground resistance:

3.Error of main line voltage:

1K
1.5%

4.Error of ground resistance of main line: 15%

5.Error of ground resistance of branch: 20%
6.Amount of loops being detected:
7.Running way:

0~96 (Sum of 2 sects)

Running Continuously; Inspecting Automatically

8.Maximum Power consumption:

50VA

9.Amount of main line sects being detected:

158

Battery input
1.Range of measuring voltage:

0~3V(0~18V)/Single Battery; 0~3000V/Batteries Group

2.Range of measuring current:

0~1000A (Sensor can be chosen.)

3. Range of measuring temperature: -25~125

4. Error: 0.5%/Voltage; 0.5%/Cuttent; 2 /Temperature
5.Inspection period:

45S

6.Inspection amount:

1~108

7. Running way:

Running Continuously; Inspecting Automatically

8. Maximum Power Consumption: 50VA

AC Input: 3-phase 4-wire System: about 220V/phase-voltage; about 5A/phase-current
Defence Grade: IP20
Displayer: 320*240 lattice LCD screen
Communication Interface: RS-232RS-485
3

Using Conditions
a. Altitude less than 2000m;
b. Surrounding temperature: -10 T40
c. Surrounding humidity less than 90 , no dew (Namely surrounding temperature is
205)
d. No conductive or explosive dust, no erosive or insulation-damaging air in the
surrounding;
e. No strong quiver or impact in the surrounding.

Basic Methods For Operating Intelligence Monitor Equipment

159

Sketch Map of Operation Panel

1)

Main Menu (See The Fig.)

a.

Running monitor: it monitors the system running.

b.

Battery monitorit monitors the Battery Voltage

c.

Branch monitorit monitors the branch insulation resistance.

d.

Switch input state: it monitor the switch input state

e. Warning list: it lists what failures and the time they have occurred at. The items
include warning type, setting value, real value and time.
f. Parameter setting: it is managed by operating men. The following text describes the
detail.
g.

Maintenance setting: it can only be operated by our maintenance men.

Menu select: Press or to selects item that you want Then Press confirm
160

2)

Page Of Running Monitor

In this screen display all Parameter of monitor system collection and monitors the
systemWhen happen alarmLight of back of screen has Lighted and pop-up new alarm
information Press 0 to close alarm bell At normal Light of back has closed when
screen savingPress any key to exits screen saving and Lights the light of back.Press
ESC to exits the screen
3) Page Of Battery Voltage
In this screendisplay Battery Voltage of monitor system collection

161


001:
002:
003:
004:
005:
006:
007:
008:
009:
010:
011:
012:

02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35

013:
014:
015:
016:
017:
018:
019:
020:
021:
022:
023:
024:

02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35

025:
026:
027:
028:
029:
030:
031:
032:
033:
034:
035:
036:

02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35
02.35

Press or to monitors other battery voltagePress ESC to exits the screen

4)

Page Of Branch monitor

162

Press or to monitors other branchPress ESC to exits the screen

5)

Page Of Switch Input State

163

Display Switch input state Press ESC to exits the screen.

6)

Page Of Warning List

Press or to inspects Warning ListPress ESC to exits the screen

7) When Parameter Setting is selected and confirm is pressed, the following page will
display.

164

Twineows default of password is 0000. After keying in password and pressing conform,
the following twineow appears.

8)

Charger Parameter Setting:

165

The parameters can be set both when the charger is charging and when it is not charging.
After Parameter Setting in the main menu being chosen and the equipment showing that
it has enter setting state, you can start to set parameters. Parameters are divided into four
parts respectively in the four frames with broken lines in the figure. Press to choose
parts and press or to move cursor.
Charge state0-- main charge1-- equalizing charge2-- Float charge
System switch: 0-- Stop; 1-- Work;
Module mode: 0--10A1--20A
Warning list: 0Clear; 1RecordRecord means recording a new log after the previous
ones each time the system is started; Clear means recording a new log after deleting the
previous ones each time the system is started. And on choosing Delete state, the current
log is deleted;
Screen saving0Have no Screen saving1Have Screen saving
Device address0255
The rest parameters can be set directly by pressing number keys. After being pressed,
the numbers inputted are valid. They are saved to system after Conform key is pressed,
and system exits from parameter setting screen and return main menu screen. The
parameter setting has function of checking given parameters validity. Namely, the system
cannot exit from parameter setting screen after pressing Conform key if the inputted
voltage of balancing, float or main charge is incorrect. So you should correct the numbers
and try again. The inputted numbers are not valid and the system backs to main menu
screen if you press Exit key.
In the main menu, consumer can choose other menus, or the system automatically enters
running monitor screen and displays work state.
Parameters can be set:
See Fig.
Alarm limits setting:
Here, failure alarms up and low limits can be set.

When setting Battery upper limit and lower limit, need to be noticed:
The fact value is that input value multiplied by 0.01. For example, inputs 1255, So fact
value is 12.55. The rest are integer input.
Time and date setting:
20YYMMDD ( 2 )
Here, time and date can be set.

Format HHMMSS

20YYMMDD
Indicator Lights:
166

1. Power
2.

Main Charge

3 Equalizing Charge
4. Float Charge
5. Work
6. Stop
7. Alarm 1
8. Alarm 2
9. Alarm 3
Charger normal work state: the indicator lights of Power, Work, Main Charge/Equalizing
Charge/Float Charge are lightened, while Failure lights are off.
Charger abnormal work state: Failure lights are lightened. Charger Were stopped by
Monitor system when module failure, Charger work state Were not affected when other
failure.
5.

Charge Management
According to the charge sampling information of storage battery and complying with set
management procedure, the intelligence monitor equipment can automatically choose and
switch charge modes, and dynamically manage storage batterys to keep them running in
full capacitance state..

5.1.

Constant current charge (main charge) work mode:

When charge current of storage batterys loop is high up to 0.1C10A, the charge
equipment automatically shifts to the work mode of main charge---constant current limiting
voltage charge. During the first phase, it charges with constant current of 0.1C10A, and it
automatically shifts to the second phase of equaling charge---constant voltage and limiting
current charge, when the batterys end voltage is high up to the set voltage of equalizing
charge. Charge voltage of constant voltage charge is set as 2.35VN (Nnumber of
single batteries).

5.2

Constant voltage charge (equalizing charge) work mode:

With this work mode, the batterys end voltage does not increase any more, while the
charge current of batterys loop decreases continuously as the batterys capacitance
tends to be full. Several hours after the charge current having decreased to
0.008~0.01C10A (the set values can be changed according to consumers need), the
equipment automatically shifts to the third phase---float charge work mode, normal
running mode.

5.3

Float charge work mode

With this work mode, equipments output voltage is set as 2.25VN (Nnumber single
battery). When the charge current of storage batterys loop increases to 0.1C10A, it
167

automatically shifts to constant current charge (main charge) work mode.

5.4

Temperature compensation for storage batterys voltage:

Ut=-3.3t-25N/1000 V
The basic surrounding temperature of storage battery running is 25. By way of
detecting surrounding temperature of storage battery running, the quantitative value of
batterys voltages temperature compensation is determined. Temperature compensation
value for voltage of each single battery is 3.3mV/, and each battery groups voltagetemperature compensation is:
Ut=-3.3t-25N/1000 V
t: surrounding temperature of battery running
N: number of single batteries
Ut: temperature compensation value for voltage of all batteries

6.

Computer Communication

6.1

Signal Collection

6.1.1

analogue collection: 12 analogue collection channels of charger voltage (HM voltage),

charger current, KM voltage, KM current, storage batterys voltage, storage batterys
current, AC A-phase voltage, AC B-phase voltage, AC C-phase voltage, AC A-phase
current, AC B-phase current, AC C-phase current, etc. See appendix1 Communication
Conventions

6.1.2

Switch collection: work/stop, charge/discharge, main/equalizing/float charge state, 9

switch quantum collection channels and 12 switch quantum output channels.

6.2

Communication Modes Choice

HJZ-MC- intelligence monitor equipment communicates to its previous equipment
through communication interface RS-232 or RS-485. Consumer can choose interfaces
according to the real conditions of the spot.

6.3

System Communications Message format

This system adopts asynchronous serial communication With 8-bit data. 1 Stop-bit
occupies one bit, no parity bit. Baud rate can be chosen within the range of 600-4800
according to the need of consumer. The Baud rate should be inputted by consumer on the
Parameter Setting screen, and the value must be valid. Its set value of leaving factory is
1200. The system must be restarted after the baud rate is set.
Definition And Specification Of Interface
See appendix : Definition And Canonical Instruction Of Interface

168

Appendix
Intelligence Monitor Equipment Interface specification

Sketch Map Of Back Panel Of Intelligence Monitor Equipment Its includes from left to right
AVR-CPU card The AC date collection card The DC date collection card switch input
cardswitch output cardItinerant battery-inspection card123Itinerant GroundInspection card 12 and Itinerant Ground-Inspection card
1

The AVR-CPU card includes from up to down respectively 9-pin D-type head interface and
phoenix 5-pin
Terminals.( output passive contact, capacity is 0.3A 125VAC, or 0.3 A 110VDC or 1A 30 VDC.)
It is composed of 9-pin D-type head
2--- 232 output TXD
3--- 232 input RXD
5--- 232 GND
6--- 485 Data+
7--- 485 Dataphoenix 5-pin terminals
12--- module Start/stop signal terminal
34--- N.C
45 N.O Alarm bell control terminals

AC card has 9-pin D-type head (Female) interface.

169

1---AC A-phase voltage input

6---AC B-phase voltage input
2---AC C-phase voltage input
7---AC A-phase current input
3---AC B-phase current input
8---AC C-phase current input

The fourth, fifth and ninth pin are for common (AC date collection card is optional element)
3

The DC date collection card includes from up to down respectively indicator light for
communication to main CPU, 25-pin D-type head interface.
25--- charge voltage
24--- charger current
23--- KM voltage
22--- KM current
21---battery group voltage
20---battery group current
19--- spare 1
18--- spare 2
the fourth to the thirteenth are for 12 V grounding
the first and second are for +12V
the third and the fifteenth are for -12V
the sixteenth is for output 0V~5V
the seventeenth is for control high frequency output 6.5V~ +6.5V

The upper of switch and pulsed input card is indicator light for communication to main CPU;
the low part is DB 15-pin terminal. Its input signal is passive contact or photoelectric switch
1- charger alarm
9- battery fuse break
2- feed line switch alarm
10- arrester alarm
3 - spare 1
170

11 - spare 2
4 - spare 3
12 - spare 4
5 - spare 5
13- temperature pulse input
6- ammeter pulse1
14- ammeter pulse2
7+12V
8 and 15- 12V grounded (for common)
5

Switch output card has DB 15-pin terminal. Its output signal is passive contact, capacity is
0.3A 125VAC, or 0.3 A 110VDC or 1A 30 VDC.
1- charger failure
9- battery fuse breaker
2- feed wire switch alarm
10- arrester alarm
3- HM voltage alarm
11- KM voltage alarm
4- output current alarm
12- AC alarm
5- Mother line grounded
13- Mother line voltage to ground alarm
6- battery voltage alarm
14- spare 1
7,8 and 15- for common

Itinerant battery-inspection cardcontains 37 needles with D-type heads.

171

Itinerant Ground-Inspection card is composed of 37 needles with D-type heads (Male) and
phoenix 3-needle terminals
Through the first to the thirty-twelfth needles the sensors sampling voltages (0-5V) of the first
to the thirty-twelfth branches are inputted respectively, and the other five needles are not used.
When the branches are more than 32, the cardis needed. The 3 needles of the phoenix
terminal supply work voltage to the sensors respectively with +12V, 12VGND and 12V.

Itinerant Ground-Inspection card is composed of phoenix 12-needle

terminals

1:

I +HM Voltage 2: I +KM Voltage

3:

I -KM Voltage 4: II -KM Voltage

5:

II +HM Voltage 6: II +KM Voltage

7:

Signal 1 of Parallel Connection of Two Sects

8:

GND

9:

Signal 2 of Parallel Connection of Two Sects

10:

+12V

11: 12VGND

12: -12V

172

7
7.1

Maintenance manual of relay protection

Specification of relay protection and auto device
Specification of 150KV line protection equipment
150KV line protection device is RCS-902-ID line distance protection device
manufactured by Nanjing Neri electrical relay company.

173

174

175

176

177

178

179

180

181

7.1.2

Equipment specifications of RCS-924A differential protection device of 150KV

switchyard

182

183

184

185

186

187

188

189

190

7.1.3

Technical specifications of RCS-9611C line protection measuring control device

191

192

193

194

195

196

197

198

199

7.1.4

Protection device of RCS-985A digital generator and transformer unit

200

201

202

203

204

205

206

207

208

209

210

211

212

213

214

215

216

7.1.5

Specification requirement of 150KV busbar protection device

7.1.5.1

Basic parameters of 150KV busbar microcomputer protection device

7.1.5.1.1

Manufactory:

7.1.5.1.2

Model: RCS-924A

7.1.5.1.3

Rated value
Rated AC secondary current(A):
Rated AC primary voltage(kV)

1
150

Rated PT voltage ratio(KV) 150/ 3 /0.10/ 3

Rated frequency(Hz): 50
Rated DC voltage(V): 110
7.1.5.1.4

Basic requirement:power consumption

7.1.5.1.4.1

Power consumption(including line circuit load,under rated current) of protection

device AC current circuit should be <1VA in each phase.

7.1.5.1.4.2

Power consumption(under rated voltage) of protection device AC voltage circuit

should be <1VA in each phase.

7.1.5.2

Technical data of 150KV busbar microcomputer protection device

7.1.5.2.1

DC voltage: 110V

7.1.5.2.2

AC voltage;phase voltage: 1OOV

7.1.5.2.3

AC current

7.1.5.2.4

Acting time of the whole group of protection <Ioms

50HZ

1A

7.1.5.2.5

Fault measuring time: <3ms

7.1.5.2.6

Differential relay KD set value: (o.4+o.6)Ie

7.1.5.2.7

Startup relay Ks set value

7.1.5.2.8

Differential relay brake coefficient

7.1.5.2.9

CT line-break block set value

(o.4 O.6)Ie
0.8

40~2100mA adjustable Pole difference 10mA

7.1.5.2.10

Line-break delay:
10~9990ms adjustable

Pole difference 10 ms

217

7.1.5.2.11

Outlet reset delay

10~9990ms adjustable

Pole difference 10 ms

Compound voltage block:

Low voltage: 20

lOOV adjustable

Sequence voltage

Zero sequence voltage

Pole difference 1v

lOV adjustable
5~65V adjustable

Compound voltage acting time

Grade 1v

<30ms

m fast low voltage block:

Fast low voltage

40~90V adjustable

Fast low voltage acting time

<8ms

7.1.6

Specification requirement of 150KV line protection device

7.1.6.1

Basic parameters of 150KV line protection device

AC current:
Precise measuring range 0

64In

Overcurrent capacity 400%IH

Power consumption is less than

continue 10000%IH
0.15VA

1s

lower than IH

AC voltage:
Precise measuring range 0
Overvoltage capacity

1.85UH

200%UH continue 300%UH

Power consumption is less than

7.1.6.2
7.1.6.2.1

lower than UH

Technical parameters of 150KV line protection device

Acting time:
Typical acting time

7.1.6.2.2

0.02VA

<20 ms

Minimum acting time

18 ms

Return time

<60 ms

Trip/close output joint

Switch on capacity

30A

3S, 10A

Continuous breaking capacity 50W (L/R= 40ms ) 110V

7.1.6.2.3

Signal output joint

218

1s

Switch on capacity

30A

3S, 10A

Continuous breaking capacity 50W (L/R= 40ms ) 110V

7.1.6.2.4

Auxiliary output joint

Switch on capacity

30A

3S, 10A

Continuous breaking capacity 50W (L/R= 40ms ) 110V

7.1.6.2.5

Input joint
Switch on capacity

30A

3S, 10A

Continuous breaking capacity 50W (L/R= 40ms ) 110V

7.1.6.2.6

Distance protection
Impedance set range
Time set range:

0.1/ IH

250/ IH (

0 10S

pole difference 0.01/ IH (

pole difference

0.01S

Impedance characteristics:
Mho, Quadrilateral
7.1.6.2.7

circle characteristics

Overcurrent direction protection

Current set range

0.08

4%IH pole difference

Direction characteristics angle

Time set range
7.1.6.3

quadrangle characteristics

-95

0.01%IH

+95

100S pole difference 0.01S

150kV line automatic reclose

Single-phase reclose time set range
0.2

5 S pole difference 0.01 s

Three-phase reclose time set range

0.2

30 S

pole difference 0.01 S

Return time set range 1

600 S

Phase voltage set range 10

132 V

Synchronization angle set range 5

Reclose pulse set range 0.01
7.1.7

pole difference 1 S
pole difference 0.5V

90o

600ms

pole difference 1o
pole difference 0.01ms

Specification requirement of auxiliary transformer protection device

LV transformers include LV auxiliary transformer, LV standby transformer, common
transformer, E.S.P transformer,chemical water transformer,coal-conveying
transformer. MTPR-310Hb Protection device produced by Zhuhai Wanlida electric
219

Co LTD is adopted, and the operation of each protection will be realized

by corresponding control words in the protection device.
7.1.8

Specification requirement of 6KV auxiliary motor protection device

6KV auxiliary HV motor adopts MMPR-310Hb protection device produced by Zhuhai
Wanlida electric Co LTD
Operation circuit inside the device can only adopt DC power supply, and AC power
supply is forbidden.
In device verification and interlock test, long time big current or big current to zero
sequence CT is not allowed; live connecting function boards is prohibited, connect
after you confirm power supply switch of the device is in closed position, or the
device may be damaged.

7.1.8.1

Basic parameters of 6KV auxiliary motor protection device

Set range of relative parameters of the device

Set value description

Range

Operation/retreat
of
sequence protection

positive

Positive sequence current

(during startup)

Operation: act to signal and trip;retreat:the

function exits(set as retreat upon leaving factory)
0.599.99A

Positive sequence current(after

startup)

0.599.99A

Positive
delay

0-10s

sequence

breaking current

definite
time

(set as 99.99A upon leaving factory)

Set pole difference: 0.01A
(set as 99.99A upon leaving factory)
Set pole difference: 0.01s

Operation: block function operates;retreat:the

function exits(set as retreat upon leaving factory)

mode

sequence

protection

Set pole difference: 0.01A

(set as 10s upon leaving factory)

Negative

Instructions

0.599.99A

Set pole difference: 0.01A

(set as 99.99A upon leaving factory)

Definite time limit

operation
and
retreat
Definite time limit
current

Operation: act to signal and trip;retreat:the

function exits(set as retreat upon leaving factory)
0.2-5A

Set pole difference: 0.01A

(set as 5A upon leaving factory)

220

limit

Negative
sequence
inverse
time
limit

Definite time limit

delay

0-10s

Set pole difference: 0.01s

(set as 10s upon leaving factory)

Inverse time limit

operation
and
retreat

Operation: act to signal and trip;retreat:the

function exits(set as retreat upon leaving factory)

Inverse time limit

current

0.2-5A

Inverse time limit

constant

1-9999

Set pole difference: 0.01A

(set as 5A upon leaving factory)
Set pole difference: 1s
(set as 1000s upon leaving factory)

Operation and retreat of zero

sequence protection
Zero sequence protection current

Operation: act to signal and trip;retreat:the

function exits(set as retreat upon leaving factory)
0-2A

Set pole difference: 0.01A

(set as 2A upon leaving factory)

Zero sequence protection delay

0-10s

Set pole difference: 0.01s

(set as 10s upon leaving factory)

Undervoltage protection operation

and retreat
Undervoltage protection voltage

Operation: act to signal and trip;retreat:the

function exits(set as retreat upon leaving factory)
10-90V

Set pole difference: 0.01V

(set as 10V upon leaving factory)

Undervoltage protection delay

0.2-60s

Set pole difference: 0.01s

(set as 60s upon leaving factory)

PT line-break
retreat

operation

and

Operation:send out alarm dignal;retreat:do not

judge as PT line-break

PT line-break block

Operation:PT
line-break
block
undervoltage;retreat:PT line-break non-block
undervoltage(set as retreat upon leaving factory)

Block protection operation and

retreat
Block protection current

Block protection delay

Operation: act to signal and trip;retreat:the

function exits(set as retreat upon leaving factory)
0.599.99A

Set pole difference: 0.01A

0-60s

Set pole difference: 0.01s

(set as 99.99A upon leaving factory)

221

(set as 60s upon leaving factory)

Overheating protection operation
and retreat
Heat radiation time constant

Operation: act to signal and trip;signal:send out

alarm signal;retreat the function exits(set as
retreat upon leaving factory)
1-9999

Set pole difference: 1

(set as 1000 upon leaving factory)

Return time

104000s

Heat alarm coefficient

Set pole difference: 1

(set as 4000 upon leaving factory)

0.5-1

Set pole difference: 0.01

(set as 0.5 upon leaving factory)

Heat radiation coefficient K1

0-1

Set pole difference: 0.01

(set as 0 upon leaving factory)

Heat radiation coefficient K2

0-10

Set pole difference: 0.01

(set as 0 upon leaving factory)

Other

Rated current

0.5-5A

Set pole difference: 0.01A

set

(set as 5A upon leaving factory)

values

(motor)Start

1-99s

Set pole difference: 0.01s

time

Process

(set as 99s upon leaving factory)

Three-phase
fuse
operation
and retreat

Operation: send out fault information;retreat:the

function exits(set as retreat upon leaving factory)

Display primary
operation
and
retreat

Operation:
display
primary
side
current,voltage,power;retreat:display secondary
side current,voltage,power (set as retreat upon
leaving factory)

PT
no-load
voltage ratio

1-5000

CT
no-load
voltage ratio

1-5000

Set pole difference: 1

(set as 1 upon leaving factory)
Set pole difference: 1
(set as 1 upon leaving factory)

Process interlock
1 operation and

Operation:

222

act

to

trip;retreat:the

function

interlock

retreat

trip

exits(set as retreat upon leaving factory)

Process interlock
1 delay

0-60s

Set pole difference: 0.01s

(set as 60s upon leaving factory)

Process interlock
2 operation and
retreat
Process interlock
2 delay

Operation: act to trip;retreat:the function

exits(set as retreat upon leaving factory)
0-60s

Set pole difference: 0.01s

(set as 60s upon leaving factory)

Process interlock
3 operation and
retreat
Process interlock
3 delay

Operation: act to trip;retreat:the function

exits(set as retreat upon leaving factory)
0-60s

Set pole difference: 0.01s

(set as 60s upon leaving factory)

Process interlock
4 operation and
retreat
Process interlock
4 delay
Communication address

Operation: act to trip;retreat:the function

exits(set as retreat upon leaving factory)
0-60s

Set pole difference: 0.01s

(set as 60s upon leaving factory)

1-99

Communication address of protection deivce

(set as 1 upon leaving factory)

Communication
mode)

baud

rate(485

0-4

0-9600;1-4800;2-2400;3-1200;4-600(
0)
0-9600;1-4800;2-2400;3-1200;4-600
(set as 0 upon leaving factory)

Control computer address(CAN

1-99

Address of control computer

(set as 99 upon leaving factory)

Current set value section code

7.1.9

0-1

set as 0 upon leaving factory

Specification requirement of 6KV fast-switchover device

Basic parameters of 6KV fast-switchover device
Hardware of the device:

223

The hardware of MFC2000

station consists of following parts:

Front panel

Module plug-in (including terminal)

3A microcomputer auxiliary plant power transfer

Panel
The panel of this device consists of display, operational keys, shortcut keys, indication
lamps and 232 communication commissioning interface as shown in following drawing:

MFC20003A microcomputer auxiliary plant power transfer station

Xx Power plant #1 section A switching

1.Operation
2.Interlock switching
3.Switching
4.Operation power
5.Standby power
6.Remote
7.Protection
8.Reserve
9.Receive
10.Send

Reset

Cancel

Confirm

Fig 1 Device panel

LCD screen
LCD screen is the main communication tool for operators and device. This device uses
224

320240 big LCD. It can accomplish measured value display, function activation and
deactivation, value setting, local manual switching, sequence of event, fault recoding
checking and pringting in coordination with operational keys.
Operational keys
There are totally 7 operational keys, they are:

Directional keys (,,,): four direction keys can be used to move the menu focus)

Cancel: Cancel current value input or quit current menu.

Confirm: Confirm menu selection or value modification.

Reset: Reset the master and slave CPU simultaneously and clean the signal.

Shortcut keys
There are 5 shortcut keys

Shortcut keys 1~4: Have different functions in different interface. The specific function
will be displayed in right shortcut column on LCD. The function of these keys can also be
defined based on the need of users.

Shortcut key 5: it is also called help hotkey. Press this button in all interfaces (not default
interface), relevant help will appear. In default interface, the current operation state will
be shown in fast display for users to check.

Indication lamp
There are totally 10 indication lamps in the panel:

Operation : It will flicker slowly in normal operation and quickly in interlock state. When
the device is in commissioning or operation without CPU, this lamp should be off.

Interlock switching: When it is on, the device is in interlock state so the switching logic
can not be implemented.

Switching: When it is on, the switching is just finished, it will be off after reset.

Operation power: When it is on, the working auxiliary contact is closed, and when it is off,
the working auxiliary contact is open.

Standby power: When it is on, the standby auxiliary contact is closed, and when it is off,
the standby auxiliary contact is open.

Remote: When it is of, the device is in remote operation mode, and when it is off, it is
local operation mode.

Protection: Not in use now.

Reserve: Reserved for device expansion.

Receive: communication receiving lamp. It is used for communication between device

and the portable computer.

Send: Communication sending lamp. It is used for comminucation between device and
portable computer.

225

232 Communication interface

It is used for communication with portable computer. It can be connected to 232 serial port.
The engineers and users connect this port with computer and call MFC2000 3A system
management software to accomplish comminucation between power transfer device and
computer. Then the functions like setting value modification, event query, curve printing and
program upgrade. The detailed application and function of softwate can be referred in
Operating Instruction Manual of MFC2000-3A Plant Power Transfer Device System
Management Software.
Backplate plug-in and terminals
Plug-in layout
Fig 2 Back plate plug-in and terminals

226

227

Fig 2 Backplate plug-in and terminals

Note 1: The terminals in parenthesis is not in use now.
Note 2: The trip and close outlet of MDO-400 and MDO-401 modules has polarity difference.
The function of plug-in modules

Power board (MPW400)

Convert DC220V/DC110V/AC220V voltage into +5, 15V and +24V power to supply for
the internal of the device. The specially made voltage delay circuit in the plug-in
modules can avoild malfunction or faulty signal during device step-up or step-down.

AC modules (MAI400)
Change the signal of isolation transformer of site PT secondary output voltage and CT
secondary output current into small signal to main CPU plug-in modules. Both PT and
CT are high accuracy current output type.

ON/OFF output modules (MDI400)

Isolate the ON/OFF output value(air contact) from control console, protection circuit and
other control equipment via relay and photoelectricity for CPU measurement.

DCS signal modules (MSO400) and console signal module (MSO401)

The ON/OFF value is put out in the form of air contact. It can be connected with display
twineow, DCS system or other equipment. The contact will not change.

Outlet module (MDO401) and outlet module (MDO400)

Outlet conversion plug-in module. The outlet trip command sent by CPU is isolated and
228

magnified by photoelectricity and intermediate relay and then sent to relay plug-in. the
outlet command of this plug-in can usually be kept for 0.5s.
Note: There is polarity difference among outlet CLOSE OPERATION, TRIP
OPERATION, RESERVE OUTLET 1, RESERVE OUTLET 2, CLOSE STANDBY LOW,
TRIP STANDBY, CLOSE STANDBY HIGH and PROTECTION OUTLET. If it is
connected reversely, the switch can not trip or close correctly.

Master CPU module (MCPU400)

It is mainly used for ON/OFF value measurement, calculation and outlet activation. The
communication between master and slave CPU is accomplished by SPI.

Slave CPU module (also called management module MCPU401)

It is mainly used for LCD display, keyboard operation, communication and printing.

Commissioning and test module (MTEST400)

The dedicated commissioning and test module is designed in the device for the
convenient commissiong and test of users. The module includes analogue circuit
breaker, control button and signal indication lamp. The integrity of internal inout and
output circuit and activation logic of auxiliary power switch test device does not need to
be practically operated. This module is equipped with dedicated hardware switch which
can disconnect the test circuit during normal operation and connect test circuit during
the test.

Terminal wiring
Power module (MPW

400)

DC+ and DC-; it is used for operation power (can be powered by 220/110V and AC/DC
power supply).

Power supply location.

AC module (MAI

400)

Ua, Ub, Uc and Un. Auxiliary busbar voltage (three phase). If line voltage is needed,
connect with Ua, Ub and Uc. If phase voltage is needed, connect with Ua, Ub, Uc and Un

Ugz and Ugz*. Operating power voltage (auxiliary branch or generator PT voltage). It can
measure line voltage or phase voltage.

Uby and Uby*. Standby power voltage. It can meaure line voltage or phase voltage.

Urs1, Urs1*, Urs2 and Urs2*. Voltage input reserve.

Igz and Igz*: operating branch current input. It can get line current or phase current.

Iba, Iba*, Ibb, Ibb*, Ibc and Ibc*: standby branch three phase current input.

ON/OFF input value module (MDI

400)

Protection startup (XC-1): connected with generator, transformer or G-T unit protection
contact. It can connect all outlet contacts need plant power transferring in parallel. The
connective mode is closed short impulse.

229

Protection interlock (XC-2): connected with outlet contacts of 6KV busbar protection (if
there is), operation power branch protection and HV auxiliary standby protection. The
plant power transfer station should be blocked when there proections are activated. The
connective mode is closed short impulse.

Operation auciliary contact (XC-3): auxiliary constant open contact of auxiliary HV

transformer power switch (operation power switch).

Standby auxiliary contact (XC-4)): auxiliary constant open contact of standby branch
power switch (standby power switch).

PT disconnector (XC-5): auxiliary constant open switch of auxiliart busbar PT

disconnector (or drawable CB plug).

Manual switching (XC-6): switch the startup contact manually, and the connective mode
is closed short impulse no less than 50ms. This signal is only useful when the control
mode of the device is REMOTE.

Manual switching mode (XC-7): manual switching mode selective contact. The
connective mode is sustaining. It is serial connection when it is disconnected. The
switching mode when it is connected is determined by setting value REMOTE
CONTROL ASSEMBLY. If the setting value is SERIAL /PARALLEL CONNECTION, then
the connective mode is parallel connection. Ifit is PARAKKEK SIMULTANEITY, then the
connective mode is simultaneous mode. This signal is only effective when the control
mode is REMOTE.

Switching activation and deactivation (XC-8)): manual switching activation /deactivation

contact. The connective mode is sustaining. It will activate switching function when ir is
disconnected and deactivate switching function when it is connected. When the switching
function is deactivated, the device will send SWITCHING DEACTIVATION signal to warn
operators.

Reserve (XC-9): reserved for device expansion.

Reset (XC-10): The connective mode is closed short impulse no less than 50ms. If the
device is blocked because the switching function is activated or there is fault ot
abnormality, eliminate the fault or abmormality firt, and then reset the signal and clean
the signal.

Single operation of activation and deactivation (XC-11): manual activation/deactivation

function contact. The connective mode is sustaining. It can only accomplish deactivation
function when it is disconnected and only activation function when it is connected.

Close operation only (XC-12): the connective mode is closed short impulse. The ON/OFF
input value is used to send CLOSE OPERATION SWITCH command. This signal is only
effective when the control mode of the device is REMOTE.

Close standby only (XC-13): the connective mode is closed short impulse no less than
50ms. The ON/OFF input value is used to send CLOSE STANDBY SWITCH command.
This signal is only effective when the control mode of the device is REMOTE.

Protection activation/deactivation (XC-14): not in use now.

+24V(XC-15) : 24V DC power output is used to connect debugger and power the
debugger.

The common end of ON/OFF value (XC-16).

DCS signal module and centralized control signal (MSO

230

400 and MSO

401)

These dodules are signal output. All signals are put out in air contact mode.

Switching finished (XG1-1and XG1-2): constant open contact. When the switch needs to
be opened has been tripped and the switch needs to be closed has been closed, the
device will send out this signal. The air contact output will be maintained until the device
is reset.

Switching abnormal (XG1-3 and XG1-4) : constant open contact. If the switch should trip
does not trip, the switch should be closed is not closed or the switching conditions can
not be satisfied within the set time after switching is started (for example, in 5s), the
device will send out signal. The signal will be sent out is air contact mode and be
maintained until the device is reset.

Abnormal switching (XG1-3 and XG1-4) : constant open contact.

Switching interlock (XG1-5 and XG1-6) : constant open contact. When any of following
conditions appears, the device will carry out interlock switching automatically. The signal
will be sent out in air contact output and maintained until the interlock is unlocked.

If there is PT wire break, switch position abnormal, device internal fault, eternal
protection interlock, standby de-energization interlock or one of the switching
functions is out of operation.

The device is activated once.

Switching exit (XG1-7 and XG1-8) constant open contact. When any of following
conditions happens, the device will send out this signal and the switching operation can
not be carried out. The signal is sent out in air contact mode. When the SWITCHING
EXIT signal is sent out, the SWITCHING INTERLOCK signal will be sent out
simultaneously, when none of following conditions happens, the SWITCHING EXIT
signal will be relieved automatically and the switching can be carried out, which means
the device can be activated and deactivated reciprocately without resetting.

The ETERNAL ACTIVATION/DEACTIVATION of ONOFF value of device is set

on DEACTIVATION ( the contact is closed);

The SWITCHING ACTIVATION/DEACTIVATION of the device is set on

SWAXTIVATION;

The switching functions of fast switching, leading phase angle, leading switching
time, residual voltage switching and long delay switching are all set on
DEACTIVATION.

De-energization (XG1-9,,XG1-10, XF1-9 and XF1-10) : constant close contact. Open

when the device is not de-energized. Close when the device is de-energized. There are
two contacts with same function.

Remote/local (XF1-1 and XF1-2) : Output air contact shows that the current control mode
is remote or local. It is remote when it is open and local when it is closed.

Parallel/serial (parallel/ simultaneous) (XF1-3 and XF1-4) : the remote switching mode is
parallel when the contact is open. The meaning of connection is determined by setting
value REMOTE SWITCHING SET. If the setting value is PARELLEL/SERIAL, then the
connective mode is serial mode, but if it is PARALLEL SIMULTANEOUS, it is
simultaneous mode.

Protection activation (XF1-5 and XF1-6) and protection deactivation (XF1-7 and XF1-8) :
not in use now.

231

Switch position abnormal (XG2-1 and XG2-2) : constant open contact. Switch position
abmormal signal. When any of following conditions happens, the device will be blocked
automatically and sends out this signal. The signal will be sent out in air contact mode
and maintained until the condition is eliminateda and the device is reset.
Switch position abnomal includes : full open or full closed during energization, close the
operating brach during operation to result in full closed or close the standby branch
during operation to result in full closed, open standby during the operation to result in
full open, the switch is full open or closed in single operation, faulse opening of
operation branch and PT disconnector open.

Standby de-ergization interlock (XG2-3 and XG2-4) : constant open contact. When the
auxiliary busbar is powered by operation power, the standby power is backup power.
When the auxiliary busbar is powered by standby power, the operation power is backup
power. When the voltage of backup power is lower than set value and the backup power
loss interlock is activated, this contact is closed. The signal is sent out in air contact
output and maintained until the power loss is relieved.
Note : when the standby PT is in maintenance, the backup power loss interlock function
can be exited via value setting menu, the device can still be switched, but the switching
mode is different with normal switching mode. The device can still carry out switching
when no power loss. But it can only accomplish residual voltage switching and long
delay switching when there is power loss.

PT wire break (XG2-5 and XG2-6) : constant open contact. The device will be blocked
and send out signal automativally when it is detected to have wire break on busbar. The
signal will be sent out in air contact output and maintained until the fault is eliminate and
the device is reset.

Device abnormal (XG2-7 and XG2-8 ) : constant open contant. If the device detects that
there is abnormality, it will be blocked and send out signal automatically. The fault
condition can be checked in the fault report. The signal is sent out in air contact output
and maintained until the fault is eliminated and the device is reset.

Reat acceleration activation (XG2-9 and XG2-10) : constant open contact. Thid contact
will be closed simultaneously to start the rear acceleration function of branch protection
when the deviceswitching is started. The time of duration of contact closing is the
switching time plus 500ms.

Single close allowed (XF2-1 and XF2-2) : constant open cantact. If the current operation
allows single close operation, this signal will be sent out.

Reserve 1, 2, 3 and 4 (XF2-3, XF2-4, XF2-5, XF2-6, XF2-7, XF2-8, XF2-9 and XF2-10) :
constant open contact. It is reserved for the expansion of the device.

Outlet module 1 (MDO

401)

Close operation (XE1-1 and XE1-2) : close the operation power switch outlet contact.
This contact is current self-holding type. When it is connected, it will be relieved
sutomatically after the auxiliary contact of operation power switch on closing circuit. This
outlet has polarity difference. XE1-1 is connected to positive end while XE1-2 is
connected with negative end.

Trip operation (XE1-3 and XE1-4) : trip operation power switch outlet contact. This
contact is current self-holding type. It will be relieved after the auxiliary contact of
operation power switch on trip circuit is open when it is connected. This outlet has
polarity difference. XE1-3 is connected with positive end and XE1-4 is connected with
negative end.
232

Reserved outlet 1 (XE1-5 and XE1-6) and reserved outlet 2 (XE1-7 and XE1-8) :the
reserved outlet contact of the device. The connective mode is similar with above. The
outlet has polarity difference. XE1-5 is connected with positive end and XE1-6 is
connected with negative end. XE1-7 is connected with positive end and XE1-8 is
connected with negative end.

Auxilaries switching 1(XE1-9 and XE1-10) and auxiliaies switching 2 (XE1-11 and XE112) : they will respectively be the outlets for section one and section two when the LV
auxiliaries switching function is needed.

Outlet module 2 (MDO

400)

Close standby low (XE2-1 and XE2-2) : close standby power switch outlet contact. This
contact is current self-holding type. It will be automatically relieved after the auxiliary
contact of close circuit switch is open when it is connected. This outlet had polarity
difference. XE2-1 is connected with positive end and XE2-2 is connected with negative
end.

Trip standby (XE2-3 and XE2-4) : trip standby power switch outlet contact. The
connective mode is the same with above. This outlet has polarity difference. XE2-3 is
connected with positive end and XE2-4 is connected with negative end.

Close standby high (XE2-5 and XE2-6) : close the HV CB of standby transformer or
another outlet contact of LV side. The connective mode is the same with above. This
outlet has polarity difference. XE2-5 is connected with positive end and XE2-6 is
connected with negative end.

Protection outlet (XE2-7 and XE2-8) : not in use now. this outlet has polarity difference.
XE2-7 is connected with positive end and XE2-8 is connected with negative end.

Reserved output 1 (XE2-9 and XE2-10) and reserve output 2 (XE2-11 and XE2-12) :
reserved for device expansion.

Main CPU module (MCPU

400)

Commissioning port: used for communication port 232 connected with the computer. It is
just used for program upgrading currently, not open to users.

Slave CPU module ( management module, MCPU

401)

Commissioning port: the function of this port is totally the same with 232 communication
port on the panel and used for communication with system management software.

Parallel port: printer interface.

NET1A and NET1B: on site bus 485 interface. The communication protocal can be
selected as MFC1.0 or Modbus protocol.

NET2A and NET2B: on site bus 485 interface. The communication protocal can be
selected as MFC1.0 or Modbus protocol.

GPS+ and GPS-: used for GPS timing. It requires 24V impulse signal connected from the
external.

Commissioning test module (MTEST

400)

The device is equipped with a commissioning test module for the convenience of on site
commissioning. Remember to turn the module K1~K6 to open position and K7 to working
position or draw out the commissioning test module.
233

The indication and definition of panel lamps is as follows:

Operation power lamp: the working switch is closed when it is on.
Standby power lamp: the standby switch is closed when it is on.
Test state lamp: the divice is in test state when it is on. then the activation logic is about
the simulation switch on commissioning panel.
Close working switch: used to close the working switch on the panel.
Trip working switch: used to trip the working switch on the panel,
Close standby switch: used to close standby switch on the panel.
Trip standby switch: used to trip standby switch on the panel.
The meaning of switches on the test board is as follows:
K1 is CLOSE WORKING ALLOWED switch. When this switch is open, the working
switch on the panel will not accept CLOSE command.
K2 is TRIP WORKING ALLOWED switch. When this switch is open, the working
switch on the panel will not accept TRIP command.
K3 is SWITCH RESET ALLOWED. When this switch is open, the CPU will deem
that working switch is always on OPEN position.
K4 is CLOSE STANDBY ALLOWED switch. When this switch is open, the standby
switch on the panel will not accept CLOSE command.
K5 is TRIP STANDBY ALLOWED switch. When this switch is open, the standby
switch on the panel will not accept TRIP command.
K6 is STANDBY RESET ALLOWED switch. When this switch is open, the CPU will
always deem that the standby switch is on OPEN position.
K7 is overall test switch. This switch must be turned to TEST position during the
switching test and turned to WORKING position when the test is finished.
Set value
All set value of the device can be set with keys on the LCD following the hints in the menu.
Input correct passwords befire modifications. The password is four numbers, the factory
password is 1000, and the user can set the password according to their needs.
Value setting
Default value is the set value for reference when the closing time of CB is 65ms, it can be
adjusted based on the actual working conditions on site.
Numb
er
1

Set
type

value

Operation mode

Unit

Scope

Default
value

No

Mode1,2 and 3

Mode 1

234

Remark

Normal parallel
switching
voltage
difference

Normal parallel
switching
frequency
difference

Hz

0.02

Normal parallel
switching phase
difference

Degree

0.5

Normal parallel
trip delay

0.01

Simultaneous
switching close
standby delay

Ms

500

50

Standby HV/LV
close delay

Ms

120

Fast switching
frequency
difference

Hz

0.1

2.0

1.5

Fast switching
phase difference

Degree

0.5

60.0

30.0

10

Synchronous
switching
frequency
difference

Hz

0.1

5.0

5.0

11

Synchronous
constant leading
phase angle

-30

-120

-90

12

Synchronous
constant leading
time

Ms

13

Residual
switching
voltage
magnitude

20

235

20

20

0.50

20.0

5.00

150

60

0.50

15.0

0.50

70

25

Close circuit
total time

14

Voltage
loss
startup
switching
voltage
magnitude

20

90

15

Voltage
loss
startup delay

0.10

16

Backup power
loss
voltage
magnitude

50

17

Backup power
loss delay

ms

18

LV switch over
to
auxiliaries
section
one
voltage
magnitude

20

80

60

19

LV switch over
to
auxiliaries
section
two
voltage
magnitude

20

80

60

20

Auxiliaries
swiching section
one delay

0.0

20.0

0.5

21

Auxiliaries
swiching section
two delay

0.0

20.0

9.0

22

Initial
angle 1

phase

Degree

0/30.0/60.0/9
0.0/120.0

Related to
actual wiring
of voltage

23

Initial
angle 2

phase

0/30.0/60.0/9
0.0/120.0

Related to
actual wiring
of voltage

24

No
current
criterion
set
value

0.10-2.00

0.50

5.00
90

200-500

236

40

1.00
80

200

25

Long delay set

value

0.5-10.0

26

Single operation
no voltage set
value

27

Single operation
synchronous
phase difference

Degree

28

Single operation
synchronous
phase difference

29

Single operation
synchronous
frequency
difference

9.0

0-60

60

0.5-60.0

Hz

30.0

0-20

20

0.1-2.0

1.5

Control word setting

N
u
m
be
r

Set value type

Scope

Default
value

Remote/local

Remote

Control mode

Protection
mode

switching

Serial/simultaneous

Serial

Voltage loss switching

mode

Serial/simultaneous

Serial

Local manual switching

mode

Parallel semi-auto, parallel

auto,
serial
and
simultaneous mode

Parallel
auto

Remote
parallel
switching mode

Semi-auto/auto

Auto

Remote swiching set

Parallel /serial,
simultaneous

Voltage loss startup

parallel

Activation/deactivation

237

Parallel /
serial
Activatio
n

Remark

Fast switching

Activation/deactivation

Activatio
n/deactiv
ation

Synchronous
phase angle

leading

Activation/deactivation

Deactivat
ion

10

Synchronous
time

leading

Activation/deactivation

Activatio
n/deactiv
ation

11

Residual
switching

voltage

Activation/deactivation

Activatio
n/deactiv
ation

12

LV switch over to
auxiliaries section 1

Activation/deactivation

Deactivat
ion

13

LV switch over to
auxiliaries section 2

Activation/deactivation

Deactivat
ion

14

Backup power
interlock

Activation/deactivation

Activatio
n/deactiv
ation

15

Switching
activation/deactivation

Activation/deactivation

Activatio
n/deactiv
ation

16

Single
operation
activation/deactivation

Activation/deactivation

Deactivat
ion

17

No current criterion
activation/deactivation

Activation/deactivation

Deactivat
ion

18

Long
delay
activation/deactivation

Activation/deactivation

Deactivat
ion

19

Single operation close

activation/deactivation

Activation/deactivation

Deactivat
ion

20

Single
operation
synchronous
close
activation/deactivation

Activation/deactivation

Deactivat
ion

loss

Set value and control word instructions

123

Operation mode: there are three sets of set value for the device, they are respectively
called operation mode1, 2 and 3.
238

Normal parallel switching voltage difference, normal parallel switching frequency

difference, normal parallel switching phase difference and normal parallel trip delay:
normal parallel switching means manual parallel switching mode. The parallel switching
must be accomplished in fast switching mode. When the voltage,frequency and phase
differences on two sides of the working switch (standby switch) are lower than that of
normal switching, the device will send out CLOSE command to close the switch need to
be closed, and then trip the switch on the other side after normal parallel trip delay.

Simultaneous switching close standby delay: if the switching mode is simultaneous, then
TRIP WORKING (standby ) command will be sent, the command to close standby
(working) LV switch will be sent after a time delay set according to the set value.

Standby HV/LV close delay: when the CLOSE STANDBY HIGH command is sent, the
device will send CLOSE STANDBY LOW command after this time delay.

If the switching mode of fast switching frequency difference and fast switching phase
difference is fast switching, then the device will send CLOSE command when the
frequency and phase difference on two sides of switches to be closed are lower than the
fast switching frequency and phase difference.

Synchronous switching frequency difference: this set value is one of necessary

conditions of leading phse angle switching, the default value is 5HZ/

Synchronous constant leading phase angle: when the frequency difference on two sides
of switch to be closed is lower than synchronous switching frequency difference, the
device will send CLOSE command if the angle difference of switch on both sides is within
the set value scope.

Synchronous constant leading time: this value is usually set based on the ingerent total
delay of standby switch close circuit.

Residual voltage switching voltage magnitude: if the switching mode is residual voltage
switching, then the busbar voltage is less than this set value and the device will send out
CLOSE command. The default value is 25.

Voltage loss startup voltage magnitude and delay: when the busbar voltage is less than
voltage loss startup voltage magnitude, in-coming current is less than no current set
value and the duration exceeds voltage loss startup delay, the conditions of voltage loss
startup are satisfied. Because the voltage during voltage loss startup is very low, the
device usually uses residual switching and long delay switching. The fast switching and
synchronous swiching usually fail because the working condition fail to meet
requirements.

Backup power loss voltage magnitude and backup power loss delay: when the standby
side voltage is lower than backup power loss voltage magnitude and the time exceeds
backup power loss delay, the condition of backup power loss is satidfied. If the backup
power loss interlock control word is activated, then the device will carry out switching
interlock. The default value is 80% and 200ms.

LV switching auxiliaries section one voltage magnitude, LV switching auxiliaries section

two voltage magnitude, auxiliaries section one switching and auxiliaries section two
switching: the short time power interruption during switching will cause auxiliary busbar
voltage decrease and motor rotary speed decrease. Whether the motor can
automatically start up is determined by standby transformer capacity, busbar voltage
when standby power is activated and loads amount and capacity involved in auto
239

startup. If the condition does not allow all loads to startup up automatically, disconnect
some unnecessary loads to be directly useful for auto startup of other important motors..
this device is equipped with two LV load decreasing outlet which can set voltage and
time delay respectively. The LV load decreasing function is only effective during device
switching. The default value are 60%, 60 , 0.5s and 9.0s.

Initial phase angle difference 1: it is used to compensate phase angle difference between
standby transformer power voltage and busbar voltage caused by wiring and so on. the
default value is 0. For instance, assume that the busbar voltage and standby power
voltage is the same phase, and they are connected via Y/Y-12 transformer, then if the
standby power takes UAN and busbar takes UAN, the set initial phase angle1 difference
is 0 degree. If the standby power takes UAN and busbar takes UAB, the initial pgase
angle difference 1 is -30 degree. If the standby power takes UAC and busbar takes UAB,
the initial phase angle difference 2 is -60 degree.

Initial phase angle difference 2: it is used to compensate phase angle difference between
working power voltage and busbar voltage caused by wiring and so on. The default value
is 0. For instance, assume that the busbar voltage and standby power voltage is the
same phase, and they are connected via Y/Y-12 transformer, then if the standby power
takes UAN and busbar takes UAN, the set initial phase angle2 difference is 0 degree. If
the standby power takes UAN and busbar takes UAB, the initial pgase angle difference 2
is -30 degree. If the standby power takes UAC and busbar takes UAB, the initial phase
angle difference 2 is -60 degree.

No current criterion set value: in faulty trip startup logic, if the CB is tripped and the
current is lower than this set value, the device will enter faulty trip logic. The no-current
criterion in faulty trip can be activated and deactivated with control word no-current
criterion. The default value is 0.5A.

Long delay set value: when the long delay switching is in operation, after the switching is
started, the device will send out CLOSE command after time delay set by this set value.

Single operation no voltage set value: In switch single close, when the voltage on any
one side of the working switch is lower than this set value, the no voltage close condition
is satisfied. The default value is 60.

Single operation synchronous phase difference, single operation synchronous voltage

difference and single operation synchronous frequency difference: when single close the
switchm if the phase, voltage and frequency differences on two sides of working switch
(standby LV switch) are respectively lower than single operation synchronous phase
difference, single operation synchronous voltage difference and single operation
synchronous frequency difference, then the condition of synchronizing closing is
satisfied. The default value is 30 degree, 20% and 1.5 Hz.

Control mode: only when the control word is REMOTE, can manual switching and single
operation be carried out on remote control console or DCS system. Then the local (on
the device) manual switching and single operation can not be operated. When the
control word is set LOCAL, the manual switching and single operation can be carried out
on the device and then the remote operation can not be carried out. The default value is
REMOTE.

Protection switching mode: this condtro word is used to determine the switching mode
under protection startup mode. The default value is serial.

Voltage loss switching mode: this control mode is used to determine switching mod
under voltage loss mode. The default value is serial.
240

Local manual switching mode: this control word is used to determine the switching mode
under local manual switching mode. The default value is parallel auto.

Remote parallel switching mode: this control mode is used to determine parallel auto ot
parallel semi-auto mode during remote manual serial switching.

Remote switching assembly: this control word determines the selection scope of control
mode during remote manual switching. When this control modes selects parallel/serial
mode, the remote control can only select serial or parallel. When this control word
selects parallel/simultaneous mode, the remote manual switching can only select parallel
or simultaneous.

Voltage loss startup: this control word demines if the voltage loss startup mode will be
activated. The default value is activated.

Fast switching: this control word is used to determine if the fast switching mode is
activated in serial or simultaneous switching. The default value is activated. Note: the
parallel switching mode also uses fast switching, but it is not affected by this set value.

Synchronous leading phase angle: this control word is used to determine whether the
synchronous leading phase angle switching mode is activated. The default value is
deactivated.

Synchronous leading teme: this control word is used to determine if the synchronous
leading switching mode is activated. The default value is activated.

Residual vaoltage switching: this control word is used to determine if the residual
switching mode is activated. The default value is activated.

LV switching auxiliaries section 1 and section 2: these two set value are used to
determine if the function of LV switching auxiliaries section 1and section 2 is activated.
The default value for both sections is deactivated.

Backup power loss block: when this control word is activated, if the backup power loss
block conditions are satisfied, then the switching function of the device will be blocked,
none of switching mode can be carried out. When some conditions like PT maintenance
happen, the backup power loss block needs to be deactivated temporarily. When this
control word is deactivatedm even backup power loss conditions are satisfied, the device
will not be blocked and can still carry out switching. But the switching mode is different
with normal switching mode. Only residual switching and long delay switching can be
carried out when there is backup power loss but no block.

Switching activation and deactivation: in this control word setting, the device is blocked
so none switching can be carried out when this control word is deactivated. The default
value is activated.

Single operation activation and deactivation: in this control word setting, the single
operation is blocked when the control word is deactivated. The default value is
deactivated.

No current criterion activation and deactivation: this control word is used to determine if
the no current criterion needs to cooperate with faulty trip startup logic. If this control
word is activated, then we need to figure out if it is faulty trip after the switch is trip based
on no current criterion set value. If this control word is deactivated, then no current
criterion when faulty trip startup. The default value is deactivated.

Long delay switching activation and deactivation: this control word is used to determine if
the long delay switching needs to be activated. The default value is deactivated.

241

Single operation closing activation and deactivation: this set value is used to determine if
no voltage closing mode is allowed when single switch closing. The default value is
deactivated.

Single operation closing activation and deactivation: this set valur is used to determine if
the synchronous closing mode is allowed when single switch closing. The default value is
deactivated.

7.1.10

Specification requirement of 400V standby power supply auto operation device

400V standby power supply auto operation device adopts MBZT-320Hb type
microcomputer standby power supply auto operation device produced by Zhuhai
Wanlida electric Co LTD
Configuration features of the device:
MBZT-320Hb type microcomputer standby power supply auto operation&auto
restore device adopts top grade 16 bits SCM as controller, which is of fast aculation,
complete function and reliable action. It has power loss memory chip storage set
value and power loss real time clock. It can record information of 8 times action
acurately and has perfect self-inspection function. By adopting Chinese crystal
display, it realizes simple operation on various menu via keyboard and good display.
The device is set with high-speed RS485 communication joint to upload to the
background computer supervision system. At the same time when the device
finishes action, it unloads all the action information and remote information through
communication net. It is of insert structure with simple wiring connection and strong
anti-quake & anti-electromagnetism capability, and can build up screen or be
directly installed in switchgear. Therefore, it is taken as ideal equipment for
substation automatization system.
Description of set value

Range

Instruction

Working mode operation

and retreat

Main standby:the mode operates,

mutual standby: the mode operates

Main
incoming
selection

1# incoming lead as main incoming

lead

lead

Auto-operation
action
operation and retreat

Operation:the
function
retreat: the function exits

operates,

Auto-restore
action
operation and retreat

Operation:the
function
retreat: the function exits

operates,

Incoming lead electrifying

mode

Joint:the mode operates, voltage:the

mode operates

External
joint
block
operation and retreat

Operation:the
function
retreat: the function exits

operates,

Overcurrent
block
operation and retreat

Operation:the
function
retreat: the function exits

operates,

PT

Operation:the

operates,

line-break

block
242

function

operation and retreat

retreat: the function exits

Busbar with voltage value

10-400V

Set pole difference: 1V( set as 90V

upon leaving factory)

Busbar low voltage value

10-400V

Set pole difference: 1V( set as 10V

upon leaving factory)

Incoming
lead
voltage value

10-400V

Set pole difference: 1V( set as 90V

upon leaving factory)

incoming lead no current

value

0.5-5A

Set pole difference: 0.1A ( set as 0.5A

upon leaving factory)

incoming lead no current

value

0.5-5A

Set pole difference: 0.1A ( set as 0.5A

upon leaving factory)

Trip 1DL delay

0-10s

Set pole difference: 0.1s ( set as 10s

upon leaving factory)

Close 1DL delay

0-10s

Set pole difference: 0.1s ( set as 10s

upon leaving factory)

Trip 2DL delay

0-10s

Set pole difference: 0.1s ( set as 10s

upon leaving factory)

Close 2DL delay

0-10s

Set pole difference: 0.1s ( set as 10s

upon leaving factory)

with

Display primary operation

and retreat

Exit

PT no-load voltage ratio

1-5000

Set pole difference: 1

CT no-load voltage ratio

1-5000

Set pole difference: 1

line
overcurrent
operation and retreat
line
value

overcurrent

set

Operation:the
function
retreat: the function exits
0.5
99.99 A

Set pole difference: 0.1A

0-60s

Set pole difference: 0.1s

operates,

line overcurrent delay

line
accelerating
operation and retreat
line

current

accelerating

line accelerating delay

Operation:the
function
retreat: the function exits
0 .5 99.99 A

0-3s

Set pole difference: 0.1s

line
overcurrent

operation and retreat

line overcurrent value

Set pole difference: 0.1A

Operation:the
function
retreat: the function exits

0.5
99.99 A

243

operates,

operates,

Set pole difference: 0.1A ( set as

99.99A upon leaving factory)

 line overcurrent delay

0-60s

line
accelerating
operation and retreat

7.1.11

Set pole difference: 0.1s ( set as 10s

upon leaving factory)
Operation:the function
retreat: the function exits

operates,

line accelerating current

0.5
99.99 A

Set pole difference: 0.1A ( set as

99.99A upon leaving factory)

line accelerating delay

0-3s

Set pole difference: 0.1s ( set as 3s

upon leaving factory)

Communication address

1-99

Communication address of the device

Telecommunication baud
rate (485 mode)

0-4

0- 9600 1-4800
3-1200 4-600

Set value section code

0-1

Set pole difference:1,with two set

value areas

2-2400

Technical specification of auto pre-synchronizaiton device

The power station adopts SID-2CM auto pre-synchronizaiton device of Shenzhen
Intelligent Equipment Development Co.,LTD.

7.1.11.1

Technical index

7.1.11.1.1

Input TV secondary voltage 110v at both sides of circuit breaker to be parallel

connected.

7.1.11.1.2

All of the input binary(parallel connection points selection, remote reset, start
synchronization work, single-side no voltage close confirm,no-voltage no-load
close confirm, circuit breaker auxiliary joints,etc.) are normal open spare joints.

7.1.11.1.3

Output binary(acceleration, deceleration, voltage increase, voltage decrease,

close, power angle overlimit, alarm, power loss etc.)
Control signal uses mini-electromagnetic relay normal open spare joint, with joint
capacity of 220V DC 0.5A.

7.1.11.1.4

A RS-485 communication joint and electrical computer supervision system

transmitting action information

7.1.11.1.5

Working power supply 220V DC power supply, power consumption is less than
20volt-ampere.
Insulation intensity: weak electricity circuit against ground
Strong electricity circuit against ground

50V 50Hz/min

2000V 50Hz/min

Between strong and weak electricity circuits

1000V 50Hz/min

Working environment: working temperature: 0(C

-20( 70(

50(C

storage temperature:

Relative humidity: less than 90%

7.2

Periodical inspection and maintenance of power plant trlay protection and

244

automatic equipment
7.2.1

Requirement for relay protection personnel

7.2.1.1

He must be familiar with protection device and secondary circuit connection;

7.2.1.2

Be familiar with operation protection device and various output information

reference of the protection;

7.2.1.3

Be familiar with criterion and present set value of each protection;

7.2.1.4

Knowing the reference methods and simple judgment of device fault;

7.2.1.5

Grasp the normal maintenance outline of equipment

7.2.2

Overhaul and maintenance of relay protection automatic device in Indonesia

Pakitan 2*315 power plant.

7.2.2.1

Checking category and cycle:

All of the relay protection device, safe automatic equipment and its circuit
connection should be checked according to requirement of the regulation to
determine whether the elements of equipment are all right, circuit connection, set
values and characteristics are correct.

7.2.2.1.1

Checking is divided into three types:

1) Periodic check:
2) Full check.
3) Partial check.
4) Use the equipment to do circuit breaker trip close test.

7.2.2.1.2

Complementary check:
1) Check after equipment alteration
2) Check after maintenance or replacement of primary equipemnt.
3) Check after the abnormal is found during operation
4) Check after accident

7.2.2.1.3

Check and acceptance of newly installed equipment should be carried out under
the following situation:

7.2.2.1.3.1

When the newly installed primary equipment is put into operation.

7.2.2.1.3.2

When newly installed device is put into the existing primary equipment.

7.2.2.1.3.3

When make big changes to the operating equipment or add new circuit.

7.2.2.1.3.4

The newly installed and reconstructed equipment which is not checked according
to the regulation requirement should be prohibited to be put into operation.

7.2.2.1.3.5

Periodic check must be carried out according to the time limit specified in the
regulation.

7.2.2.1.4

Checking cycle
Refer to Table 7.2.2.1.4
Table 7.2.2.1.4
equipment

Checking cycle table of relay protection and automatic

245

No.

Description of equipment

Microcomputer
protection
device
including generatortransformer set protection device,
150KV busbar protection, 150KV
line protection,
LV auxiliary
transformer
protection,
motor
protection,etc.

Whole set commissioning test check and

static performance test check shoud be
carried out on the newly operated
microcomputer
protection
equipment.Within the first year of
operation, comprehensive checking
should be conducted once. After that
comprehensive checking should be
made every four year or along with the
unit overhaul. Partial check should be
done annually.

All the equipment(including auto

reclose, fast-switchover, standby
power
supply
auto-operation
device, fault recorder etc.)

Whole set commissioning test check and

static performance test check should be
carried out in first operation. Within the
first year of operation, comprehensive
checking should be conducted once.
After that comprehensive checking
should be made every four year or along
with the overhaul. Partial check should
be done annually.

Current
types

various

Whole set commissioning test check and

static performance test check shoud be
carried out in first operation. Partial
check should be done every five years
after normal operation, and check once
when its no-load voltage ratio changes.

Transformer Buchholz protection

device

Whole set commissioning test check and

static performance test check shoud be
carried out in first operation. Partial
check should be done every year after
normal operation, and comprehensive
check every four years.(you may replace
relay)

High
frequency
protection
channel(including channels used
together with communication while
maintained by commonication
department)device:1.high
frequency cable; connecting wave
filter 2.high frequency wave

Whole set commissioning test check and

static performance test check should be
carried
out
in
first
operation.
Comprehensive check on channel
equipment itself every four years after
normal operation. Partial check should
be done every year. Every day you

transformer

of

Checking cycle

246

5
6

7.2.2.2

hindering device

should supervise to see if channel

equipment is normal in the way of signal
receiver/sender signal exchange.

Device in operation signal circuit

Carry out by combining the test of

affiliated equipment

Circuit insulation test

Make primary insulation determination

per year, and primary insulation voltagewithstanding test every four years or in
overhaul along with unit.

Test under special situation:

When protection device refuses to act, act falsely or in unknown causes, we
should set down specific checking items and sequence to make checking after
the accident.

7.2.2.3

Generally, periodic check during the period below on protection devices should be
made along with the primary equipment maintenance.

7.2.2.3.1

Main system protection and busbar protectionbefore thunder storm season.

7.2.2.3.2

Line high frequency protectionbefore the protected line transfering high peak
load.

7.2.2.3.3

Generator-transformer protectionduring primary equipment maintenance.

7.2.2.3.4

Auto reclose function of linecarry out along with circuit breaker power off period.

7.2.2.3.5

Secondary circuit cablebefore the season with secondary circuit fault

occurrence high probability according to specific area climate features.

7.2.2.3.6

Other equipment check is distributed along the whole year.

7.2.2.3.7

Multi-protection of the same element. If the whole check can not be arranged in
the period of protected equipment power off, it may be arranged in the season
with low probability of fault occurrence to make each set of protection device
retreat from operation in turn.

7.2.2.4

Preparation before check

7.2.2.4.1

The basic requirements to test power supply are as follows:

7.2.2.4.1.1

AC test power supply and corresponding adjusting equipments should be with

enough capacity so as to ensure the voltage and current energizing equipments
are sine wave under max test load. The harmonic wave of test current and
voltage better not exceed 5% of basic wave.

7.2.2.4.1.2

The rated voltage of DC test power supply shall be same as DC rated voltage of
equipment. The test branch is furnished with special safety CB. The fuse must
satisfy the safety requirement. It is not allowed to use DC branch power supply of
running equipment to test.

7.2.2.4.2

Before check at local, we need know the primary equipment and neighboring
equipment of test devices, and prepare the technical measures for system safety
operation during the check. The work principal fills out Relay Protection Safety

247

Measures Permit and the foreman and operator check it.

7.2.2.4.3

As for the setting test of equipment, it shall be carried out based on the setting
values inform provided by relevant relay protection authorities. The test principal
shall be familiar with the setting values, check the setting values complete or not
and check the ratio of current and PT in accordance with site practice or not.

7.2.2.5

Basic requirements of test to test loop wiring

7.2.2.5.1

The test shall apply suitable instruments. The measuring of insulated resistance is
generally of 1000V megger.

7.2.2.5.2

The wiring principle of test loop is to make sure electric quantity energizing device
in accordance with practical work condition. The test loop of simulation fault shall
have the conditions testing the whole set of devices. The whole set of test of
device refers to the voltage of auto device and incoming terminal of current
secondary loop energize all devices of the same protected equipment by
simulated voltage and current so as to test the actions of all devices during fault
and reclose.

7.2.2.5.3

For the test of complicated device, the simulation test loop shall be with following
conditions.

7.2.2.5.3.1

The relative phase of test current and voltage can vary within 0 0 360 0 . Test
power supply is generally 3-phase 4-wire system and test current can be single
phase but with conditions energizing three phases. The current of single phase
can be adjusted within 0-50A equally, while, the current of simulated 3-phase
short circuit shall be not less than 20A.

7.2.2.5.3.2

There shall be logic control loop simulating fault occurring and eliminating.
Generally it can simulate following cases:

7.2.2.5.3.2.1

Varied 2-phase short circuit, 2-phase short circuit grounding and single phase
grounding fault;

7.2.2.5.3.2.2

Synchronous 3-phase short circuit; asynchronism of 3-phase short circuit shall be

not more than fault of 1.0ms;

7.2.2.5.3.2.3

Elimination of above-mentioned faults, reclose success and fail of reclose (instant

and permanent short circuit);

7.2.2.5.3.2.4

Conversion from single phase short circuit into 2-phase grounding or 3-phase
short circuit fault after specified delay (test to complex reclose and test after
accident);

When checking complex reclose or single phase relcose device, in order to reduce the
trip and close of CB, we need prepare special 3-phase CB separate operation
simulating loop which shall meet following basic requirements:
Simulating separate phase trip and close loop basically same as practical current
Logic loop similar with convert performance and time of CB trip and close auxiliary
contacts
Light indication loop similar with functions of control panel CB position monitor light
248

The wiring type of act time test loop of device shall meet following requirements:
Try not to dismantle the wiring on loop for test of some relay act time in device loop.
As for the required relay, we shall measure the practical difference of relay act time limit
according to mutual act relationship of loops so as to know the allowance.
Act time of device measuring shall be all the time limit from tested devices fault voltage
and current until trip pulse to CB. We use the chronograph to read the time
difference between the simulated fault occurring and startup. Generally it is less
than 5ms unless special requirement. The measurement of protected device act
time shall apply electronic millisecond meter which will not be impacted power
supply frequency.
The check of HF dispatcher shall apply electronic meter with suitable frequency
range. The grounding of meter measuring terminal or connecting type of ground
potential terminal shall obey the specifications of meter application so as to avoid
error measurement.
The measurement of high frequency shall apply digital frequency meter.
Before connecting AC work frequency test power supply, we must disconnect the
grounding point in the device AC loop first. It is not allowed that there is one more
grounding point except the test power supply. When the terminal of measuring
instrument has grounding point, these grounding points must connect to the same
grounding point.
For the measuring instrument specifying grounding terminal, it is not allowed to
connect DC power supply circuit directly so as to avoid DC power grounding
when checking on site.
For the protect device applying transistor or IC element, we need pay more attention to
following items so as to avoid element from damage when checking.
The display screen shall be connected with grounding grid of substation solidly.
The measuring instruments specifying grounding terminal are not allowed to connect to
element loop directly.
There shall be the measures to prevent electrostatic induction power from introducing to
element.
7.2.2.6

Checking items and content

7.2.2.6.1

Checking of microcomputer protection and auto devices

7.2.2.6.1.1

Visual checking of microcomputer and auto devices

7.2.2.6.1.1.1

Checking conditions:
Disconnect all added power supply (DC and AC power supply)

7.2.2.6.1.1.2
7.2.2.6.1.1.2.1

The quality of device, device case and auxiliary equipments, lead, terminal and
material etc:
Observe the protection cabinet (screen) and all cases have no deformation or
scratch. The color is suitable. No damage to buttons or indicator; nameplate
and vendor name are clear;

249

7.2.2.6.1.1.2.2
7.2.2.6.1.1.2.3
7.2.2.6.1.1.2.4
7.2.2.6.1.1.2.5

All standard plugs shall be sound; the plug has no damage and contact solid.
All grounding wires and copper sockets are solid;
The soleplate on cabinets and small switches are solid. The wiring of wiring
terminal is solid and reliable.
Checking of terminals wiring behind cabinet
The marks on terminals are clear; the specifications and numbers of wiring
terminals shall be completely consistent with design drawing. Use
corresponding screw driver to tighten the screws of wiring terminals. There
shall be spring sheets and other vibration-proof sheets on fixed screws to
ensure the wiring solid. The link between inner and outer terminals of TA
secondary wiring on terminal strip is sound. The fixed screws shall be
tightened. All metal conductors of terminal strip wiring shall contact terminals
reliably and the gap has no insulation objects. The wiring terminals shall have
plastic tubes with tabs and the tabs shall be clear.

7.2.2.6.1.1.2.6

Checking of reset and test buttons, soleplate and test elements

Operate reset, test button and the switches on plug separately; the operation
shall be flexible without block or damage. The wiring on soleplates is solid.
The buttons shall operate flexibly without block or abnormal cases.

7.2.2.6.1.1.3

Whether the technical data test report is complete and correct;

7.2.2.6.1.1.4

The symbols on display shall be correct, complete and clear.

7.2.2.6.1.1.5

The outer checking of all relays shall be carried out according to related test
regulations.

7.2.2.6.1.1.6

Check if the wiring is in accordance with drawings;

7.2.2.6.1.2

The whole set check of microcomputer protection and auto devices;

7.2.2.6.1.2.1

The correctness of electric input loop wiring;

7.2.2.6.1.2.2

Check if the isolating converter of AC and DC is sound, if the polarity is

correct and if the load is reasonable;

7.2.2.6.1.2.3

Correctness of input loop wiring;

7.2.2.6.1.2.4

Check if signal relay is sound and check the correctness of output loop
wiring;

7.2.2.6.1.2.5

Check if trip relay is sound and check the correctness of output loop wiring;

7.2.2.6.1.2.6

Check if the soleplate loop is correct;

7.2.2.6.1.2.7

Check if the operate loop is normal;

7.2.2.6.2

Checking of PT, CT and loops

7.2.2.6.2.1

Check the polarity of all windings;

7.2.2.6.2.2

Check the ratios of all windings;

7.2.2.6.2.3

Measure the excitation character curve of CT secondary winding work tap

U 2 FI 2 . Generally, it shall be measured to saturated part.

7.2.2.6.2.4

Outer checking of CT and its secondary loop;

250

7.2.2.6.2.4.1

Check the correctness of CT secondary winding wiring at wiring box,

correctness and reliability of terminal strip lead bolt connecting.

7.2.2.6.2.4.2

Check the grounding points and grounding status of current secondary loop.
Only one grounding point is allowed in one current loop.

7.2.2.6.2.5

Outer checking of PT and its secondary loop;

7.2.2.6.2.5.1

Check voltage secondary loop grounding point and grounding status.

7.2.2.6.2.5.2

Check the correctness of PT secondary winding at grounding box and

reliability of terminal strip lead bolt connecting;

7.2.2.6.2.5.3

Check if the erection of electric discharger is in accordance with stipulations;

7.2.2.6.2.5.4

Check the erection sites of all fuses of PT secondary loop and check if the
fusing current is proper (the fusing current of fuse need be decided by test);
check the quality and selectivity. Check if the fuse coil impedance is proper.

7.2.2.6.2.5.5

Check the reliability of swithes, DS and contact switching devices serial

connected in voltage loop;

7.2.2.6.2.6

Check insulation resistance by 1000V megger.

7.2.2.6.2.6.1

Outer cases and winding cells of transformer secondary winding;

7.2.2.6.2.6.2

All secondary loop grounding and cells in one cable; the regular check is only
to measure all secondary loop grounding insulation.

7.2.2.6.2.6.3

Checking of the secondary loop of PT applying discharger grounding need

check the correctness of wiring and work frequency discharging voltage of
discharger.
When checking regularly, apply megger to check if the work condition of
discharger is normal. Geneally, the discharger shall not breakdown when
using 1000V megger, while contrary for 2500V megger.

7.2.2.6.2.6.4

For the current and voltage loop newly run or varied, we shall check voltage
loop by work voltage directly. Check the correctness of current secondary
loop wiring by load current;

7.2.2.6.3

Checking of related devices and loops installed in CB and DS driving devices;

7.2.2.6.3.1

Check the open and close of auxiliary contacts related with protection loop or
the switchover time of these contacts;

7.2.2.6.3.2

Check the loop insulation resistance connected with protection loop.

7.2.2.6.3.3

Relay protection test personnel shall check the correctness of CB (including

DS) wiring box terminal strip to protection loop side cable grounding wires
and reliability of bolts connecting.

7.2.2.6.4

Checking of all conducting loop of microcomputer protection and auto devices

7.2.2.6.4.1

Clean all elements of microcomputer and auto devices and carry out
necessary maintenance. The elements including: power supply related with
device, operate handle, button, plug, protection soleplate, socket, location
indicator, central signal device, terminal strip, cable and fuse in these
elements loop etc.

251

7.2.2.6.4.2

Insulation measurement

7.2.2.6.4.2.1

Technical requirement: the insulation resistance of all conduct loop grounding

and among all conduct loops shall not be less than 20M.

7.2.2.6.4.2.2

Test method: under normal test atmosphere, connect all terminals of current,
voltage, DC control signal loop respectively together; measure all loops
grounding by 1000V megger; the insulation resistance of all electric contact
loops shall be more than 100 M.

7.2.2.6.4.3
7.2.2.6.4.3.1

Medium intensity
Technical requirement:
Among all conduct loops grounding and the loops, the loops of rated
insulation voltage more than 60V shall be able to bear 2.0kV work frequency
voltage or 2.8kv DC voltage; the loops of rated insulation voltage not more
than 60V shall be able to bear 500V work frequency voltage or 710V DC
voltage for 1 minute without breakdown, flashover or element damage;

7.2.2.6.4.3.2

Test method:
In the place of cabinet grounding with copper strip, remove all grounding
wires (except cabinet shield wires) to insulation locations; keep all except the
plate of upper weak circuit drawing out and keep together if there is operate
cabinet in one cabinet (short-circuit wire is generally connected). Connect the
grounding wire of voltage proof device to cabinet grounding wire and connect
HV output terminal to voltage proof wire on terminal; the select time on
voltage proof device is 60s; input 2KV work frequency voltage; if the voltage
proof device has no alarm, it is qualified; if it has alarm, check related plugs.
Test result: details see Insulation Performance Test Table
Insulation performance test table

Test location

Insulation
resistanc
e

Medium intensity
Voltag
e

Test result

K
V
AC input to ground

100 M

2.0

DC input to ground

100 M

2.0

Input loop to ground

100 M

2.0

Output loop to ground

100 M

2.0

AC input to DC input

100 M

2.0

AC input to input and output loops

100 M

2.0

DC input to input and output loops

100 M

2.0

100 M

2.0

Input loop to output loop

7.2.2.6.5

Regular check of microcomputer protection device

7.2.2.6.5.1

Protection set value test of various principles in device;

252

7.2.2.6.5.3

Protection act characteristics test of various principles;

Before test, first check the correctness of all protection set values. And then
input corresponding voltage and current to corresponding terminals on
terminal strip according to act principle and set value. As for the protections
with binary block or startup, we shall measure the release and block functions
of binary.

7.2.2.6.5.4

The correctness check of logic loop and its interlock action;

Notes:
When checking some one protection function and act logic, other protections
may quit running temporarily.
For the simulated fault, the protection must have enough sensitivity and act
reliability;

7.2.2.6.5.4.1

Added faults equal to 0.95 and 1.05 of protection set values respectively,
observe the act of various sections of protections. When inputing 0.95 of set
value, the protection shall be reliable without act; when 1.05, the protection
shall act reliably.

7.2.2.6.5.4.2

For the logic loop with and condition, we need confirm by test. As long as
one conditions lost, the protection shall not act or no act in outlet.

7.2.2.6.5.4.3

Static stability test: adjust the static test according to commissioning guidline;
increase or reduce the electric quantity inputing to protection slowly until the
protection act. Record the added electric quantity when protection acts.

7.2.2.6.5.4.4

Operate MMI to do the drive test to protection. Check the interlock

correctness of device (details see the instructions of protection)

7.2.2.6.5.5

Other functions and technical requirement test of micreoprotection;

7.2.2.6.5.6

Self-check of hardware system;

7.2.2.6.5.7

Clock check of hardware system;

7.2.2.6.5.8

Communication and information output function test;

7.2.2.6.5.9

Binary and input/output loop check;

7.2.2.6.5.10

Precision and linearity scope test of data acquisition sytem;

7.2.2.6.5.11

Print loop and function correctness check

7.2.2.6.5.11.1

Set values print

7.2.2.6.5.11.2

Fault report print

7.2.2.6.5.11.3

Analysis of fault oscilloscope

7.2.2.6.5.12

MMI display is clear and stable; the operate course, corresponding functions
and display sequence are in accordance with instructions.

7.2.2.6.6

Check of operation, center signal device and its loop

7.2.2.6.6.1

Observe all parts of operate loop signal, clean and do necessary

maintenance. Above-mentioned parts include: operate handle related with
device, buttons, plug, socket, location indicator, center signal device and
terminal strip in these parts loop, cable and fuse etc.
253

7.2.2.6.6.2

Measure cable core to ground and insulation resistance between cores by

1000V megger; the insulation resistance shall not be less than 11M. The
regular check only measures the insulation resistance to ground.

7.2.2.6.6.3

After one equipment unit power off, we shall check if the indications of all
signal loops are correct when checking the protection. The signal loop
equipmet may not be checked separately.

7.2.2.6.7

Insulation check of secondary loop

7.2.2.6.7.1

Disconnect all loops induced from outside and cables at terminal strip of
protection screen. Connect all terminals of current, voltage and DC control
signal loop together. Measure the following insulation resistance by 1000v
megger. The values shall be more than 10M.

7.2.2.6.7.1.1

All loops to ground

7.2.2.6.7.1.2

Among all loops

7.2.2.6.7.2

Connect all terminals of current, voltage and DC loops together at terminal

strip of protection screen. Open the grounding point of AC loop. Measure
insulation resistance of loop to ground by 1000V megger; the value shall be
more than 1.0 M.

7.2.2.6.7.3

Carry out voltage proof test once every 5 years to running equipment and its
loops; when insulation resistance more than 1M, it is allowed to replace in
the way of measuring insulation resistance by 2500V megger temporarily.

7.2.2.6.8

Check of protection device electric performance

7.2.2.6.8.1

Check principle: check according to the relevant check regulations and

commissioning guideline provided by Indonesian local authorities.

7.2.2.6.8.2

For basic check items of all common relay and auxiliary equipment and
standards to intermediate relay, the check items are as following:

7.2.2.6.8.2.1

Measure the resistance of coil. The difference between measuring value of

relay DC resistance and vendor standard data shall be less than 3 .

7.2.2.6.8.2.2

Act voltage (current) and reset value test

7.2.2.6.8.2.3

For the relay with two or more coils, we shall check the correctness of polarity
indication among coils and measure the insulation resistance between two
coils.

7.2.2.6.8.2.4

Check maintaining voltage (current) is in accordance with loop wiring. The

possible max voltage drop of current maintaining coil in actual loop shall be
less than 5% of loop rated voltage.

7.2.2.6.8.2.5

Act (reset) time measurement is to protect the relay and output intermediate
relay having requirement to act (reset) time in protection loop design and to
prevent from tripping relay.
For the grid protection used to super HV and intermediate relay directly used
to CB trip, the act time shall be less than 10ms.
The act current preventing from tripping relay shall be suitable to intermediate
relay directly acting to CB trip. Under the same actual CB trip current, the act
254

time of relay shall be less than the convert time of trip CB auxiliary contact.
In regular check, the act time check and the whole set test of device shall be
carried out together.
7.2.2.6.8.3

For electromagnetic time relay, the check items are as following:

7.2.2.6.8.3.1

Measure the resistance of coil. The difference between measuring value of

relay DC resistance and vendor standard data shall be less than 3 .

7.2.2.6.8.3.2

Act voltage (current) and reset value test

7.2.2.6.8.3.3

The act time of set point and measurement of approximate value

7.2.2.6.8.4

For the signal relay, the check items are as follows:

7.2.2.6.8.4.1

Act voltage (current) check: for the serial signal relay reflecting current act,
the voltage drop shall not exceed 10% of work DC voltage.

7.2.2.6.8.4.2

When several signal relays are parallel and possible least intermediate relays
are serial connected, check the reliability of act.
The display voltage (act current) of signal relay shall be lower than act
voltage of connected relay. And check the protect screen will have to error
display when possible outside vibration occurs.

7.2.2.6.8.4.3

When one signal relay connected to possible most parallel intermediate

(time) relay by serial, the voltage drop shall not exceed 10% of work DC
voltage.

7.2.2.6.8.5

For current (voltage) relay, the check items are as follows:

7.2.2.6.8.5.1

The act and reset value when act graduations are at max, min and
intermediate positions;

7.2.2.6.8.5.2

Measurement of act and reset values of set point

7.2.2.6.8.5.3

For LV relay, input running voltage respectively and check it has no shake.

7.2.2.6.8.5.4

For induction relay of reverse time limit, we shall record the current in min
graduation and set valuetime characteristics curve.

7.2.2.6.8.6

For electric directional relay, the check items are as follows:

7.2.2.6.8.6.1

Check the latent act of relay current and voltage. It is not allowed to have
latent act with act direction, but allowed to have small non act direction
(reverse) latent act.

7.2.2.6.8.6.2

Check the act zone of relay and check the correctness and sense angle of
current and voltage coil polarity indication in accordance with technical
instructions.

7.2.2.6.8.6.3

Under the condition of max sense angle or within 200 difference, measure the
min act volt-ampere and lowest act voltage;

7.2.2.6.8.6.4

Measure the act time under 2 and 4 times act volt-ampere.

7.2.2.6.8.6.5

Check the act of contacts in the case of possible max short-circuits capacity
to obverse and reverse phases;

7.2.2.6.8.7

For directional impedance relay, the check items are as follows:

7.2.2.6.8.7.1

Check the latent act of current and voltage loop

255

7.2.2.6.8.7.2

Adjust, measure and record max sense angle, act impedance and reset
impedance.

7.2.2.6.8.7.3

In regular check, calibrate the static min act current and min accurate work
current in setting position.

7.2.2.6.8.7.4

Measure and record the Z DZ f ( )

round characteristics of relay,

determine the max and min act impedance; and calculate the excursion.
7.2.2.6.8.8

For HF channel, the check items are as follows:

7.2.2.6.8.8.1

The test items of process equipments such as damper, connect filter and HF
cable etc. in relay protection special HF channel shall be in accordance with
electric power carrier wave communication regulations.

7.2.2.6.8.8.2

Open HV side of connect filter in channel (close GDS) and after remove the
grounding point, measure the insulation resistance to ground of connect filter
secondary side (including HF cable) and primary side and insulation
resistance in primary and secondary bays.

7.2.2.6.8.8.3

Measure the HF channel transmission attenuation. In partial check, we can

measure receiving level instead. When the difference between receiving level
and measured receiving level in the latest channel transmission attenuation
test is not more than 2.5dB, the detailed check will be not necessary.

7.2.2.6.8.8.4

For the special HF channel, the result of transmission attenuation test shall
satisfy the channel allowance of dispatcher receiving signal not less than
8.6dB when it is new and some device is replaced or added, otherwise the
protection is not allowed to run.

7.2.7.7

Test Items and standards of 150KV circuit protection device

Use the standard RCS-902 Protection Instruction
Na-Ri-Ralys Electric Co.,LTD to carry out the test

7.2.2.8

Test Items and standards of 150KV bus protection device

Use the standard RCS-924A Protection Instruction
Na-Ri-Ralys Electric Co.,LTD to carry out the test

7.2.2.9

from Nanjing

Test Items and standards of 150KV feeder circuit protection device

Use the standard RCS-9611C Protection Instruction
Na-Ri-Ralys Electric Co.,LTD to carry out the test

7.2.2.10

from Nanjing

from Nanjing

Test Items and standards of generator-transformer unit protection device.

Use the standard

RCS-985C Generator-Transformer Protection

Instruction from Nanjing Na-Ri-Ralys Electric Co.,LTD to carry out the
test

7.2.2.11

Test Items and standards of generator automatic excitation regulating device

Use the standard *** type automatic excitation device operation and
maintenance manual
from
Dongfang electromechanical control
equipment Co.,LTD to carry out the test

7.2.2.12

Test Items and standards of 150KV bus protection

256

Use the standard RCS-921A Busbar differential protection device

instruction from Nanjing Na-Ri-Ralys Electric Co.,LTD to carry out the
test
7.2.2.13

Check items and standard of 6.3KV auxiliary HV motor protection device

Check items and standard of feed water pump protection device:
Check according to Zhuhai Wanlida Electric Company MMPR-23CY
protection device sectional commissioning record and the whole set test
guideline.
Check according to Zhuhai Wanlida Electric Company MMPR-310Hb
protection device sectional commissioning record and the whole set test
guideline.
Check items and standard of other 6.3KV auxiliary HV motor protection
device:
Check according to the regulations of Zhuhai Wanlida Electric Company
MMPR-310Hb protection device

7.2.2.15

Check items and standard of LV auxiliary transformer protection

Check according to the regulations of Zhuhai Wanlida Electric Company
MMPR-310Hb protection device O&M instructions.

7.2.2.16

Check items and standard of microcomputer fault recorder

Check according to the regulations of Harbin Guoli Electric Company FGL3000 generator transformer unit integrate monitor device.

7.2.2.17

The maintenance items and standards uses the MFC 2000-3A type
mirco-auxiliary Quick Shut Device Instructions from Jiangsu Jingzhi Co.,
Ltd.

7.2.2.18

Check items and standard of LV auxiliary standby power supply auto

operation device
Check according to Zhuhai Wanlida Electric Company MBZT-330H
microcomputer standby power supply auto operation and reset device

7.2.3

Checking the test by primary current and work voltage

7.2.3.1

Measure the phase relationship of voltage and current

7.2.3.2

Input simulated fault to corresponding elements in protection device by

primary current and work voltage or change the test wiring type of checked
elements so as to distinguish the wiring correctness of protection device.

7.2.3.3

Measure the phase of all current differential protection CT and the differential
current (differential voltage) in differential loop so as to distinguish the
correctness of loop wiring and current ratio compensate loop.

7.2.3.4

Phase sequence filter unbalanced output

7.2.3.5

For the transformer differential protection, we need check if the protection can
be impacted by excitation surge in the way of running transformer under full
voltage.

257

7.2.3.6

For generator-transformer unit differential protection, we shall measure

differential current of differential protection loop during short-circuit test before
generator running so as to distinguish the correctness of current loop polarity.

7.2.3.7

The requirements and methods of connection correctness of checking zero

sequence direction element current and voltage loop shall be in accordance
with check regulations.

7.2.3.8

Check HF channel attenuation and channel allowance under line energized

running for HF protection so as to measure the reliability of HF channel
running.

7.2.4

The preparation before relay protection and auto device running

7.2.4.1

Cover all protection devices, relays and auxiliary equipments well. Take antidust measures to necessary elements.

7.2.4.2

Dismantle the test equipment, instrument and wires used in check and clean
the site. All dismantled or temporary wires shall be resumed and all signal
devices reset.

7.2.4.3

Relay protection personnel explain the check results to operators and clarify if
the protection device can run.

7.2.4.4

The operators must check and prove the protection device has no trip or
close impulse in the way of one end to ground measuring voltage according
to signal light indication or high internal resistance voltmeter before running
protection device. And then the operators can connect the linkage sheet of
protection device to operation positions.

7.2.4.5

The relay protection check personnel shall complete the check report in
specified time. The technician in this group shall check carefully. Take
necessary measures as the case may be if the problems impacting protection
running are found.

7.3

Spare parts of relay protection and auto device in power plant

7.3.1

Spare parts of generator transformer unit protection device:

Special tools and instruments

7.3.2

Spare parts for 150KV line bus protection device

Spare parts and special tools for 150KV line bus protection device

Electrical Equipment Test Manual

8.1

General description

8.1.1

The preventative test is an important part of electrical equipment operation

and maintenance and an very effective method to guarantee safe operation
of electrical system.

8.1.2

This specification regulated items, period and requirements for preventative

test of all electrical equipment, and it is used to judge if the equipment meets
the requirement of operation to prevent equipment damage and guarantee
safe operation.

8.1.3

Definition and symbols

258

8.1.3.1

Preventative test
Preventative test is checking, test and monitoring (including oil sampling and
air sampling) to the equipment to find out the potential problem and prevent
accidents or equipment damage.

8.1.3.2

Insulation resistance
The ratio of DC current and voltage value applied between two electrodes of
insulation structure and discharge current value flowing through these
electrodes. The insulation resistance value is usually measured directly with a
megameter.

8.1.3.3

Absoor[tance
The insulation resistance value ratio of insulation resistance when 1min and
insulation resistance when 15s in the same test.

8.1.3.4

Polarization index
The insulation resistance value ratio of insulation resistance when 10min and
insulation resistance when 1min.

8.1.3.8

Symbols used in this manual

Un stands for rated voltage of equipment (rated excitation voltage for rotor);
Um stands for maximum voltage of equipment;
U0/U stands for rated voltage of cable (U0 stands for design voltage between
cable conductor and metallic sheath or metallic shield, U stands for design
voltage among conductors);
U1mA stands for reference voltage when the current is DC 1mA;
Tg stands for medium loss factor.

8.1.4

This test results should be campared with all precious resuts and test results
of equipment of the same type. Make a estimation after a thorough analysis
based on relevant results and changing law and trend.

8.1.5

If the test items, periods or requirements need to be changed because of

some special confitions, the approval from senior department is needed for
main equipment and appri\oval from chief engineer is needed for other
equipment.

8.1.6

The withstand voltage test should be carried out on 20KV and below
electrical equipment following this manual (except for some equipment with
special regulations). The withstand voltage test should also be carried out on
150KV electrical equipment if necessary.

8.1.7

When the voltage during 50Hz AC voltage withstand test reaches test
voltage, the duration time should always be 1min if there is no special
instruction. The voltage application time for other voltage withstand test is
regulated in test requirements of relevant equipment.

8.1.8

The voltage withstand test for oil filling equipment can only be carried out
after sufficient delay duration when it is filled with oil. The delay duration
should meet following requirements according to the rated voltage of the
259

equipment if there is no regulation from manufacturer:

150kV

48h

110kV and below

24h

8.1.9

When carrying out voltage withstand test, all equipment connected together
should be separated to do test (not including complete set equipment
assembled by manufactuere), but the equipment of same test voltage can be
tested together. The electrical equipment with different test voltage in single
test can be tested together with other equipment if it is difficult to carry out
single test. Then the test voltage should uses the minimum test voltage in all
connected equipment.

8.1.10

When the rated voltage of electrical equipment is different with rated voltage
used in actual operation, the test voltage should be confirmed based on
following rules:

8.1.10.1

When equipment with high rated voltage is used to strengthen the insulation,
the test voltage should be ascertained by the rated voltage of the equipment.

8.1.10.2

When equipment with high rated voltage is used as substitution equipment,

its test voltage should be ascertained by actual rated working voltage.

8.1.11

When carrying out all tests relevant with temperature and humidity (like
measuring DC resistance, insulation resistance, tg and leaked current),
measure the temperature of the test subjects and temperature and humidity
of ambient air.
The temperature of test subject in insulation test should not be lower than
+5. The outdoor test should be carried out in good weather and relative air
humidity should not be higher than 80%.

8.1.12

Negative connection mode should be used in DC high voltage test.

All test personnel, relevant leaders and managerial staff in this company
should be familiar with this manual and strictly implement provisions in the
manual. All electrical maintenance personnel should also be familiar with
relevant part of this manual.

8.1.14

If there is any contradiction with regulations of superior department during the

implementation of this manual, the superior regulations should be taken as
the standard, meanwhile, the test personnel should report the contradiction
for modification.

8.2

Basic requirements of HV test

8.2.1

Requirements for test personnel

8.2.1.1

All test personnel should be familiar with relevant part in Safety Code of
Electrical Industry and relevant HV test codes and pass the exam.

8.2.1.2

All personnel involved in the test should be familiar with capability,

connection, operation method and precautions of test equipment and test
criterion.

8.2.1.3

A work permit needs to be filled in when carrying out test on electrical

260

equipment.
8.2.1.4

The responsible person must fill test report when all high voltage work is
finished. The test report should be checked by foreman or technician and
handed in to technical department in three days. If the report is for
preventative test of unit major overhaul, it should be handed in 10 days after
the work is finished.

8.2.1.5

There should be no less than 2 persons in each test.

8.2.1.6

Each test should be carried after with the permission of respondible person.
The operator should report timely when the voltage gets to standard value.
Cut off the power supply and report to the responsible person timely when the
voltage is decreased.

8.2.1.7

If there is electric shock that threatens personnel and equipment safety

during the test, the operator should decease the voltage and cut off the power
supply immediately.

8.2.1.8

Assembly and disassembly of test power must be carried out by two persons.
Work permission procedures must be implemented when assembling and
disassembling power supply on LV distribution panel.

8.2.1.9

The responsibility of work responsible person

8.2.1.9.1

Handle work permit approval procedures

8.2.1.9.2

Division of worl for work members

8.2.1.9.3

Safety inspection and supervision

8.2.1.9.4

Issue all test commands

8.2.1.9.5

Quality acceptance and work termination checking

8.2.1.9.6

Handle work permit procedures

8.2.1.9.7

Make necessary analysis, estimations and conclusions to test results.

8.2.1.9.8

Draft test report

8.2.1.10

The responsibility of memembers in this shift

8.2.1.10.1

Comply with Safety Code carefully and in obedience with the command of
responsible person.

8.2.1.10.2

Preparations before test

8.2.1.10.3

Implement the test safely and correctly.

8.2.1.10.4

Round-off work after the test.

8.2.2

Basic requirements of test equipment

8.2.2.1

Check the condition of the test equipment before the test.

8.2.2.2

The power switch of test equipment should use disconnector with obvious
break point. The power board should be right beside the switchyard operator
so that the operator can cut off the power supply quickly.

8.2.2.3

The test equipment should be laid steady and firmly and be close to the test
subject as much as possible. The HV lead wire should be short and
supported with insulation objects if necessary.
261

8.2.2.4

The test equipment should be packaged and banded when loading in a truck
for transporting to avoid vibration or hitting damage on the equipment.

8.2.2.5

All test equipment should be thoroughly checked before and after unit major
overhaul.

8.2.2.6

The test instruments and meters should be regularly calibrated once every
year to guarantee accuracy of the test.

8.2.2.7

The test equipment should be placed in dry and clean place and avoid
extrusion, piling and dust.

8.2.2.8

All test equipment should be kept by specialized keeper and recorded in

equipment technical account.

8.2.2.9

The insulation tools used in the test should be carried out with AC voltage
withstand test once a year. Check the voltage withstand before the test if
necessary.

8.2.2.10

The other department should get the approval from the test department if
they need to borrow the test equipment and carry out relevant procedures.
The returned equipment should pass the acceptance. If there is damage, the
test department should claim for compensation to the borrower.

8.2.3

Basic requirements of test subjects

8.2.3.1

The power supply should be cut off; external connection wire should be
completely dismounted and there should be obvious break point, then the test
can be carried out.

8.2.3.2

The metal shell of test subjects should be properly earthed.

8.2.3.3

The external surface of the test subjects should be clean and dry. Do
shielding treatment if necessary.

8.2.3.4

The test subject must be earthed in short circuit and discharged sufficiently.

8.2.3.5

The safe distance between test subject and energized equipment and
personnel should meet the requirement in the Safety Code of Electric
Industry.

8.2.3.6

After the voltage and the time of test subject are both in required scope,
evenly decrease the voltage to 25% below test voltage in 5s and then cut off
the power supply.

8.2.3.7

In HV DC test, when the test voltage is decreased to zero position, cut off the
power supply and discharge the test subject to ground with a discharging rod.
The test subject of large capacity need to be charged via discharging resistor
first and then directly charged. Wear insulation gloves during discharging.

8.2.3.8

The induction HV test can only be carried out when the insulation property
(insulation resistance, oil voltage withstand, medium loss and DC resistance)
of the test sunject meet requirements. The no-load characteristic should have
no obvious change before and after the test, otherwise, find out the cause.

8.2.3.9

When measuring the insulation resistance of subject of large capacity, the

megger can not be stopped before the lead wire of the megger is pulled out.
262

8.2.4

Precautions during the test:

8.2.4.1

The fluctuation of test power voltage in the laboratory should not be too
violent. The allowable distortion rate of sinewave should not exceed 5%. It is
better to take line voltage as test power when there is strict requirement on
waveform.

8.2.4.2

There should be permanent or temporary rail in laboratory, and hang a

warning board reads STOP, HIGH VOLTAGE!.

8.2.4.3

The responsible person should thoroughly check the wiring condition and test
site before the test.

8.2.4.4

Ring the alarm or inform orally before voltage increasing. Report the
increasing value during each stage of voltage increasing.

8.2.4.5

If the wiring needs to be changed after the test, cut off the power supply first.
Earth the test subject in short circuit on the voltage increasing part after the
discharging.

8.2.5

Basic requirements on test site

8.2.5.1

A temporary rail should be set in test site and hanging a warning board reads
STOP, HIGH VOLTAGE! Outside.

8.2.5.2

If two ends of the test subject are not in the same place, another end should
be guarded by an appointed person.

8.2.5.3

All participants in the test should also condider adjacent energized

equipment. The safe distance should meet relevant provisions in the Safety
Code of Electric Industry.

8.2.5.4

Pay attention to the superposition of test voltage and system voltage among
electrical break points.

8.2.5.5

The safe distance with adjacent energized equipment and package

convenience should be considered when dismounting connection wire of test
subject on site, meanwhile, banded the dismounted connection wire tightly,

8.2.5.6

If there is no abvious color or phase sequence on dismounted connection

wire, mark the connection clearly.

8.2.5.7

If rain or thunder occurs during outdoor test, stop the test timely and leave the
site.

8.2.5.8

If the sunshade is used in the test, fix it to avoid any accident.

8.2.5.9

Pay attention to safe distance with energized equipment when moving long
tools like bamboo (aluminum) ladder.

8.2.5.10

Corresponding technical measures should be taken if interruption occurs.

8.2.5.11

Other conditions that may affect the test should be recorded on test site.

8.2.6

Others

8.2.6.1

Meters and instruments no less than 0.5 levels should be used in the test to
reduce test error.

8.2.6.2

During the test, input low voltage into the test subject first to observe if the

263

indication in the meter is normal and then increase to rated voltage.

8.2.6.3

The short circuit switch for measurement should trip when rated value is
reached and will be closed immediately after reading the value. It should not
be open for too long.

8.2.6.4

Decrease the voltage, disconnect the power supply and find out the cause if
any of following condition happens:
The swaying of the measurement meter is too violent;
Flashover occurs on test subject;
Abnormal discharging sound is found on test subject.

8.2.6.5

The voltage increasing speed can never be too fast, too slow or increase to
full voltage duddennly. The voltage is usually increased from 1/2 of the test
voltage to full volume and this process should last no less than 15min. Do not
disconnect the test power when full voltage.

8.2.6.6

During the test, if discharging occurs on the surface of the test subject, as
long as the test voltage is kept and no indication change in the meter, the test
does not need to be interrupted.

8.2.6.7

The test should be carried out in good weather and the temperature of test
subject and ambient air temperature should be not lower than +5; the
relative air humidity is not higher than 80%, otherwise, the result can only be
reference.

8.2.6.8

Use 2500V Megohmmeter to measure and its measuring range should be no

less than 10000M. The measuring range of Megohmmeter of 5000V should
be no less than 5000V.

8.2.6.9

The instrument and meter in the test site should be placed steady. The
instruments need level calibration should meet the requirement.

8.2.7

Test log

8.2.7.1

Upper layer oil temperature and tap position of the transformer must be
recorded when measuring DC resistance of transformer coils (except for dry
type transformer).

8.2.7.2

Record motor model number, site number, capacity, factory numer and
manufacturer of motor in motor test.

8.2.7.3

If the wquipment ot ambient temperature changes obviously during the test,

record the wquipment or ambient temperature immediately after one item is
finished.

8.2.7.4

In order to analyze test data better after the test, record the multiplying power
grades and indication scale as well as test data if the meter used have
multiplying power.

8.2.7.5

If the phase difference of the motor lead wire can not be distinguished by
other permanent mark, it can be marked with spatial location (like up, down,
left and right), and record the phase combining with the color belt banding on
the lead wire.
264

8.2.7.6

The external accessory standard voltage divider should be taken as standard

when DC HV generator is used in the zinc oxide arrestor test for future
analysis and judgement. The voltage of generator and voltage divider can be
recorded together.

8.2.7.7

When carrying out test on more than one cables in parallel, mark the test site
and cable, for example, front, behind, left or right. Explain this is the position
taking XX as reference object.

8.2.7.8

When carrying out voltage withstand test on some equipment, the insulation
resistance of its associated equipment should also be measured and
reflected in original record before and after the test.

8.2.7.9

The power frequency voltage withstand test can be carried out on several
equipment or two equipment simultaneously, but note which equipment is
tested together.

8.2.8

Test termination

8.2.8.1

The high voltage should be decreased to zero position. Cut off the power
supply. The test power circuit should be obviously open. Earth the test
subject in short circuit and charge sufficiently, and then restore the orihinal
wiring of the test subject.

8.2.8.2

Dismount the temporary earthing short cirxuit wire after the test. Thoroughly
check the test subject to prevent anything left on the test equipment.

8.2.8.3

Compare the test result with previous test or factory test data, and convert
the value into the value when the temperature is 75 (or 75) based on
relevant formula.

8.2.8.4

If the value exceeds the regulation compared with precious data, find out the
cause; solve it and measure again.

8.2.8.5

If the test result does not meet the requirement and the test subject has sever
defect, report to superior department immediately.

8.2.8.6

All test personnel and equipment need to be withdrawed from the site after
the site is cleaned.

8.3

Preventative test criterions

8.3.1

Preventative test criterions of generator

If there is no special instruction, discharge all the hydrogen as well as cooling
water of stator bar and lead wire before test. Disconnect the metallic wire
between temperature wiring board and earthing wire post (steam end and
excitation end), and restore after the test. The test working condition (cold
state and hot state) is determined according to actual condition. The test
items is following:

8.3.1.1

The insulation resistance and absorptance of the stator coil should be

measured before and after the major and minor overhaul or during the minor
overhaul.
The insulation resistance measured with 1000V megger should be 1M or
265

compare the value with the initial measurement under the same temperature.
If the value is 1/3~1/5 lower than initial value, find out the cause and eliminate
it. The unblanced coefficient should not be more than 2, and the absorptance
R60/R15 should be 1.6.
8.3.1.2

The coil to ground and inter-phase AC voltage withstand test 1.5UN should
be one minute when there is water or the residual water is blown dry in the
stator.
Carry out stator DC voltage withstand test and measure the leaked current
before and after the generator major overhaul or after winding replacement.
The voltage will stay in each stage for 1min when increasing from 1.5UN to
2.5UN, and following criterions need to be met:
Leaked current should not increase with the time;
The phase difference among phases should not be 100% higher than
minimum value;
The maximum leaked current is below 20A;
The inter phase difference should have obvious change compared with initial
test result;
The earthing plates on the flange of steam excitation collecting pipe and
stator coil out-going assembly water pipe should be disconnected.

8.3.1.4

Measure the DC resistance of stator coil when generator major overhaul:

The differential value of maximum and minimum value after the DC
resistance error caused by different lead wire length is calibrated should be
no more than 2%, and relative change compared with initial measurement
should be no more than 2%.

8.3.1.5

The rotor coil insulation resistance should be measured when generator

overhaul or before and after the rotor cleaning.
The insulation resistance should be 1M when measured with 1M
megger and 0.5M when measured with 2500V megger.

8.3.1.6

Measure the DC resistance when generator major overhaul.

8.3.1.6

The DC resistance value should not exceed 2% of initial value.

8.3.1.7

Measure the insulation resistance of steam and excitation collecting pipe and
stator out-going collecting pipe.
The insulation resistance measured with 1000V megger should be 30K
(manufacturer regulation when with water); and it should be 100K when
there is no residual water.

8.3.1.8

The stator out-going bushing should bear 64500V AC power frequency dry
arc electrical strength after major overhaul, and the test takes 1min.

8.3.1.9

Measure the AC impedance of rotor winding when generator major overhaul:

Test voltage peak value should not be 463V higher than rated excitation
voltage, and measured value should not have obvious change compared with

266

initial value.
8.3.1.10

Measure the insulation resistance of bearing of generator and exiciter during

generator major overhaul.
The insulation resistance measured with 1000V megger should be 1M.

8.3.1.11

Measure the shaft voltage after generator major overhaul:

When the bearing oil membrane is short circuited, the voltage on two ends of
rotor should be equal with the voltage between bearing and pedestal.

8.3.1.12

Measure no-load characteristic curve after generator major overhaul or

winding replacement.
The stator voltage can be increased to 130% of rated voltage at most with
rated rotary speed. This value should be within range of measurement error
compared with manufacturer data.

8.3.1.13

Measure the short circuit characteristic curve after winding replacement or

when it is necessary.
This value should be within range of measurement error compared with
manufacturer.

8.3.1.14

Measure the potential to ground of stator anti-corona layer when necessary.

8.3.1.15

Carry out stator iron core test when there is partial damage, partial high
temperature and suspect that there is short circuit duting major overhaul. The
highest temperature of iron tooth should not exceed 15 and temperature
among tooth should not exceed 15.

8.3.2

DC motor

8.3.2.1

The test items, period and requirements of DC motor refer to table 2.

8.3.2.2

Test items:
The periodic test items can refer to number 1 in table 2.
Major overhaul test items can refer to number 1,2,3,4,5,7 and 9 in table 2.

8.3.2.3

Table 2 Test items, period and requirements of DC motor

Numbe
r
1

Item
Insulation
resistance
winding

Period

of

Requirements

Instruction

Not lower than 0.5M

With
1000V
megogmmeter

1.
Minor
overhaul
2.
Major
overhaul

DC resistance
of winding

Major
overhaul

The difference can not be

more than 2% compared with
manufacturer test data and
previous test data.

DC resistance
among
armature

Major
overhaul

The differential value should

not exceed 10% of normal
minimum value.
267

Compare and
judge
among
corresponding

winding
blades

blades

AC voltage
withstand test
of winding

Major
overhaul

Test voltage of field winding

to shell and armature to shaft
is 1000V.

The armature to
shaft AC voltage
withstand test
can be replaced
by
2500V
Megohmmeter
test.

Adjust central
position
of
carbon brush

Major
overhaul

Check the position and meet

reversing requirements.

Do no spark
reversing test if
necessary.

Check
the
polarity
of
winding and
the
correctness of
its connection

During
connection
change

Polarity
and
connection
should be correct.

Measure the
air clearance
between
armature and
magnetic pole

Major
overhaul

The
deviation
of
air
clearance of each point and
average value:

No-load run
check of DC
motor

1.
After
major
overhaul;

Below 3mm: 10%

3mm and above: 5%
Rotation is normal

The no-load run

check lasts no
less than 1h.

2.
After
winding
replacemen
t
8.3.3

AC motor

8.3.3.1

Test items, period and requirements of AC motor refer to table 3.

Table 3 Test items, period and requirements of AC motor

Numbe
r

Items

Insulation
resistance
and
absorptance
of winding

Period
1.
Minor
overhaul;
2.
Major
overhaul.

Requirements

Instruction

1) Insulation resistance:

1)
The
absorptance
should
be
measured if the
motor
is
of
500kW or above.

a) If the rated voltage is below

6300V, the insulation resistance
should not be lower than 0.5M
in ambient temperature;
b) If the rated voltage is or
268

above 6300V, the insulation

resistance of stator winding
before AC voltage withstand
test should not be lower than 1
M per 1KV when the
temperature
is
close
to
operating temperature;
c) The insulation resistance of
rotor winding should not be
lower than 0.5M.
2) The absorptance is regulated
based on actual condition.
2

DC
resistance
of winding

1) One year
(6KV and
above or
100KW and
above
motor)
2)
Major
overhaul
3)
Minor
overhaul

1) The DC resistance difference

of phase winding of 6KV and
above or 100KW and above
motor should not exceed 2% of
minimum value. Measure the
resistance among wires if the
neutral point is not led out and
the difference should not
exceed 1%;
2) Other motors can be
regulated based on actual
condition;
3) Pay attention to relative
change in different years.

Stator
winding
leaked
current and
DC voltage
withstand
test

1)
Major
overhaul;
2) winding
replacemen
t

1) The test voltage is 3Un when

all windings are replaced and
2.5Un when major overhaul or
partial replacement;
2) The inter-phase difference of
leaked current is not 100%
higher than minimum value. No
regulations for leaked current
below 20A;
3) The test voltage of motor
below 500kW is regulated
according to actual condition.

AC voltage
withstand
test of stator
winding

1)
After
major
overhaul
2)

After
269

2) Use 1000V
Megohmmeter
on motor below
6.3KV;
use
2500V
Megohmmeter
on motor of or
above 6.3KV.

winding
replacemen
t
5

Check the
polarity of
the stator
winding

When
connection
changes

The polarity and connection

should be correct.

1) Check if the
connection
of
two branches is
correct
for
double windings
motor.
2) Do not check
the polarity if the
neutral point is
not led out.

Stator iron
core test

1) When all
windings
replacemen
t or after
iron core
repair

1) This test is
carried out on
motor of 6KV or
above 500kw;
2) If there is no
partial defect on
stator iron core,
just need to
check
overall
condition, then
we can only
measure the noload loss value.

2)
When
necessary

Motor noload run and

no-load
current and
loss
measureme
nt

When
necessary

Run normally, the no-load

current is regulated by actual
condition;

1) The no-load
run checking is
no less than 1h;

The no-load loss value can not

exceed 50% of original value.

2)
No-load
current is only
measured when
we suspect there
is
something
wrong with the
motor;
3) Only the noload
current
needs to be
measured
for
motor of below
6KV. Do not

270

measure no-load
loss.
8.3.3.2

Test items:
Periodic test items refer to number 1 and 2 in table 3.
Test items in major overhaul refer to number 1, 2, 3 and 4 in table 3.

8.3.4

Power transformer

8.3.4.1

Test items, period and requirements of power transformer refer to table 4.

Table 4 Test items, period and requirements of power transformer

1

Items

Period

Requirements

Chromatograp
hic study of
gas dissolved
in the oil

1) 6 months
for
main
transformer
and
HV
auxiliary
transformer
is regulated
based on
their own
requirement
s

1) If the H2 and hydrocarbon

gas content (volume fraction)
in oil of operating equipment
exceed
any
one
value
following, we should pay
attention to it:
Total hydrocarbon content is
higher than15010-6;
H2 content is higher than
15010-6;
C2H2 content is higher than
510-6(110-6 for transformer of
500KV);
2) The gas production rate of
all hydrocarbon gas is higher
than 0.25ml/h (open type),
relative gas production rate is
higher than 10% per month,
then there is abnormality in the
equipment.

winding
DC
resistance

1)
1~3
years
or
regulated
by
themselves;
2) After the
tap position
of
no
excitation
regulation
transformer
is changed.

1) For generator obove

1.6MVA, difference among
three phases should not be 2%
more than average value. for
winding without neutral point
leading out, the difference
should not be 1% more than
average value.
2) For transformer below
1.6MVA, the difference among
three phases should not be 4%
of average value and the
271

Instruction
1) All hydrocarbons
include
CH4, C2H6,
C2H4 and C2H2.
2) If the dissolved gas
content
has
the
increasing
trend,
judge
with
the
combination of gas
production
rate,
shorten the period to
for tracking analysis if
necessary;
3) Do not judge with
the combination of
gas production rate
for the equipment with
low
hydrocarbon
content.

1) If the resistance
difference
among
phases
when
production exceeds
thw required value
and the manufacturer
has explained the
cause
of
the
difference, implement
based on item 3).
2) Resistance value
during
different

3) After the
tap of tap
changer
transformer
is repaired (
on all taps);

difference among lines should

not be 2% more than average
value.

temperature
is
calculated according
to following formula:

3) The difference compared

with previous value should not
be more than 2%.

R2 R1

4)
After
major
overhaul;

T t2
T t1

R1 and R2 are
respectively
resistance value when
the temperature is
t1and t2. T is constant
value for calculation
which is set as 235.

5)
When
necessary

3) The transformer
without
excitation
voltage
regulation
should be measured
after the tap is locked.
3

winding
insulation
resistance,
absorptance
and
polarization
index

1)
1~3
years
or
regulated
by
themselves;
2)
After
major
overhaul;
3)
When
necessary.

Tg of winding
1) 1-3
years
or
stipulate by
itself

1
Comvert the insulation
resistance to value under the
same temperature, the value
should have no obvious
change
compared
with
previous test result.
2) The acsorpance should not
be lower than 1.3 (within 10
30 ) or the porlarity index
should not be lower than 1.5.
1) When the temperature is
20,the tg is not greater than
the following values:
66

220kV 0.8%

66

220kV 0.8%

35kV

1.5%

2 After
overhaul

35kV and below 1.5%

3 Whe
n
necessary

2)There is no obvious variation

between the tg value and the
history ones (no greater than
30% normally)

272

1) Connect and shield

the
non-tested
winding
2) The required value
of all the windings of
the same transformer
is the same
3)

3) Refer to the
temperature of the oil
in the top layer

3) The test voltage is as

follows:
10kV
winding voltage
is 10kV and
above
Un
winding voltage
is 10kV and
below

tg 2 tg 1 1.3( t2 t1 ) / 10
4) Try to measure
when
the
oil
temperature is below
50 . The tg value in
different temperatures
can be calculated
through the following
formula:

tg 2 tg 1 1.3( t2 t1 ) / 10
5
The tg and
capacitance of
the capacitivetype bushing

1) 1-3 years

Seen in the Chapter Bushing

2 After
overhaul

1) Measure in positive
connection way
2) While measuring,
record the ambient
temperature and the
oil temperature in the
top layer of the
transformer

3 Whe
n
necessary

6
Insulation
test

oil

1) 1-3 years
2 After
overhaul

Seen in Chapter Insulation oil

and Chapter SF 6

3 Whe
n
necessary
7
1) 1-5 years
(6kV and
below)
2)
2 After
overhaul
3)
After
changing of
winding

1) The voltage value of oil

impregnation transformer is
shown in chart 6 (for the
periodical test, refer to partial
changing of winding voltage
value )
2) For the dry transformer,
when windings are changed,
refer to the test voltage value
given by factory. When the
273

1)

1)
Conduct
in
frequency
doubling
induction or operation
wave induction
2) If no transformer of
66kV and below is
equipped, conduct the
external
power

4 Whe
n
necessary

windings are partially changed

and the periodical test is
conducted, refer to that 0.85
times of the test voltage value
given by factory.

1) 1-3 years
or stipulate
by itself

1) There is no obvious
difference comparing with the
history value

2 After
overhaul
3 Whe
n
necessary
9

Moisture
content in the
oil

Seen
in
Chapter
Insulation
oil

1
0

Air content in
the oil

Seen
in
Chapter
Insulation
oil

11

The
winding
leaking current

1) 1-3 years
or stipulate
by itself
2 After
overhaul

2) In the case of
grounding
through
clamp, measure the
clamp independently

1) The normal test voltage is

as follows:

Read the value of the

leak current at 1min

The
windin
g rated
voltage

6
kV

20k
V

150K
V

10k
V

20k
V

40kV

2) There should be no obvious

variation comparing with the
last test result
Voltage ratio of
all the tapping
sections
of
winding

1) After the
disconnecti
ng
and
connecting
of
the
tapping

1) The 2500V megger

is used

2) During running, the iron core

grounding current is no greater
than 0.1A normally

DC test
voltage

1
2

frequency
voltage
withstand test

1) There should not be any

difference between the voltage
proportion and value on name
of all the relative contacts
%

274

switch
2)After
changing
the winding
3)
When
necessary

1
3

1
4

2) Below the voltage of 35kV,

the allowable deviation of
voltage
proportion
of
transformer, of which the
proportion is below 3. All the
other
transformers:
The
allowable deviation of rated
tapping voltage ratio
is
0.5%, the voltage proportion
of other tapping sections
should be in the sphere of 10%
of impedance voltage value of
the transformer, which should
not exceed 1%

Check
connection
type
of
transformer

After
the
winding is
changed

Consistent with the terminal

mark in the nameplate and the
top cover of the transformer

No-load
current and noload loss

1) After the
winding is
changed

There is no obvious variation

comparing with the last test
value

The
3-phase
or
single-phase
test
power source can be
used.
The
rated
voltage or the lower
voltage value can be
used as the test
voltage

There is no obvious variation

comparing with the last test
value

The
3-phase
or
single-phase
test
power source can be
used.
The
rated
voltage or the lower
current value can be
used as the test
voltage

2)
When
necessary

1
5

Short-circuit
impedance and
load loss

1) After the
winding is
changed
2)
When
necessary

1
6

Test
and
inspection of
AVR with load

1) One year
or
as
required by
the
manufactur
er
275

2)
After
overhaul
3)
When
necessary
Check
activation
sequence and
tangle

It is required that the activation

sequence is in accordance
with the technical requirements
of the manufacturer and the
activation
tangle
is
in
accordance with the test
record given by factory

Conduct
the
manual control,
electric control
and
remote
control for 2
circulation

Manual operation should be

relaxed. The torque meter is
used when necessary with the
measured value within the
sphere of stipulation of the
manufacturer. The electric
operation should be smooth
without interlock situation. The
electrical and mechanical limit
switch is normal

Measure
the
resistance
value of the
transitional
resistance

Accord with the value given

factory

Measure
switching time

The 3-phase synchronous

deviation, the switching time
and time deviation of forward &
reverse switch are all in
accordance with the technical
requirements of manufacturer

Check
the
contacting
state
of
insertion
contact,
movable
&
fixed contact
and connecting
state of electric
circuit

The 3-phase synchronous

deviation, the switching time
and time deviation of forward &
reverse switch are all in
accordance with the technical
requirements of manufacturer
movable & fixed contacts are
flat and smooth, of which the
burnt thickness does not
276

exceeds the stipulated value

and the circuit connecting is
good

1
7

Check
clearance
among the odd
contacts and
even contacts

No burns or variation

Check
operation box

Contactor, motor, transmission

gear, auxiliary contact, position
indicator and counter work
normally

Insulation
oil
test of selector
switch
chamber

Accord with
requirements
manufacturer

Secondary
circuit
insulation

The insulation resistance is no

lower than 1M normally

The
temperature
measuring
device and its
second circuit

1) 1-3 years
2)
After
overhaul
3)
When
necessary

1
8

Gas relay and

its secondary
circuit

1) 1-3 years
(secondary
circuit)
2)
After
overhaul

the

technical
of
the

The resistance value is in

accordance with the measured
value given factory

2500V megger is
used while measuring
insulation resistance

The insulation resistance is no

lower than 1M normally

The set value accords with the

requirements of operating code
and the activation is correct
The insulation resistance is no
lower than 1M normally

3)
When
necessary
1
277

2500V megger is
used for measuring
insulation resistance

2
0

Inspection
pressure
releaser

of

Whole sealing
inspection

When
necessary

The
difference
between
activation value and the value
on the nameplate should be in
sphere of 10% and accords
with
the
stipulation
of
manufacturer

After
overhaul

1) For the tubular transformer

and transformer with plain oil
tank which is of 35kV and
below, the test that the oil
column exceeds 0.6m over the
roof of oil conserver is
conducted
(approximate
pressure is 5kPa). For ripple oil
tank and oil tank with radiator,
the test that the oil column
exceeds 0.3m over the roof of
oil conserver is conducted
(approximate
pressure
is
2.5kPa). There is no leaking
for persistent 12h during
testing

The cooler is used

during testing while
the press releaser is
not used

2) For the transformer of

110kV
and above,
add
pressure of 0.035MPa to the
roof of the oil conserver. There
is no leaking for persistent 24h
during testing
2
1

Inception
of
cooling
devicendary
circuit

1)
Stipulated
by itself
2) After how
overhaul
3)
When
necessary

After activated, the flowing

direction,
temperature
increasing and sound are
normal. No leaking

2500V megger is
used while measuring
the
insulation
resistance

2) Inspection and testing of

forced oil-water cooling device
is in accordance with the
stipulations
of
the
manufacturer
3) The insulation resistance is
no lower than 1 M normally

The insulation

1)

After

The insulation resistance is no

278

2500V

megger

is

test of the
current
transformer in
the bushing

overhaul

lower than 1 M normally

used

2)
When
necessary

8.3.4.2

The oil impregnation type power transformer

8.3.4.2.1

Periodical testing items

Seen as No. 1,2,3,4,5,6,7,8,11,16,17,18,22 in chart 4

8.3.4.2.2

Overhaul test items

a) The general overhaul is seen as No. 1,2,3,4,5,6,7,8,11,16,17,18,20,21,22 in
chart 4.
b) The overhaul where the winding is changed
1,2,3,4,5,6,7,8,12,13,14,15,16,17,18,20,21,22 in chart 4.

is

seen

in

No.

8.3.4.3

Dry transformer

8.3.4.3.1

The periodical testing items are seen as No. 2,3,7,17 in chart 4.

8.3.4.3.2

The overhaul where the winding is changed is seen in No. 2,3, 7, 12,13,14,15, 17
in chart 4.

8.3.4.4

Grounding transformer

8.3.4.4.1

Regular tests are number 3, 6 and 7 in list 4.

8.3.4.4.2

Test items during overhaul are number 2, 3, 6, 7, 9, 15, 16 and 22, of which
number 15 and 16 are for winding replacement.

8.3.4.5

Available tests for failure ascertainment

8.3.4.5.1

The following tests are available when abnormal results of analysis for gases in
oil are available.
wineing D.C resistance
Iron core insulation resistance and grounding current
No-load loss, no-load current measurement, long time no-load operation or light
load operation monitored by analysis of gas content in oil and partial discharge
detector
Long time load test performed by short circuit method and monitored by
chromatographic analysis of gas content in oil
Check tests for oil pumps, coolers
Check test for oil tank leakage of on-load voltage regulation switch
Insulation characteristic (insulation resistance, absorptance, polarization index,
tg and leakage current)
Insulation oil breakdown voltage, tg
Water content in insulation oil
Gas content in insulation oil (500kV)
Voltage withstand test

279

8.3.4.5.2

After relay alarm, analyze dissolved gas content in transformer oil and gas
content in relay.

8.3.4.5.3

The following tests are available for transformer outlet short circuit.
Analysis of dissolved gas content in oil
winding D.C resistance
Short circuit impedance
winding frequency response
No-load current and loss

8.3.4.5.4

The following tests are available for insulation dampness.

Insulation characteristic ((insulation resistance, absorptance, polarization index,
tg and leakage current)
Insulation oil breakdown voltage, tg, water content and gas content (500kV)

8.3.4.5.5

The following tests are available for insulation aging.

Analysis of dissolved gas content in oil, especially CO, CO2 content and their
changes
Insulation oil acid value
Water content in oil

8.3.4.5.6

The following tests are available for abnormal vibration and noise.
Vibration measurement
Noise measurement
Analysis of dissolved gas content in oil
Impedance measurement

8.3.5

Standards for transformer preventive test

8.3.5.1

Current transformer

8.3.5.1.1

Items, cycles and requirements for current transformer are available in list 6.

List 6

Items, cycles and requirements for current transformer

1

Item

Cycle

Requirement

Insulation
resistance
winding
tapping

1)before
activation

1) There should not

be
obvious
difference
from
initial value and
previous values.

of
and

2) every 1-3
years
3)after
overhaul
4)when
necessary

2)
Insulation
resistance between
earth and capacitor
current transformer
tapping should not
be
less
than
1000M.

280

Description
2500V insulation resistance
meter is applied.

tg and electric
capacity

1)before
activation
2) every 1-3
years
3)after
overhaul
4)when
necessary

1)tg (%) of main

insulation
should
mot exceed the
values
in
the
following table. and
there should not be
obvious difference
from the values in
the previous years.
Voltage
class

2
0
k
V

15
0
kV

After
overhaul

3
.
0

2.0

during
operatio
n

3
.
5

2.5

1) tg test voltage for main

insulation should be 10kV.
2) tg test voltage between
tapping and earth should
be 2kV.

2) Ascertain the
causes when the
differential
value
between
electric
capacity
of
capacitor CT main
insulation and initial
value or factory
value is 5%.
3) When insulation
resistance between
earth and capacitor
CT tapping is less
than 1000M, tg
between earth and
transformer tapping,
and it s should not
exceed 2%.
3

chromatographic
analysis
for
dissolved
gas
content in oil

1)before
activation
2) every 1-3
years
3)after

Attention should be
paid
when
gas
components
of
dissolved
gas
components

281

1) C2H2 should not be

available in oil of newly
activated transformer.
2) The analysis for allsealed transformer should

overhaul
4)when
necessary

(volume fraction) in
oil exceeds any of
the following values.

be based on manufacturer
requirements.

Overall hydrocarbon
(10010-6)
H2(15010-6)
C2H2(210-6)
The above values
are for
110kV and below.
4

A.C
voltage
withstand test

1)every 1-3
years
2)
after
overhaul
3)when
necessary

1) The value for

primary test should
85% factory value.
2)
The
voltage
between earth and
transformer tapping,
between secondary
windings should be
2KV.
3) The test should
be
carried
out
based on factory
value
after
all
windings have been
replaced.

Polarization check

1)after
overhaul
2)when
necessary

Check for each

tap ratio

1)after
overhaul
2)when
necessary

Check
and
calibration
for
excitation
characteristic
curve

Leakage check

When
necessary

1)after

They should accord

with
the
label
plates.
They should accord
with
the
label
plates.

Value difference and phase

difference
should
be
measured after winding
replacement.

There should not be

obvious difference
from
that
of
transformer of the
same
type
or
characteristic curve
from manufacturer.
No leakage should
282

Check method should be

overhaul

be available.

based on regulations from

manufacturer.

2)when
necessary
1)after
overhaul
2)when
necessary
1
0

Insulation
breakdown
voltage

oil

1)after
overhaul
2)when
necessary

There should not be

obvious difference
from the initial value
or factory value.
Details are available
in chapters and
sections
about
insulation oil and
hexafluoride.

Notes
Before activation means the condition that equipment is ready to be activated
after handing over, getting ready to activate, and also before putting the storage
fresh equipment into operation.
8.3.5.1.2

Items for all kinds of tests

Items for regular test are available in number 1, 2, 3, 4 in list 6.
Items for test after overhaul are available in number 1, 2, 3, 4, 5, 6, 7, 8, 9 in list 6.

8.3.5.2

Potential transformer
Items, cycles and requirements for electromagnetic voltage, capacitor voltage
transformer
List 7 Items, cycles and requirements for electromagnetic voltage, capacitor
voltage transformer
1

Item

Cycle

requirement

description

Insulati
on
resista
nce

1)every 13 years

It is up to the power plant.

2500V
insulation
resistance
meter
is
applied
for
primary
winding.

2)after
overhaul
3)when
necessary

1000V
insulation
resistance
meter
is
applied
for
secondary
winding.
10

283

20

3
0

4
0

tg test
cascade

for
PT

150
kV

tg

1.5

2.
0

3.
5

5
.
0

2.0

2.
5

4.
0

5
.
5

1)winding
insulation

winding tg(%) should not exceed

the values in the table.

a)

Temperatur
e

1
0

2
0

3
0

40

150
kV

Ov
er
ha
ul

1.
5

2.
0

3
.
5

5.0

Op
er
ati
on

2.
0

2.
5

4
.
0

5.5

should apply
end shielding
method. Other
teats methods
are up to
power plant.

Support insulation tg(%) should

not exceed 6%.
3

chroma
tograph
ic
analysi
s for
dissolv
ed gas
content
in oil

1)before
activation

A.C
voltage
withsta
nd test

1)every 3
years(for
20kV and
below)

2) every 13 years
3)after
overhaul
4)when
necessary

2)
after
overhaul
3)
when
necessary

Attention should be paid when gas

components of dissolved gas
components (volume fraction) in oil
exceeds any of the following values.
Overall hydrocarbon (10010-6)
H2 (15010-6)

C2H2 should
not
be
available in oil
of
newly
activated
transformer.

C2H2 (210-6)

1) Test for primary winding should

be performed based on 85% factory
value. If no factory value is
available, it should be based on the
following values.
Voltage class KV

15

Test voltage KV

21

38

2) Voltage between secondary

winding and tapping should be 2Kv.

284

1) Frequency
multiplication
induction
voltage
withstand test
is applied for
cascade or
multi-staged
insulation
transformer.

3) It should be performed based on

factory values when all windings
have been replaced.

2)
Transformer
allowable
voltage rise
should
be
taken
into
consideration
when
the
above
test
method
is
applied.
3) Check for
insulation
damage
should
be
performed
before and
after the test.

Noload
current
measur
ement

1)after
overhaul
2)when
necessary

1) When rated voltage is available,

obvious difference between no-load
current and factory value.
2) No-load current should not
exceed maximum allowable current
with the following test voltages
available.
Neutral
system

ineffectively

grounded

1.9U n / 3
neutral grounded system

1.5U n / 3
6

Leakag
e
check

Insulati
on
resista

1)after
overhaul

No leakage should be available.

Check
method
should
be
based
on
regulations
from
manufacturer.

It is up to the power plant.

2500V
insulation
resistance

2)when
necessary

During
overhaul

285

nce of
iron
core
tighten
ed bolt
8

meter
applied.

1)winding
replaceme
nt

is

They should accord with the label

plates and terminal palates.

2)after
wiring
change
9

Voltage
ratio

1)winding
replaceme
nt

They should accord with the label

plates

2)wiring
change

10

Insulati
on oil
breakd
own
voltage

1)after
overhaul
2)when
necessary

Value
difference and
phase
difference
should
be
measured
after winding
replacement.

Details are available in chapters

and sections about insulation oil
and hexafluoride.

Notes

Before activation means the condition that equipment is ready to be activated

after handing over, getting ready to activate, and also before putting the storage
fresh equipment into operation.
8.3.5.2.2

Test items, cycle, and requirement of capacitor voltage transformer (CVT) in sheet
8

No.

Items

Cycle

Voltage ratio

1)After
overhaul

Requirement
major

2)When necessary
2

Insulation
resistance of
middle
transformer
tg of middle
transformer

1)After
overhaul

Same
nameplate

Remark
as

mark

major
Set by user

2)When necessary
1)After
overhaul

major

2)When necessary

There should be
no
significant
change compared

286

Adopt tramegger of
2500V

with initial value

8.3.6

Switch gear

8.3.6.1

SF6 breaker

8.3.6.1.1

See test items, cycle, and requirement of SF6 breaker in sheet 9

Sheet 9 Test items, cycle, and requirement of SF6 breaker
Items

Period

Requirements

Test items of
SF6 gas

See chapter of insulation oil and SF6 gas

Leak test of
SF6 gas

1)After major
overhaul
2)When
necessary

Secondary
circuit and
control
circuit
insulation
resistance

1)1~3 years

Withstand
voltage test

1)After major
overhaul

2)After major
overhaul

2)When
necessary

Description

Annual leak rate

more than 1%
according
requirement
manufacturer

no
or
to
of

Conduct
according
GB11023

to

Insulation resistance
no less than 2M

Adopt
tramegger
of
500V or 1000V

Test voltage of AC
withstand voltage or
operation
impact
withstand voltage test
is 80% of leave
factory test voltage

Test
is
conducted with
rated voltage of
SF6 gas

Secondary
circuit and
control
circuit AC
voltage
withstand
test

After major
overhaul

Test voltage is 2kV

Insulation
resistance after
withstand
voltage
test
should not be
dropped

Speed
character of
breaker

After major
overhaul

Measuring method
and measuring result
should
meet
manufacturer
provision

No test if no
requirement
from
manufacturer

Time
parameter
of breaker

1)After major
overhaul
2)After

If
there
provision

287

is

no
from

mechanism
major
overhaul

manufacturer,
synchronism
of
breaker
opening,
closing should meet
following
requirement:
5ms
Non-synchronous
closing in phase-tophase no more than
5ms
Non-synchronous
opening in phase-tophase no more than
3ms
Non-synchronous
same phase closing
between each open
contacts no more
than 3ms
Non-synchronous
same phase opening
between each open
contacts no more
than 2ms

Action
voltage of
opening,
closing
electromagn
et

1)1~3 years
2)After major
overhaul
3)After
mechanism
major
overhaul

1)Lowest
action
voltage of control
mechanism opening,
closing
electromagnet should
be within 30%
65% of rated value of
control voltage
2)Imported
equipments
follow
manufacturer
provision

Conducting
circuit
resistance

1)1~3years

Measure by DC
pressure drop
method, current

2)After major

288

overhaul

10

11

Opening,
closing coil
DC
resistance

SF6
gas
density
monitor test

1)After major
overhaul
2)After
mechanism
major
overhaul
1)1~3years
2)After major
overhaul

flow should be
no less than
100A
Should
manufacturer
provision

meet

By
manufacturer
provision

3)When
necessary
12

13

8.3.6.1.2

Pressure
meter
calibration,
mechanism
operation
pressure(air
pressure,
hydraulic
pressure)
setting value
calibration
Performanc
e of locking,
anti-jump
etc auxiliary
control
device

1)1~3years
2)After major
overhaul

By
manufacturer
provision

1)After major
overhaul

By
manufacturer
provision

Should calibrate
setting value of
air pressure of
each grade for
pneumatic
mechanism

2)When
necessary

Each test items:

See regularly test items in number 1

sheet 9
1 2 3
13 in sheet 9

See
4

after major overhaul test

5 6 7 8 9

9
items
10

11

12 in

in number
11 12

8.3.6.2

Low voltage breaker and automatic erasing switch

8.3.6.2.1

See test items, cycle, and requirement of low voltage breaker and automatic
289

erasing switch in number 9 and 10 in sheet 9.

8.3.6.2.2

Each test items:

See regular test items in number 9 in sheet 9.

See after major overhaul test in number 9 and 10 in sheet 9.
8.3.6.2.3

For automatic erasing switch, should check opening and closing switching order
of normally opened and closed contact, and main contact, arcing contact surface
condition and action cooperation condition etc.

8.3.6.3

Vacuum breaker

8.3.6.3.1

See test items, cycle, and requirement of vacuum breaker in sheet 11.
Sheet 11 Test items, cycle, and requirement of vacuum breaker

Items

Period

Requirements

Insulation
resistance

1)1~3
years

1)Integral
insulation
resistance consult to
manufacturer provision

2)After
major
overhaul

2)Open contact and

insulation which lift rod is
made from organics
should not less than
following number: M
After
overhaul

major

In operation
2

AC voltage
withstand
test(main
circuit over
ground,
phase
to
phase
and
open
contact)

Secondary
circuit
and
control circuit
AC voltage
withstand
test

1)1~3
years
2)After
major
overhaul

Descriptions

100
0
300

Test for breaker is

conducted
separately
under
conditions
of
opening and closing, test
voltage is based on shop
instruction

Test voltage is 2kV

1)1~3
years
2)After
major
overhaul

290

1)Loft
rod
changed or been
dried must have
voltage withstand
test
2)Voltage
withstand value
of
phase
to
phase, phase to
ground and open
contact are same

Conducting
circuit
resistance

Mechanical
character of
breaker

1)1~3
years
2)After
major
overhaul

After
major
overhaul

1)Should
meet
manufacturer provision
after major overhaul
2)Set
by
user,
recommend no more than
1.2 times of factory
setting
Should
meet
manufacturer provision

Measure DC drop
voltage method,
current flow no
less than 100A

Conduct
under
rated operation
voltage

6
Lowest
action
voltage
of
control
mechanism
opening,
closing
electromagn
et

After
major
overhaul

Insulation
resistance
and
DC
resistance of
opening,
closing
electromagn
et coil

1)1~3
years

Measuring of
vacuum
degree
of
vacuum
extinction
chamber

When
major
and
minor
overhaul

2)Imported
equipment
bases on manufacturer
provision

2)After
major
overhaul

1) Lowest action voltage

of control mechanism
opening,
closing
electromagnet should be
30%~65% of within rated
operation voltage

1)Insulation resistance no
less than 2 M
2)DC resistance should
meet
manufacturer
provision

Set by user

Check if soft

Should be tight
291

Adopt tramegger
of 1000V

connection
clipping
piece
on
moving
contact loose
8.3.6.3.2

After
major
overhaul

All kinds of test items:

See regular test items in number 1

1
8.3.6.4

7 in sheet 11.

See test items during and after major overhaul in number

2 3 4 5 6 7 8 9 in sheet 11.

Disconnector

8.3.6.4.1

Conduct test items and cycle of 150KV disconnector by manufacturer

requirement.

8.3.6.4.2

See test items and cycle of 13.8KV disconnector in sheet 12.

Sheet 12 Test items and cycle of disconnector
Test item

Requirement

Remark

1)1~3 years
Insulation
resistance
of insulator
and lift rod

2)After major
overhaul

Insulation resistance should

be no less than 1000 M

Adopt tramegger
of 2500V

Insulation
resistance
of
secondary
circuit

1)1~3 years

Insulation resistance should

be no less than 2 M

Adopt tramegger
of 1000V

Test voltage under DL/T593

provision

Should measure
insulation
resistance before
and
after AC
voltage withstand
test; resistance
after
voltage
withstand should
not drop

3
AC voltage
withstand
test

Cycle

Secondary
circuit AC
voltage

2)After major
overhaul
3)When
necessary
After
major
overhaul

Test voltage is 2kV

After
major
overhaul

292

withstand
test
5

Lowest
action
voltage of
control
mechanism
coil

After
major
overhaul

Lowest action voltage is

usually within 30%~80% of
operation power supply
rated voltage

Conducting
circuit
resistance
value

After
major
overhaul

No more than 1.5 times of

factory setting

Action
condition of
control
mechanism

After
major
overhaul

1)Under rated operation

voltage, control mechanism
conducts opening, closing
for 5 times, action normal

Measure with DC
drop
voltage
method, current
value is no less
than 100A

2)Flexible and no jam in

manually operating control
mechanism
3)Locking device should be
reliable
8.3.6.4.3

Each testing item

Regulate testing item refer to No.1 and No.2 of form 12.
Testing item after overhaul refers to 1,2,3,4,5,6,7 of form 12.

8.3.4.5

Available tests for failure ascertainment

8.3.4.5.1

The following tests are available when abnormal results of analysis for gases in
oil are available.
winding D.C resistance
Iron core insulation resistance and grounding current
No-load loss, no-load current measurement, long time no-load operation or light
load operation monitored by analysis of gas content in oil and partial discharge
detector
Long time load test performed by short circuit method and monitored by
chromatographic analysis of gas content in oil
Check tests for oil pumps, coolers
Check test for oil tank leakage of on-load voltage regulation switch
Insulation characteristic (insulation resistance, absorptance, polarization index,
tg and leakage current)

293

Insulation oil breakdown voltage, tg

Water content in insulation oil
Gas content in insulation oil (500kV)
Voltage withstand test
8.3.4.5.2

After relay alarm, analyze dissolved gas content in transformer oil and gas
content in relay.

8.3.4.5.3

The following tests are available for transformer outlet short circuit.
Analysis of dissolved gas content in oil
winding D.C resistance
Short circuit impedance
winding frequency response
No-load current and loss

8.3.4.5.4

The following tests are available for insulation dampness.

Insulation characteristic ((insulation resistance, absorptance, polarization index,
tg and leakage current)
Insulation oil breakdown voltage, tg, water content and gas content (500kV)

8.3.4.5.5

The following tests are available for insulation aging.

Analysis of dissolved gas content in oil, especially CO, CO2 content and their
changes
Insulation oil acid value
Water content in oil

8.3.4.5.6

The following tests are available for abnormal vibration and noise.
Vibration measurement
Noise measurement
Analysis of dissolved gas content in oil
Impedance measurement

8.3.5

Standards for transformer preventive test

8.3.5.1

Current transformer

8.3.5.1.1

Items, cycles and requirements for current transformer are available in list 6.
List 6 Items, cycles and requirements for current transformer
Item

Insulation
resistance
winding
tapping

Cycle
of
and

1)before
activation
2) every 1-3
years
3)after
overhaul
4)when

Requirement

Description

1) There should not

be
obvious
difference
from
initial value and
previous values.

2500V insulation resistance

meter is applied.

2)
Insulation
resistance between
earth and capacitor
294

tg and electric
capacity

necessary

current transformer
tapping should not
be
less
than
1000M.

1)before
activation

1)tg (%) of main

insulation
should
mot exceed the
values
in
the
following table. and
there should not be
obvious difference
from the values in
the previous years.

2) every 1-3
years
3)after
overhaul
4)when
necessary

Voltage
class

2
0
k
V

15
0
kV

After
overhaul

3
.
0

2.0

during
operatio
n

3
.
5

2.5

1) tg test voltage for main

insulation should be 10kV.
2) tg test voltage between
tapping and earth should
be 2kV.

2) Ascertain the
causes when the
differential
value
between
electric
capacity
of
capacitor CT main
insulation and initial
value or factory
value is 5%.
3) When insulation
resistance between
earth and capacitor
CT tapping is less
than 1000M, tg
between earth and
transformer tapping,
and it s should not
exceed 2%.
3

chromatographic

1)before

Attention should be

295

1) C2H2 should not be

analysis
dissolved
content in oil

for
gas

activation
2) every 1-3
years
3)after
overhaul
4)when
necessary

paid
when
gas
components
of
dissolved
gas
components
(volume fraction) in
oil exceeds any of
the following values.

available in oil of newly

activated transformer.
2) The analysis for allsealed transformer should
be based on manufacturer
requirements.

Overall hydrocarbon
(10010-6)
H2(15010-6)
C2H2(210-6)
The above values
are for
110kV and below.

A.C
voltage
withstand test

1)every 1-3
years
2)
after
overhaul
3)when
necessary

1) The value for

primary test should
85% factory value.
2)
The
voltage
between earth and
transformer tapping,
between secondary
windings should be
2KV.
3) The test should
be
carried
out
based on factory
value
after
all
windings have been
replaced.

Polarization check

1)after
overhaul
2)when
necessary

Check for each

tap ratio

1)after
overhaul
2)when
necessary

Check
and
calibration
for
excitation
characteristic

When
necessary

They should accord

with
the
label
plates.
They should accord
with
the
label
plates.
There should not be
obvious difference
from
that
of
transformer of the

296

Value difference and phase

difference
should
be
measured after winding
replacement.

curve

same
type
or
characteristic curve
from manufacturer.

Leakage check

1)after
overhaul

No leakage should
be available.

2)when
necessary
1)after
overhaul
2)when
necessary
1
0

Insulation
breakdown
voltage

oil

1)after
overhaul
2)when
necessary

Check method should be

based on regulations from
manufacturer.

There should not be

obvious difference
from the initial value
or factory value.
Details are available
in chapters and
sections
about
insulation oil and
hexafluoride.

Notes
Before activation means the condition that equipment is ready to be activated
after handing over, getting ready to activate, and also before putting the storage
fresh equipment into operation.
8.3.5.1.2

Items for all kinds of tests

Items for regular test are available in number 1, 2, 3, 4 in list 6.
Items for test after overhaul are available in number 1, 2, 3, 4, 5, 6, 7, 8, 9 in list 6.

8.3.5.2

Potential transformer
Items, cycles and requirements for electromagnetic voltage, capacitor voltage
transformer
List 7 Items, cycles and requirements for electromagnetic voltage, capacitor
voltage transformer
Item
1

Insulati
on
resista
nce

Cycle
1)every 13 years

Requirement

Description

It is up to the power plant.

2500V
insulation
resistance
meter
is
applied
for
primary
winding.

2)after
overhaul
3)when
necessary

1000V
insulation
resistance
meter
is
applied
for
297

secondary
winding.
2

tg

1)winding
insulation

winding tg(%) should not exceed

the values in the table.

a)

Temperatur
e

1
0

2
0

3
0

40

150
kV

Ov
er
ha
ul

1.
5

2.
0

3
.
5

5.0

Op
er
ati
on

2.
0

2.
5

4
.
0

5.5

Support insulation tg(%) should

not exceed 6%.
3

Chrom
atograp
hic
analysi
s for
dissolv
ed gas
content
in oil

1)before
activation

A.C
voltage
withsta
nd test

1)every 3
years(for
20kV and
below)

2) every 13 years
3)after
overhaul
4)when
necessary

2)
after
overhaul
3)
when
necessary

Attention should be paid when gas

components of dissolved gas
components (volume fraction) in oil
exceeds any of the following values.
Overall hydrocarbon (10010-6)
H2 (15010-6)

C2H2 should
not
be
available in oil
of
newly
activated
transformer.

C2H2 (210-6)

1) Test for primary winding should

be performed based on 85% factory
value. If no factory value is
available, it should be based on the
following values.
Voltage class KV

15

Test voltage KV

21

38

2) Voltage between secondary

winding and tapping should be 2Kv.
3) It should be performed based on
factory values when all windings
have been replaced.

298

1) Frequency
multiplication
induction
voltage
withstand test
is applied for
cascade or
multi-staged
insulation
transformer.
2)
Transformer
allowable
voltage rise
should
be
taken
into
consideration

when
above
method
applied.

the
test
is

3) Check for
insulation
damage
should
be
performed
before and
after the test.
5

Noload
current
measur
ement

1)after
overhaul
2)when
necessary

1) When rated voltage is available,

obvious difference between no-load
current and factory value.
2) No-load current should not
exceed maximum allowable current
with the following test voltages
available.
Neutral
system

ineffectively

grounded

1.9U n / 3
neutral grounded system

1.5U n / 3
6

Leakag
e
check

Insulati
on
resista
nce of
iron
core
tighten
ed bolt

1)after
overhaul

No leakage should be available.

Check
method
should
be
based
on
regulations
from
manufacturer.

It is up to the power plant.

2500V
insulation
resistance
meter
applied.

2)when
necessary

During
overhaul

1)winding
replaceme

They should accord with the label

plates and terminal palates.
299

is

nt
2)after
wiring
change
9

Voltage
ratio

1)winding
replaceme
nt

They should accord with the label

plates

2)wiring
change

10

Insulati
on oil
breakd
own
voltage

1)after
overhaul
2)when
necessary

Value
difference and
phase
difference
should
be
measured
after winding
replacement.

Details are available in chapters

and sections about insulation oil
and hexafluoride.

Notes
Before activation means the condition that equipment is ready to be activated
after handing over, getting ready to activate, and also before putting the storage
fresh equipment into operation.
8.3.5.2.2

No.

Test items, cycle, and requirement of capacitor voltage transformer (CVT) in sheet
8
Items

Cycle

Requirement

1
Voltage ratio

1)After
overhaul

major

Same
nameplate

Remark
as

mark

2)When necessary
2
Insulation
resistance of
middle
transformer
3

tg
tg of middle
transformer

1)After
overhaul

major

Set by user

Adopt tramegger of
2500V

2)When necessary
1)After
overhaul

major

2)When necessary

There should be
no
significant
change compared
with initial value

8.3.6

Switch gear

8.3.6.1

SF6 breaker

8.3.6.1.1

See test items, cycle, and requirement of SF6 breaker in sheet 9

300

Sheet 9 Test items, cycle, and requirement of SF6 breaker

Items
1

Cycle

Requirements

Descriptions

See chapter of insulation oil and SF6 gas

Test items of
SF6 gas

Leak test of
SF6 gas

1)After major
overhaul
2)When
necessary

Secondary
circuit and
control
circuit
insulation
resistance
Withstand
voltage test

1)1~3 years
2)After major
overhaul

1)After major
overhaul
2)When
necessary

Annual leak rate

more than 1%
according
requirement
manufacturer

no
or
to
of

Insulation resistance
no less than 2M

Test voltage of AC
withstand voltage or
operation
impact
withstand voltage test
is 80% of leave
factory test voltage

Secondary
circuit and
control
circuit AC
voltage
withstand
test

After major
overhaul

Test voltage is 2kV

Speed
character of
breaker

After major
overhaul

Measuring method
and measuring result
should
meet
manufacturer
provision

Time
parameter
of breaker

1)After major
overhaul
2)After
mechanism
major
overhaul

Conduct
according
GB11023

to

Adopt
tramegger
of
500V or 1000V

Test
is
conducted with
rated voltage of
SF6 gas

Insulation
resistance after
withstand
voltage
test
should not be
dropped

If
there
is
no
provision
from
manufacturer,
synchronism
of
breaker
opening,
301

No test if no
requirement
from
manufacturer

closing should meet

following
requirement:
Non-synchronous
closing in phase-tophase no more than
5ms
Non-synchronous
opening in phase-tophase no more than
3ms
Non-synchronous
same phase closing
between each open
contacts no more
than 3ms
Non-synchronous
same phase opening
between each open
contacts no more
than 2ms
8

Action
voltage of
opening,
closing
electromagn
et

1)1~3 years
2)After major
overhaul
3)After
mechanism
major
overhaul

1)Lowest
action
voltage of control
mechanism opening,
closing
electromagnet should
be within 30%
65% of rated value of
control voltage
2)Imported
equipments
follow
manufacturer
provision

10

Conducting
circuit
resistance

1)1~3years
2)After major
overhaul

Opening,

1)After major

Measure by DC
pressure drop
method, current
flow should be
no less than
100A
Should
302

meet

closing coil
DC
resistance

11

SF6
gas
density
monitor test

overhaul
2)After
mechanism
major
overhaul
1)1~3years
2)After major
overhaul

manufacturer
provision

By
manufacturer
provision

3)When
necessary
12

13

8.3.6.1.2

Pressure
meter
calibration,
mechanism
operation
pressure(air
pressure,
hydraulic
pressure)
setting value
calibration
Performanc
e of locking,
anti-jump
etc auxiliary
control
device

1)1~3years
2)After major
overhaul

1)After major
overhaul

By
manufacturer
provision

Should calibrate
setting value of
air pressure of
each grade for
pneumatic
mechanism

By
manufacturer
provision

2)When
necessary

Each test items:

See regularly test items in number 1

sheet 9
1 2 3
13 in sheet 9

See
4

after major overhaul test

5 6 7 8 9

9
items
10

11

12 in

in number
11 12

8.3.6.

Low voltage breaker and automatic erasing switch

8.3.6.2.1

See test items, cycle, and requirement of low voltage breaker and automatic
erasing switch in number 9 and 10 in sheet 9.

8.3.6.2.2

Each test items:

See regular test items in number 9 in sheet 9.

See after major overhaul test in number 9 and 10 in sheet 9.
8.3.6.2.3

For automatic erasing switch, should check opening and closing switching order
303

of normally opened and closed contact, and main contact, arcing contact surface
condition and action cooperation condition etc.
8.3.6.3

Vacuum breaker

8.3.6.3.1

See test items, cycle, and requirement of vacuum breaker in sheet 11.
Sheet 11 Test items, cycle, and requirement of vacuum breaker
Items

Insulation
resistance

Cycle

Requirements

1)1~3
years

1)Integral
insulation
resistance consult to
manufacturer provision

2)After
major
overhaul

Descriptions

2)Open contact and

insulation which lift rod is
made from organics
should not less than
following number: M
After
overhaul

major

100
0
300

In operation
2

AC voltage
withstand
test(main
circuit over
ground,
phase
to
phase
and
open
contact)

1)1~3
years
2)After
major
overhaul

Test for breaker is

conducted
separately
under
conditions
of
opening and closing, test
voltage is based on shop
instruction

2)Voltage
withstand value
of
phase
to
phase, phase to
ground and open
contact are same

3
Secondary
circuit
and
control circuit
AC voltage
withstand
test

1)Loft
rod
changed or been
dried must have
voltage withstand
test

1)1~3
years

Test voltage is 2kV

2)After
major
overhaul

304

4
Conducting
circuit
resistance

1)1~3
years
2)After
major
overhaul

Mechanical
character of
breaker

After
major
overhaul

Lowest
action
voltage
of
control
mechanism
opening,
closing
electromagn
et

After
major
overhaul

Insulation
resistance
and
DC
resistance of
opening,
closing
electromagn
et coil

1)1~3
years

Measuring of
vacuum
degree
of
vacuum
extinction

When
major
and
minor
overhaul

1)Should
meet
manufacturer provision
after major overhaul

Measure DC drop
voltage method,
current flow no
less than 100A

2)Set
by
user,
recommend no more than
1.2 times of factory
setting
Should
meet
manufacturer provision

Conduct
under
rated operation
voltage

6
1) Lowest action voltage
of control mechanism
opening,
closing
electromagnet should be
30%~65% of within rated
operation voltage
2)Imported
equipment
bases on manufacturer
provision

2)After
major
overhaul

1)Insulation resistance no
less than 2 M
2)DC resistance should
meet
manufacturer
provision

8
Set by user

305

Adopt tramegger
of 1000V

chamber
9

8.3.6.3.2

Check if soft
connection
clipping
piece
on
moving
contact loose

After
major
overhaul

Should be tight

All kinds of test items:

See regular test items in number 1

1
8.3.6.4

7 in sheet 11.

See test items during and after major overhaul in number

2 3 4 5 6 7 8 9 in sheet 11.

Disconnector

8.3.6.4.1

Conduct test items and cycle of 150KV disconnector by manufacturer

requirement.

8.3.6.4.2

See test items and cycle of 13.8KV disconnector in sheet 12.

Sheet 12 Test items and cycle of disconnector
Test item

Cycle

Requirement

Insulation
resistance
of insulator
and lift rod

1)1~3 years

Insulation resistance should

be no less than 1000 M

Adopt tramegger
of 2500V

Insulation
resistance
of
secondary
circuit

1)1~3 years

Insulation resistance should

be no less than 2 M

Adopt tramegger
of 1000V

AC voltage
withstand
test

Remark

2)After major
overhaul

2)After major
overhaul
3)When
necessary

After
major
overhaul

Test voltage under DL/T593

provision

306

Should measure
insulation
resistance before
and
after AC
voltage withstand
test; resistance
after
voltage
withstand should
not drop

4
Secondary
circuit AC
voltage
withstand
test

After
major
overhaul

Test voltage is 2kV

5
Lowest
action
voltage of
control
mechanism
coil

After
major
overhaul

Lowest action voltage is

usually within 30%~80% of
operation power supply
rated voltage

Conducting
circuit
resistance
value

After
major
overhaul

No more than 1.5 times of

factory setting

Action
condition of
control
mechanism

After
major
overhaul

1)Under rated operation

voltage, control mechanism
conducts opening, closing
for 5 times, action normal

6
Measure with DC
drop
voltage
method, current
value is no less
than 100A

2)Flexible and no jam in

manually operating control
mechanism
3)Locking device should be
reliable
Each testing item
Regulate testing item refer to No.1 and No.2 of form 12.
Testing item after overhaul refers to 1,2,3,4,5,6,7 of form 12.
8.3.6.5

HV on-off module

8.3.6.5.1

Each testing item of vacuum breaker and HV on-off module.

Regulate testing item refer to 1, 5,8,9,10,13 of form 13.
Testing item after overhaul refers to 1,2,3,4,5,6,7,8,9,10,13,15 of form 13.
Form 13 Testing item, cycle and requirement of HV on-off module.

Item

Cycle

Requirement

Description

Isolation resistance of

1)1 3 year

Isolation

Use 1000V megger

307

auxiliary circuit
control circuit

and

2)After overhaul

resistance should
not lower than
2M

AC HV withstand testing
of auxiliary circuit and
control circuit

After overhaul

2KV
voltage

CB
characteristics

speed

After overhaul

Meet
manufacturer
requirement

CB
mechanical
characteristic

After overhaul

Meet
manufacturer
requirement

Conduction
circuit
resistance
of
CB,
isolation switch and
isolation plug

1)1 3 year

1) Meet the
requirement after
overhaul

minimum
activation
voltage for opening or
closing electromagnet of
actuator

1)1 3 year

2)After overhaul

2) Not exceed
1.5
times of
manufacturer
set
value
during operation
2)After overhaul of

After overhaul

Isolation
testing

1)1 3 year

AC withstand testing

Could be omitted if
no specification from
manufacturer

Measurement
of
isolation switch and
isolation
plug
conduct
under
suitable condition

1) Whole isolation
resistance
not
specified.
2) Isolation
resistance
of
breaking port and
organic lifting rod
must not lower
than
following
valve

Isolation resistance and

DC
resistance
of
opening and closing
magnet coil

resistance

testing

Isolation
resistance more
than 2M

Use 1000V megger

DC
resistance
should
meet
manufacturer
requirement
2)After overhaul

Meet
manufacturer
requirement

1)1 3 year

Testing

308

voltage

Conduct before and

after
AC
HV
withstand testing
1) Voltage testing

10

2)After overhaul

according
with
manufacturer
requirement

Inspect voltage tapping

(electrification display)
device

1)1 year

Meet
manufacturer
requirement

Five safe performance

checking

1)1 3 year
2)After overhaul

Meet
manufacturer
requirement

Other requirement for

CB

After overhaul

Meet vacuum CB requirement

13

14
15

CT, PT of HV on-off
module

8.3.6.5.2

2)After overhaul

method: phase to
earthing
during
closing; phase to
break port during trip

Five
safe
are:
prevent to faulty
open or close CB;
prevent to open or
close isolation switch
with load; prevent
to operate earthing
(wire)
with
load;
operate
prevent
CB with earthing wire
(switch); prevent
from enter wrong live
compartment.

When necessary
After overhaul

Refer to transformer chapter

When necessary

Various testing item of other type HV on-off module

The testing item, cycle and requirement should refer to relevant number of form
13 for other types as metering box, voltage transformer cabinet and capacitor
cabinet, etc.

8.3.7

Accumulate battery DC panel

8.3.7.1

The testing item, cycle and requirement of accumulate battery DC panel (cabinet)
refer to form 14.
Form 14. The testing item, cycle and requirement of accumulate battery DC
panel (cabinet)

No.
1

Item

Cycle

Requirement

Description

Testing
of
accumulate battery
capacity

1 year

According with manufacturer requirement

Voltage testing of
accumulate battery
after
discharging
complete

1 year

When necessary
According with manufacturer requirement

When necessary

309

Various
inspect

protection

Isolation resistance
of bus in feeder
panel

8.3.7.2

1 year

Various
function
normal

When necessary

Isolation
resistance
should
not
lower
than
10M

Inspection item:
isolation monitor system
Voltage monitor system
Use 1000V megger

Various testing item

Regularly testing item refers to 1, 2, and 3 of form 14.

8.3.8

Bushing

8.3.8.1

The testing item, cycle and requirement of bushing refer to form 15.
Form 15 The testing item, cycle and requirement of bushing

No.
1

Item
Main isolation and
capacity
bushing
terminal
earthing
isolation resistance

Cycle

Requirement

1~3 year
After overhaul
When
necessary

Isolation resistance
of main isolation
should not lower than
10000M

Description
Use 2500V megger

Isolation resistance
of terminal earthing
must not lower than
1000M
2

Capacitance
and
tg of main isolation
and
capacity
bushing
terminal
earthing

1~3 year
After overhaul
When
necessary

310

Tg (%) value at
20
should
according
with
manufacturer
requirement

When measures the

tg of transformer
bushing,
all
the
winding
terminal
which connect with
testing
bushing
increase
voltage,
other winding terminal
earthing,
terminal
connect to electric
bridge, positive wiring
measurement.

Color
spectrum
analyze
of
oil
dissolved gas

Before
activation

Pay attention when

components content
of oil dissolved gas
(volume
fraction)
exceed any value as
followed:

After overhaul
When
necessary

AC withstand testing

After overhaul

Testing voltage is
85% of set value

When
necessary

partial
test

discharge

After overhaul

According
manufacturer
requirement

When
necessary

20KV
or
below
porcelain wall through
bushing
could
withstand high voltage
together with bus
isolator

with

Attention: 1. Oil filled busing means the main isolation bushing use oil as medium.
8.3.8.2

Various testing item

Regulate testing item refer to 1, 2 of form 15
Testing item after overhaul refer to 1,2,3,4 of form 15

8.3.9

Support isolator and suspension isolator

8.3.9.1

The testing item, cycle and requirement of support isolator and suspension
isolator refer to form 16

Form 16 The testing item, cycle and requirement of support isolator and suspension isolator
No
.
1

Item
Inspection
of
zero
value
isolator (66KV
and above)

Cycle
1~5 year

Requirement
Inspect
voltage

under

Description
operation

regulation
and
inspection cycle of
isolator
could
according
with
degression ratio
Inspect
each
component
for
multicomponent
needle type isolator

Isolation
resistance

Suspending
isolator 1~5 year
Needle
type
support isolator

The isolation resistance of

each component of needle
type support isolator and each
piece of suspending isolator
should not lower than 300M;
311

Use
2500V
above megger

or

This testing not

conduct for rod type

1~5 year

AC
withstand
testing

Single
component
support isolator
1~5 year
Suspending
isolator 1~5 year
Needle
type
support isolator
1~5 year
Refer to main
equipment
When replace
isolator

Isolation resistance of 500kV

suspending isolator not lower
than 500M

support isolator

AC withstand testing voltage

value of support isolator refer
to attachment B

1) 20kV needle type

support
isolator
conduct refer to left
column 1) and 2)
according
with
particular condition

AC withstand testing voltage

value of 20KV needle type
support isolator as following:
Two cemented
component, each
component 50KV; Three
cemented component,
each
component 34KV

This testing not

conduct for rod type
isolator

3) The mechanical break

load is 60~300KN
ushaped suspending isolator
which AC
withstand testing
voltage take 60KV

Attention: Testing item of needle type support isolator and suspending isolator
during operation could select any one from zero value inspection, isolation
resistance and AC withstanding testing. The testing of 1,2,3 item not conduct for
glass suspending isolator, broken isolator in operation must be promptly replace.
8.3.10

Power cables

8.3.10.1

General regulations

8.3.10.1.1

Conduct the DC voltage withstanding test and measure the insulated resistance
for cable main insulator on each phase. The other two-phase conductor, metallic
shield or metallic sheath and armour should be grounded together while testing or
measuring one-phase.

8.3.10.1.2

Conduct a DC voltage withstand test after newly buried cables are put into
operation for 3 to 12 months. Next time they will be tested by the normal cycle.

8.3.10.1.3

Comprehensively considering, the testing cycle should be shortened for allowed

operating cables under the monitoring conditions if the testing result is abnormal.
For instance, if the 3 more times testing results are good in less than 6 months,
test it by the normal cycle.

8.3.10.1.4

The sheath over-voltage protector must be temporarily grounded when one end of
metallic shield or metallic sheath is grounded and the other end main insulator of
single chip cable with protector is conducted a DC voltage withstand test.

8.3.10.1.5

After the voltage withstand test, it is not allowed for the conductor to directed
discharge with the ground until it is no spark when repeated discharging is
finished across the 80kcurrent-limiting resistance per kilovolt

312

8.3.10.1.6

Use the megohm meter to measure the grounding insulated resistance of cable
conductor when the offpower time is more than one week and less than a month.
If there is a question, use DC voltage below common DC voltage withstanding
voltage to test and the voltage-increasing time is 1 minute. When the offpower
time is more than one month and less than a year, conduct the DC voltage
withstand test with 50% testing voltage value and the voltage-increasing time is 1
minute. When the offpower time is more than one year, conduct the common DC
voltage withstand test for the cables.

8.3.10.1.7

The 1000V or 2500V megameter measures the grounding resistance value of

cables with the rated voltage of 0.6/1kV. The measurement can replace the DC
voltage withstand test.

8.3.10.1.8

Measure the leakage current when the testing voltage rises to the specified value
after one minute and voltage-increasing time reaches the specified time while
conducting a DC voltage withstand test. The leakage current and unbalanced coexistence (the ratio of Max and Mini) are only a reference instead of the operation
evidence to check the insulated. If there is a big difference between the leakage
current and last testing value or the leakage current is instable (its current will
sharply rise as the testing voltage increases or voltage-increasing time extends,.),
find out the cause. If the cause is related to the leakage current on the surface of
terminal end or grounding stray current, eliminate it. If the cable insulated route is
not good, improve the testing voltage (the DC voltage of outgoing testing is
available) or extend the testing time to make sure the normal operating.

8.3.10.1.9

The operation division can extend the testing cycle according to operation
conditions of cables and past experience and testing achievements.

8.3.10.2

Rubber and plastic insulated power cables

Rubber and plastic power cable is the power cable of polyvinyl chloride, crosslinked polyethylene insulated and ethylene-propylene rubber insulated.

8.3.10.2.1

The testing item, cycle and requirement about rubber and plastic insulated power
cables can be seen in the following table 17.

Table 17 Testing item, Cycle and Requirement about Rubber and Plastic insulated Power cables
SN.

Item

Cycle

insul
ated
resist
ance
of
cable
main
insul
ated

1)Important
cables: every
year

Requirement
Not specified

a)3.6/6kV 3
b) 0.6/1kV 5
General
cables:
a)3.6/6kV
every 3 years

313

Explanation
1000V megameter
for
0.6/1kV
cable;2500V
megameter
for
above 0.6/1kV cable

b)0.6/1kV
every 5 years

insul
ated
resist
ance
of
cable
outer
sheat
h

Important
cables:
every year
a)3.6/6kV 3

0.5M
Each kilometer insulated
resistance should be
below 0.5M.

b) 0.6/1kV 5
General cable:
a)3.6/6kV
3years

Use
megameter.

500V

Check whether the

outer sheath leaks
when
every
kilometer insulated
resistance
below
0.5M.
The test is only fit
for outer sheath of
3-core cable.

b)0.6/1kV
5years
3
Insul
ated
resist
ance
of
cable
insid
e
liner
4

Ratio
of
copp
er
shiel
d
resist
ance
and
cond
uctor
resist
ance
cable
DC
volta

1)Important
cables:
every year

Every kilometer insulated

resistance
should
above0.5M.

2)General
cables :
every year

1)Preactivation
2)Redesigned
terminal
or
postconnecting

Not specified according

to the measurement data
before activation.

3)post-Inlet
water
when
inside liner is
damaged.

Redesigned
terminal
or
post-

1)Testing voltage value

depends on the spec of
table18.The
voltage-

314

The same as above

ge
withs
tand
test
of
main
insul
ated
8.3.10.2.2

connecting

increasing
minutes
puncture.

time

is 5
without

2)The leakage current

within 5 minutes should
below the current within
1 minute.
Table 18 DC Voltage Withstand Testing Voltage of Rubber and Plastic Power
Cable kV

Cable rated voltage

DC
testing
Voltage

Cable
voltage

rated

DC
voltage

1.8/3

11

21/35

63

3.6/6

18

26/35

78

6/6

25

48/66

144

6/10

25

64/110

192

8.7/10

37

127/220

305

testing

8.3.10.2.3

Testing method about the ratio of copper shield resistor and conductor
resistance

8.3.10.2.3.1

Use bi-arm bridge measurement to measure the DC resistance of copper shield

and conductor under the same temperature.

8.3.10.2.3.2

It indicates the DC resistance increases and the corrosion probably exists on the
copper shield when the ratio of the first and the latter is bigger than that of preactivation. When the ratio decreases compared with that of pre-activation, it
indicates that the contact resistance in the accessory components probably
increases.

8.3.11

Insulated oil and sulfur hexafluoride gas

8.3.11.1

Transformer oil

8.3.11.1.1

The testing items and requirements about transformer oil during the operation can
be seen in table 19 and the testing cycle is as following 5 8 9

8.3.11.1.1.1

The 150kV transformer oil, the project SN for one year testing cycle is 1,2,3,6 and
the SN is 5,8 and 9 when necessary.

8.3.11.1.1.2

The project SN for 20kV transformer oil with 3-year cycle of is 6.

8.3.11.1.1.3

The project SN of oil testing for the new transformer after overhaul and before the
activation is 1, 2,3,4,5,6,7,8 and 9.

8.3.11.1.1.4

The test for CT&PT, and enclosed tube oil can be conducted by the analysis test
of the dissolved gas color spectrum in oil. The item follows the regulations of
CT&PT and enclosed tube sections.

8.3.11.1.1.5

The project of SN 11 can proceed when necessary.

315

8.3.11.1.2

The speed for oiliness aging is different due to the different conditions of
equipment and operation. When the oil PH value of major equipment is
approaching 4.4 or the color turns deep and other parameters are near the
specified value or failed, shorten the testing cycle and increase the testing items.
Handle it when necessary.

8.3.11.1.3

Table19

Test items and demands of transformer oil

Numbe
r

Item

Demands

Description

Appearance

Water Soluble
Acid Ph Value

5.4

4.2

Carry Out
According
GB7598

Test
To

Acid
Value
mgKOH/g

0.03

0.1

Carry Out
According
GB264
GB7599

Test
To
or

Flashing Point
(Closed Hole)

140
(#10
Oil)

Carry Out
According
GB261

Test
To

Oil
Before
Activation

Operation Oil

Transparent, No
Foreign Matters
or Suspender
Matters

Inject
Oil
Sample
into
Test Tube. Cool
the Sample to
5. Observe
with Sufficient
Light.

#25

135 (#45 Oil)

1) Not Less
Than
5
Compare with
Lift Column.
2) Not Less
Than
5
Compare with
Last Test Value.

Water Content
mg/L

66
20

110kV

66
35

110kV

220kV 15

220kV 25

330
10

330
15

500kV

316

500kV

Attention to the
Temperature
Effect during the
Operation. Take
Sample When the
Top
Oil
Temperature
Is
Higher
Than
50. Carry Out
Test According to
GB7600
or

GB7601.

Breakdown
Voltage

Less
Than
15kV, 30

Less
Than
15kV, 25

Carry Out
According
GB/T507
DL/T429.9

Test
To
or

kV

66
40

66
35

Interfacial
Tension (25)
mN/m

35

19

Carry Out
According
GB/T6541.

Test
To

tg(90)%

Less Than or
Equal to 330kV,
1

Less Than or
Equal to 300kV,
4

Carry Out
According
GB5654.

Test
To

Volume
Resistivity

61010

330kV
3109

Carry Out
According
DL/T421
GB5654.

Test
To
or
Test
To
or

220kV

220kV

(90)m
10

Air Content in
Oil
(Volume
Fraction)%

Normally, 3

Carry Out
According
DL/T423
DL/T450.

11

Sludge
and
Deposit (Mass
Fraction)%

Normally, 0.02

Carry Out Test

According
to
GB/T511. If Only
Test
Sludge
Content, The Test
Should
Use
Ethanol
Benzene (14) to
Wash Sludge in
the
Constant
Weight Container,
Weigh.

12

Chromatographi
c Analysis of
Dissolved Gas
in Oil

Refer to Transformer, PT&CT,

Bushing and Electrical Cable.

Take Sample, Test

and
Judging
Method
Respectively
According
to
Requirements of
GB7597, SD304

317

and GB7252.

Notes:
1 Sealing equipment such as transformer, difficult to take sample or make up oil,
takes sample or not should according to specific conditions.
2 The test item, period and requirements of the transformer oil in on-load tap
changer of transformer should according to manufacturer regulations.
8.3.11.1.4

The regulations about makeup oil or different type of oil mixed use.

8.3.11.1.4.1

All property of makeup oil should meet the requirements of equipments oil. If not,
sludge will be rapidly separated out from oil at times. Therefore, mixed oil sample
separating out and tg test should be performed in advance. Mixed can be
performed only there is no deposits and tg value lower than primary equipment
oil.

8.3.11.1.4.2

Different type of fresh oil or the same quality operation oil should not be mixed in
principle. If it is a must, should according to mixed oil actual measurement
condensation point to decide if it can be used.

8.3.11.1.4.3

For imported oil, unknown oil and contained different additive oil carry out the
aging test for participating oil and the oil sample that has been mixed in advance
if it is necessary to mix with different type of oil.

8.3.11.1.4.4

The mixing ratio of oil sample should be in accordance with actually used oil. Take
the 11 to mix if the actually used ratio is unknown.

8.3.11.2

SF6 gas

8.3.11.2.1

After SF6 new gas arrival, it should be taken an acceptance according to

GB12022 before supply to equipment. Casual inspection rate is 3/10. Only test
water content and purity if the shipments with the same date.

8.3.11.2.2

Carry out the test after SF6 gas is supplied into electrical equipment with 24h.

8.3.11.2.3

The regulations of makeup gas and gas mixed use

8.3.11.2.3.1

Makeup gas must be met the new quality standard. Attention to the contact and
piping dry during making up.

8.3.11.2.3.2

The gas that meets the new quality standard can be mixed used.
Table 20

Test item, period and demands of SF6 gas during operation

Numbe
r

Item

Period

Humidity(20

1)1

Demands
3

1) After Major

318

Description
1)Perform

According

To

Volume

Fraction)10-6

Years(150k
V)
2)After
Major
Overhaul
3)When
Necessary

Overhaul of
CB
Arc
Extinguish
Chamber Air
Chamber
is
During
150.
Operation
is300.
2) After Major
Overhaul of
Other
Chambers are
250.
During
Operation
is500.

GB12022 SD306 The

Test Method of Water
Content in SF6 Gas
(Electrolytic Method) and
DL50692
The
Field
Water Content in SF6 Gas
Test Method.
2) Retest After New
Installation
and
Major
Overhaul in a Year. Retest
Once in the Normal
Operation 1 3 Years If
the Humidity Meets the
Requirements.
3)The Necessary during
Period Means that Add the
Tests
While
Retest
Humidity Does not meet
the Requirements After
Major Overhaul in a Year
or the Leakage over the
Requirements in Table 10
Number 2 and When
Equipment is Abnormal.

Density
(Under
Standard
Conditions)

When
Necessary

6.16 kg/m3

According
to
SD308
Density Test Method in SF6
New Gas to Carry Out
Test.

Toxicity

When
Necessary

Non-toxic

According
to
SD312
Biological Test Method of
SF6 Gas Toxicity to Carry
Out Test.

Acidity

1)After
Major
Overhaul

0.3

According to SD307 Acidity

Test Method in SF6 New
Gas or Using Detector
Tube to Carry Out Test.

1)After
Major
Overhaul

1) After Major
Overhaul
0.05

2)When
Necessary

2)
Operation

According to SD311 GC
Test Method of Air CF4
in SF6 New Gas to Carry
Out Test.

2)When
Necessary
5

CF4
(Mass
Fraction)%

319

In

0.1
6

Air
(Mass
Fraction)%

Hydrolyzable
Fluoride
g/g

1)After
Major
Overhaul

1) After Major
Overhaul
0.05

2)When
Necessary

2)
Operation
0.2

1)After
Major
Overhaul

1.0

2)When
Necessary
8

Mineral Oil

1)After
Major
Overhaul

g/g

10

2)When
Necessary

Refers to Number 5.

In

According
to
SD309
Hydrolyzable
Fluoride
Content Test Method in
SF6 Gas to Carry Out Test.
According
to
SD310
Mineral Oil Content Test
Method in SF6
Gas
(Infrared Spectrometry) to
Carry Out Test.

Thunder arrester
For testing items, period and requirements for metallic oxide thunder arrester, see
figure 21.
Figure 21 Testing items, period and requirements for metallic oxide thunder arrester
Item
No.

Items

Period

Requirements

Illustration

Insulation
resistance

1)Before
every
thunderstor
m season

1) The resistance value is no

less than 2500 M if the
voltage is above 35KV.

Using the ohm gauge

of 2500 V and above

2)When
necessary
2

Leakage
current
under DC
1mA voltage
(U1mA) and
0.75 U1mA

1)Before
every
thunderstor
m season
2)When
necessary

2) The resistance value is no

less than 1000 M if the
voltage is 35KV and below.
1) No less than the value
specified in GB11032
2) Chang value of the leakage
current among U1mA real-time
value, initial value and
manufactured specified value
should not exceed 5%.
3) The leakage current under
0.75U1mA should not exceed
50A.

320

1)
Recording
the
testing
environment
temperature
and
relative humidity
2) Applying screening
line
to
current
measurement
conductor wire
3) Initial value is
measuring value of test

shift.
3

AC leakage
current
under
operational
voltage

1)Measuring
the current
under fresh
operation
voltage
of
110kV and
above once
after
the
fresh
operation,
and once a
year
afterwards
before every
thunderstor
m season

Measuring under operational

voltage the entire current,
resisting current or power
waste.
Strengthening the monitoring if
measured
value
changes
obviously when compared with
initial value.

Recording
measurement value of
environment
temperature, relative
humidity
and
operational voltage
Measuring when the
porcelain
bushing
surface is dry.

Cutting off the power and

checking it if the resisting
current doubles.

Noting phase-to-phase
interference.

Corresponding to GB11032 or
the
manufactured
specifications

1)Measured
temperature should be
2015 .

2)When
necessary
4

Reference
voltage
under
reference
current for
power
frequency

When
necessary

Base
insulation
resistor

1)Before
every
thunderstor
m season

2)Proceeding
the
measurement
separately for each
section, and if one
section of the whole
phase thunder arrester
is off-test, replacing the
sectional
thunder
arrester (or the entire
phase) and ensuring
the arrester with good
quality.
Once a quarter

2)When
necessary
6

Checking
action status

1)Before
every

Testing 3-5 times, by each of

which it acts normally.

321

Using ohm gauge of

2500 V and above

of discharge
counter

thunderstor
m season

After the test, adjusting the

indicator to 0

2)When
necessary
8.3.13

Busbar
A Enclosed busbar
1) For testing items, period and requirements for enclosed busbar, see figure 21.

Figure 21

Testing items, period and requirements for enclosed busbar

Item
No.

Items

Period

Requirements

Illustration

Insulation
resistor

Major
overh
aul

1) For continuous enclosure type

isolated-phase bus with rated voltage
of 20 kV, isolated-phase insulation
resistance value should be no less
than
50M
under
normal
temperature.

Using ohm
gauge of
2500 V

2) For 6kV non-segregated enclosure

type busbar, isolated-phase insulation
resistance value should be no less
than 6M under normal temperature.
2

AC
voltage
withstand
test

Durin
g
major
overh
aul

Rated
voltage
(kV)

Test voltage (kV)

Produced

Field

4.2

3.2

42

32

15

57

43

20

68

51

2) All types of testing items

For major overhaul testing items, see items No.1 and No. 2 in figure 22
8.3.13.2

Common busbar
1) For testing items, period and requirements for common busbar, see figure 23.
Figure 23 Testing items, period and requirements for common busbar

Item No.

Items

Period

Requirements

Insulation resistor

1)1-3 years

No less
1M/kV

2)During major overhaul

2

AC voltage
test

withstand

1)1-3 years
2)During major overhaul

322

than

Illustratio
n

2) All types of testing items

For regular and major overhaul testing items, see items No.1 and 2 in figure 23.
8.3.14

Secondary circuit

8.3.14.1

For testing items, period and requirements for secondary circuit, see items No.1
and 2 in figure 23.
Figure 24 Testing items, period and requirements for secondary circuit

Item
No.

Items

Period

Requirements

Illustration

Insulation
resistor

1)During
major
overhaul

1) For small busbar of DC and

control panel voltage, insulation
resistance value should be no less
than
10M
under
normal
temperature.

Using ohm gauge

of 500 V or 1000 V

2)When
replacing
secondary
wire

AC voltage
withstand
test

1)During
major
overhaul

2) For power circuit of each subcircuit,

circuit
breaker,
disconnector, and actuator of
secondary
circuit,
insulation
resistance value should be no less
than 1M. In humid place, the
value can drop to 0.5M.
Test voltage is 1000V

2)When
replacing
secondary
wire

1) For
nonimportant circuit,
use ohm gauge of
2500 V instead.
2) No AC voltage
withstand test for
circuit of 48V or
below
3) For circuit with
electro elements,
take
out
the
elements or get a
short circuit on
both ends

8.3.14.2

Various test items

See No.1 and No.2 in table 24for the test items during overhaul.
8.3.15

Distribution device and power wiring under 1kv

See the test items, cycle and requirements of distribution device and power wiring
under 1kv in table 25.

Table 25

test items, cycle and requirements of distribution device and power wiring under
323

1kv
No.

Items

Cycle

Requirements

Description

1) The
insulation
resistance
for
each
section in distribution
device should not be
smaller than 0.5M;

Use 1000v megohmmeter;

1
Insulation
Resistanc
e

Overhaul

2) The
insulation
resistance of power wiring
is usually not smaller than
0.5M.
2

AC
Withstand
Test
of
Distributio
n Device

Overhaul

1000V test voltage

2) Disconnect fuse, house

service equipment, electric
equipment and parameters
etc. when measuring the
insulation
resistance
of
power wiring.
1) The distribution device
withstand is every phase
against earth; AC withstand
test is not done to
distribution device of or
below 48V;
2) With
2500V
megohmmeter as substitute.

Check
Phase

Change
Equipment
or Wiring

The phase of both ends

and their connected circuit
should accord with each
other.

Notes:
1. Distribution equipment refers to switchboard, distribution transformer bank,
distribution box, operating panel and conductive part;
2. AC voltage withstand test is not carried to power wiring.
8.3.16

ESP

8.3.16.1

See the test item, cycle and requirements of high-pressure silicon rectifier
transformer in table 26.

Table 26 Test item, cycle and requirements of high-pressure silicon rectifier transformer
No.

Items

Cycle

Requirements

Insulation
Resistance of HP
winding against LP
winding and Earth

1)after
overhaul

500M

Use 2500V
megohmmeter
.

300M

Use 1000V
megohmmeter
.

Insulation
Resistance of LP
winding

2)When
necessary
1)After
overhaul

324

Description

2)When
necessary
3

Insulation
Resistance
for
Silicon
Rectifier
element and HP
bushing
against
earth

1)After
overhaul
2)When
necessary

Core-through
Screw Insulation
Resistance against
Earth

1)After
overhaul
2)When
necessary

DC Resistance of
HP and LP winding

1)After
overhaul
2)When
necessary

10

Sampling
Resistance
Current
Voltage

of
and

Forward
and
Reverse
Resistance of All
Bridge Arms
Transformer
Test

Oil

1)After
overhaul
2)When
necessary
1)After
overhaul
2)When
necessary

No requirements

The
deviation
between this and
setting range is
from -2% to +2%.

With
the
conversion of
75

The
deviation
varies from -5%
to +5% of setting
range
Resistance
deviation
between bridge
arms is smaller
than 10%.

1) 1 year
2)
after
overhaul

Chromatography
Analysis
of
Dissolved gas in oil

1) 1 year
2)
after
overhaul

No-load Step-up

1) Overhaul
2)After
replacing
winding
3)When
necessary

8.3.16.2

2000M

Take the chapters and sections

related to transformer oil as
reference. Set the precaution value
flexibly.
Keep output of
1.5Un for 1min
without flashing
and
punch
through. Record
no-load currency

Electric field
without ESP

See the test items, cycle and requirements of insulation supporter and connecting
element in table 27.

Table 27 Test items, cycle and requirements of insulation supporter and connecting element
325

No.

Items

Cycle

Requirements

Insulation
Resistance

Before
replacing

Withstand Test

After

DC100kV or AC 72kV
for
1min
without
flashing

326

500M

Description
Use
2500V
megohmmeter.