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HIGH VOLTAGE & SHORT CIRCUIT

LABORATORY, RAWAT
FIRST EVER
ISO 9001 : 2008 CERTIFIED
NTDCL / PEPCO / WAPDA ORGANIZATION

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HISTORY OF THE LABORATORY

PC-1 approved by Executive Committee of National Economic Council


(ECNEC), Government of Pakistan in 1988 at a cost of Rs. 445 Million

FINANCING:

- Foreign component : Rs. 408 Mil. (Japanese Grant)


- Local component : Rs. 37 Mil. (by WAPDA)

First commercial operation begins : May 1992

As per ECNEC decision, the BoD was constituted on 11-06-1990 with


Secretary Ministry of Science & Technology as the first Chairman who held
the Board Chairmanship till 07-05-1998

Secretary, Ministry of Water and Power takes over as Chairman of the BoD :
08-05-1998

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GOVT. DECISIONS

• The project of HV&SC Lab. Rawat was approved by the ECNEC in its meeting
held on 18-2-1988 and the following decisions were taken:

(a) ECNEC approved the project entitled “High Tension & Short Circuit
Testing Laboratory at a cost of Rs. 445 Million with a foreign exchange
component of Rs 408 Million provided by JICA.

(b) Project be administrated by a Board of Directors (BoDs) whose


Chairman will be appointed by Ministry of Science & Technology.

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DECISIONS TAKEN BY WAPDA AUTHORITY & BoDs(1/2)

Rawat lab. has been declared as the “National testing and certification
Body” by the BoDs to issue test reports/certificates for the electrical
power equipment (9th BoDs meeting decision, 04-07-98).

WAPDA has imposed ban on national electrical products to be sent to


foreign laboratories unless NAC (non-availability certificate) of required
facilities at Rawat lab. is produced
(Member Power directive, 10-03-99).

Merger of Regional Testing Lab., Faisalabad into Rawat lab.


(Wapda Authority decision, 04-03-2000).

The BoDs in its 10th meeting held in (12-06-2000) recommended to give


independent status.

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DECISIONS TAKEN BY WAPDA AUTHORITY & BoDs(2/2)

WAPDA & KESC has declared HV&SC lab. at par with international
counterparts laboratories like KEMA(Netherlands), CESI(Italy),
CRIEPI(Japan) through its inclusion in all international tenders/
bidding documents.

Self-financing of HV&SC Lab., Rawat since FY 2004-05


(Budget Directorate WAPDA Notification, 16-07-04).

United Nations Industrial Development Organization (UNIDO) has


approved HV&SC Lab for full funded ISO 17025 accreditation under
EU Trade Related Technical Assistance (TRTA)-2 program.

The laboratory was declared under the administrative control of


NTDCL on 18th June, 2012.

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BOARD OF DIRECTORS

CHAIRMAN
Secretary
M/O Water & Power
Islamabad

JTA Member Power Managing Director General Manager


Joint Secretary
MoST WAPDA KESC HV&SC Lab.
M/O I&P
Islamabad Lahore Karachi Rawat
Islamabad

MD / GM MD / GM MD / GM Secretary General
Pak. Elect. Ltd EMCO Industries (Power Division) Overseas Investor
(PEL) Lahore Lahore Siemens Pak. Chamber of Commerce
Karachi & Industries, Karachi

Note: This old BoD needs de- notification being non- functional.
Since 18th June, 2012 Rawat-Lab attached with NTDCL.
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MANAGEMENT CHART
MANAGING DIRECTOR
(NTDCL)

GENERAL MANAGER
HV&SC LAB
Chief Engineer

Director Director Director Dy.Manager


Faisalabad Campus HP Division HV Division (HR & A)
Sr. B&A Officer

Sr. RO Dy.Dir.Tech Dy.Dir.Tech


Supporting Staff Supporting Staff

Jr. RO Asstt.Dir.Tech Asstt.DirTech


Sanctioned Existing
HV&SC Lab Strength Strength
Asstt.Dir (T) Sr. Techs Sr. Techs Tech: 43
Rawat Campus N/Tech: 53 74
Total: 96
Technicians Jr. Techs Jr. Techs
Tech: 24
Faisalabad
N/Tech: 18 30
Campus
Supporting Staff Helpers Helpers Total: 42
Total 138 104 7
OBJECTIVES
National self reliance (Testing of Electrical Power Equipment)

Reliability enhancement of new equipment

Enhancing reliability of repaired equipment

To encourage manufacturing of equipment of higher ratings

Save foreign exchange

Earn foreign exchange

Serve as qualified inspection resource center in foreign procurements

To have international recognition and competency levels through relevant


ISO certifications
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PROFESSIONAL ACTIVITIES

Testing of Electrical Power Equipment.

Continuing education through sharing knowledge during testing and


visits

Consultancy services

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MAJOR EQUIPMENT / FACILITIES

SHORT CIRCUIT TEST SYSTEMS

HIGH VOLTAGE TEST SYSTEMS

DIAGNOSTIC TOOLS

ENERGY METER TEST SYSTEMS

TRANSFORMER OIL TEST SYSTEMS

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SHORT CIRCUIT TEST SYSTEMS
These facilities comply with IEC standards for short circuit and synthetic
testing of power equipment. These can be manipulated for 3 major types
of tests vise:

Direct short circuit tests 16 kV, 25 kA max (Symmetrical).

Low voltage, high current tests upto 500 V, 100 kA.

Synthetic testing up to 145 kV, 40 kA.

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HIGH VOLTAGE TEST SYSTEMS

These facilities comply with IEC insulation standards of High Voltage


testing and have the following capabilities :

Lightning impulse testing of upto 1800 kV, and switching impulse


testing upto 1300 kV.

Single-phase power frequency withstand voltage tests upto a


maximum of 500 kV, 2000 kVA.

Induced over-voltage tests upto 150 kV, 1000 kVA at 200 Hz.

Artificial pollution tests upto 500 kV for single suspension insulator


string.

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MISCELLANEOUS TEST SYSTEMS

Type testing of T/F oil

Type testing of Energy-meters (Electro-mechanical)

CT Test System (0-6000 A)

Miscellaneous tests, including wet test, Partial Discharge test, and


measurement of Capacitance and Dielectric Dissipation Factor.

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CAPABILITY TO TEST POWER EQUIPMENT
(RAWAT CAMPUS)
POWER TRANSFORMERS (10/13,20/26  SPACER DAMPERS
&31.5/40 MVA, 132/11.5 kV and 160 MVA,
220/132/11.5 KV)  HIGH VOLTAGE BUSHINGS (11 kV)

DISTRIBUTION TRANSFORMERS (whole  HIGH VOLTAGE CAPACITORS(11 kV)


Range uptil 1500 kVA. 11/0.415 kV)
 HIGH VOLTAGE CABLES (11 kV)
CURRENT TRANSFORMERS (11kV)
 HIGH VOLTAGE INSULATORS (11 kV)
POTENTIAL TRANSFORMERS (11kV)
 ENERGY METERS
CIRCUIT BREAKERS (11 kV) (ELECTRO-MECHANICAL)

MOULDED CASE CIRCUIT BREAKER  CABLE TERMINATIONS ( 11 kV)


MCCB (LV)
 T/F OIL TESTING
LIGHTNING ARRESTERS (11 kV)
 GROUNDING RODS
DROPOUT / CUTOUTS (11 kV)
 SEVERAL OTHER SERVICES
FUSE ELEMENTS

DISCONNECTING SWITHCHES (11 kV) 14


LANDMARKS (1/2)
Type testing of Power T/F : 132/11.5 kV,10/13 MVA, 20/26 MVA & 31.5/40 MVA.

Routine testing of Power T/F: : 220/132/11.5 kV, 160 MVA.

Type testing of Dist. T/F : 10-1500kVA (Whole Range).

Type testing of OCB : 11 kV, 12.5 kA

Type testing of MCCB : 400 A & 800 A

Type testing of HT CT(11 kV) : 200/5,400/5,800/5 & 1600/5/5A

Type testing of LV CT(415V) : 800/400/5A

Type testing of Dropout Cutouts : 11 kV, 10 kA Asymmetrical

Type testing of Power cables : 11 kV ( 1-  and 3- )

Type testing of Termination kits : 11 kV

Type testing of cable joints : 11 kV

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LANDMARKS (2/2)
• Routine testing of capacitors : 11 kV, 100 Kv & 500 kV

• Routine testing of Bushings : 132 kV and 220 kV

• Power arc performance of porcelain insulators : up to 220 kV

• Thermo-mechanical test of porcelain insulators : up to 220 kV

• Steep-front performance tests on porcelain insulators : up to 220 kV

• Type Testing of Energy Meters : (1-  and 3- )

• Calibration of Energy-meter test sets for DISCO

• Corona performance of Spacer Dampers

RESEARCH PROJECTS

1. Failure study of Dist. Transformers


2. Insulator Contamination Survey
3. Failure of Metal-Oxide Surge Arresters

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CLIENT’S PROFILE

NATIONAL MANUFACTURERS (Power Equipment)

NATIONAL ELECTRIC UTILITIES

FOREIGN CLIENTS

MISCELLANEOUS USERS

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NATIONAL MANUFACTURERS
PRODUCT MANUFACTURER

1. HEC
POWER TRANSFORMERS 2. SIEMENS
3. PEL
1. PEL
2. J&P
3. SIEMENS
4. TRANSFO POWER
DISTRIBUTION TRANSFORMERS 5. ELMETEC
6. TRANSFAB
7. JF INDUSTRIES
8. AB AMPERE
9. PAN POWER
10. SKY POWER
11. HAMMAD ENGG.
12. SYNERGY ELECTRIC

1. PEL
CT / PT 2. ELMETEC
3. FICO
4. METELX TECHNOLOGIES
5. BAIG ELECTRIC
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NATIONAL MANUFACTURERS
PRODUCT MANUFACTURER

1. PEL
CIRCUIT BREAKERS & 2. ALSTOM
PANEL, 11 kV 3. ALBARIO TRADING CORP.
4. SIEMENS
5. FICO, GUJRANWALA
6. HASSAN ASSOCIATES
1. FICO
2. WORLD OVER
3. LION STEEL INDUSTRIES
DROPOUT / CUTOUTS 4. NAEEM & CO.
5. UPPAL BROTHERS
6. EAC
7. CREATIVE ENGG. CO.
8. ACE INDIGO INDUSTRIES
9. MALIK & SONS
10. SARA INDUSTRIES
11. UMAIR INDUSTRIES
12. UNITED ENGG.
13. AJMER ENGG.
14. CLIMATE ENGG.
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NATIONAL MANUFACTURERS
PRODUCT MANUFACTURER

CABLE TERMINATION / 1. SGWI, LAHORE


JOINTS 2. MI-TECH
3. ACA (ELASTI MOLD)
1. PAK CABLES
2. POINEER CABLES
HV CABLES 3. NEWAGE CABLES
4. ATLAS CABELS
5. UNI COMMERCIAL CABLES
1. PEL
ENERGY METERS 2. SYED BHAIS
3. ESCORTS
4. PMO
5. TIP, HARIPUR
6. SANA INTERPRISES (CHINESE)

BULK METERING PANEL/ 1. BAIG ELECTRIC


INDUSTRIAL PANEL 2. MK ENGG.
3. SIDDIQUE SONS
4. ZGL, FAISALABAD
5. PEL, LAHORE 20
NATIONAL UTILITIES
CLIENT PRODUCT

- D.T/F (Whole Range)


- Power Transformers
- POWER CABLES
- ENERGY METER (Single & 3-Phase)
KESC
- 11 kV Panels
- 11 kV CT
- 11 kV FINGER CONTACTS
- 415 kV CT

- D.T/Fs (Whole Range)


- CABLES, CABLE TERMINATIONS,
DISCOS - JOINTS, DROPOUT/CUTOUTS
- ENERGY-METRE TEST SETS

- P.T/Fs 132/11.5 kV(10/13 MVA,20/26 MVA)


- P.T/F 220/132/11.5 kV 160 MVA
NTDCL
- BUSHINGS, INSULATORS,CAPACITORS
- 500 kV DISCONNECTING SWITCH

ELECTRICITY, AJK - D.T/Fs, P.T/Fs


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FOREIGN CLIENTS

MANUFACTURER PRODUCT

DISCONNECTING SWITCH (500


AEG, GERMANY
kV)

TRANSFO, IRAN POWER / DIST. T/F (20 / 26 MVA)

XIAN ELECTRIC MACHINERY IMPORT EXPORT,


CABLE (11 kV)
CHINA

IRAN ELECT. EQUIP. ENGG. (IREEE) SPACER DAMPER (220 kV)

EMCO, SAUDI ARABIA INSULATORS (132 kV)

AL-AMIN ENERCOM, BULGARIA POWER T/F (20/26 MVA)

ELPRAM ENGRO, BULGARIA


DIST. T/F 100 kVA

CABLE TERMINATION (11 kV)


ELASTIMOLD, EYGPT
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BUDGET VERSES INCOME (FY July 2003-2014)
FY Budget Grant Exp. Estab. Exp. Dev. Exp.Total Revenue Other Incomes Total Income
Generated (Banks & Auctions) (Rs Million)

1 2 3 4 3+4 = 5 6 7 6+7 = 8

2003-2004 36.910 35.201 00.000 35.201 42.153 0.882 43.035

2004-2005 70.776 61.744 17.304 79.048 72.618 0.438 73.056


(Self Financing)

2005-2006 67.002 34.320 17.770 52.090 84.320 2.034 86.354

2006-2007 71.460 62.764 51.951 114.715 92.544 9.203 101.747

2007-2008 77.825 56.831 34.277 91.108 95.486 7.099 102.585

2008-2009 98.038 31.545 11.691 43.236 88.168 17.890 106.058

2009-2010 97.865 49.898 05.417 55.315 97.950 14.880 112.830

2010- 2011 53.544 48.937 08.462 57.399 91.156 18.066 109.222

2011-2012 66.946 39.687 9.769 49.456 78.772 32.987 111.759

2012-2013 83.849 43.209 24.949 68.158 95.458 61.961 157.419

Up to March. Awaited 38.866 15.444 54.310 55.465 82.529 137.994


2014

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LABORATORY ACCREDITATION /
ACCEPTANCE STATUS
► Declared by GoP through BoD as a testing and certification body for
electrical power sector in Pakistan

► First ever ISO 9001 : 2008 certified NTDC/PEPCO/WAPDA organization

► Accepted by WAPDA as at par with KEMA

► Accepted by KESC as at par with KEMA

► Notification for inclusion of Rawat Lab. in all WAPDA / KESC


international tenders

► Collaboration with international counterpart labs.

► MoU with KERI, South Korea

► Ban imposed upon WAPDA & KESC on all overseas inspections/


testing unless a NAC of facilities from Rawat is produced

► Partial success with foreign clients

► Accreditation of ISO-17025 is under process


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ATTACHMENT OF HV&SC LAB. with NTDCL

• The Board of Directors of NTDCL, in its 66th Meeting held on 18th June, 2012
decided that:

a. HV&SC Lab be attached with NTDCL for an interim period of 5 years or till
the time it becomes independent.

b. GM, HV&SC Lab, Rawat will draft a letter to be addressed to Secretary,


Ministry of Water and Power regarding de-notification of Board of
Directors of the Lab.

c. The Board also remarked that on possible attachment of Lab with NTDCL,
issues of employees may arise. MD, NTDCL assured that he will look into
the matter and resolve the issues of employees if arise any”.

• In compliance with the directions of the BoD, a letter was drafted by this
office and issued under the signatures of Managing Director, NTDCL.

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EXPANSION PLAN
OF
HV&SC LAB.

(Phase-2 of Japanese Grant)

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ENHANCEMENT OF THE CAPABILITY OF EXISTING EQUIPMENT

Short Circuit Generator ( Double Capacity )

Impulse Generator ( from 1800 kV to 3.2 MV )

High Voltage AC Source (1000 kV, 2000 kVA )

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NEW PROPOSED TESTING FACILITIES(1/3)
PHASE-I

2 MVA Motor generator set and step-up transformer for temperature-rise


and losses measurements of power transformer.

Three phase 2MVA MG set(100/150/200 Hz) for induced over voltage test

Portable C&DF (with 10 kV) test Set for power transformer testing

Multi Channel Partial Discharge measurement test set along with calibrator
for power transformer testing.

Capacitor bank for VAR compensation (200, 400 & 800 kVARs)

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NEW PROPOSED TESTING FACILITIES(2/3)

PHASE-II

Polycyclic aromatic content(PCA) of Transformer oil.

Polychlorinated biphenyl contents(PCB) of Transformer oil.

Interfacial Tension(IFT) of Transformer oil.

Furfural Contents of Transformer oil.

Inhibitors of Transformer oil.

Particle content of transformer oil.

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NEW PROPOSED TESTING FACILITIES(3/3)

PHASE-III

100 Ton Overhead Crane with suitable hall for installation.

Complete testing facility for electrostatic Energy meter

11 kV standard PT for existing PT accuracy test system


along with VA Burden

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REPLACEMENT OF THE EXISTING EQUIPMENT

MV SF6 gas circuit breaker for incoming cubicle for power


frequency test set up

24 kV Making Switch as replacement of existing AEG make: 01 No

24 kV Back-up-Breaker as replacement of existing 2 Nos. breakers.

new digital impulse measurement PCI card along with industrial PC

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COST OF FACILITIES REQUIRED FOR TESTS
BEING NOT CONDUCTED AT PRESENT (1/2)

EQUIPMENT TEST DEFICIENCY/ FACILITY REQUIRED COST


UNDER TEST

Power Transformer
Temperature-rise test arrangement for which
2MVA motor generator set is required.

De tanked inspection for which 100 Ton


overhead crane is required.

Induced over voltage test for which Three


phase 2MVA Motor Generator set is required.

Capacitor & Dissipation Factor test for which


portable C&DF test set is required.

Suitable Hall for Temperature-rise Test and to install


100 Ton over Head Crane (for de-tanked inspection)

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COST OF FACILITIES REQUIRED FOR TESTS
BEING NOT CONDUCTED AT PRESENT (2/2)
EQUIPMENT Equipment Required/Test Deficiency Cost

Potential Standard PT (11 kV)


Transformer
VA Burdens (2.5 to 157) in steps of 2.5 VA
at 0.8 power factor

VA Burdens (0 to 10) in steps of 1.25 VA at


unity power factor

Transformer Oil PCA (Polycyclic aromatic content)

PCB (Polychlorinated biphenyl contents

IFT (Interfacial Tension)

Furfural Contents

Inhibitors

Particle content
Note: In Oder to run Oil Laboratory smoothly,
JRO along with Chemist required.
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NEW EQUIPMENT REQUIRED FOR
UPGRADATION/REPLACEMENT (1/3)
EQUIPMENT DESCRIPTION Cost

24 kV Making Making switch is very important part of


Switch as Short Circuit Test.
replacement of
In recent past, many times making switch
existing AEG Make
(different parts) had been repaired.

Due to several operations, it has almost


completed its Life and need urgent
replacement.
24 kV Back-up- Back up breaker is another very important
Breaker as part of Short circuit test system.
replacement of
In recent past, many times Back Up
existing 2 Nos.
Breaker (different parts) had been
breakers repaired.

Due to several operations, it has almost


completed its Life and
need urgent replacement.
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NEW EQUIPMENT REQUIRED FOR
UPGRADATION/REPLACEMENT (2/3)
EQUIPMENT DESCRIPTION Cost

Medium Voltage SF6 The mechanical parts of this breaker had 03 Million
gas circuit breaker been repaired many times in past.
for incoming cubicle
The Circuit Breaker has almost completed its
of power frequency
life and Its replacement has become
test set up inevitable.

Old system was procured ten years back &


New digital impulse had malfunctioned many times.
measurement PCI
card along with Need to be upgraded.
industrial PC and
For such type of delicate software, industrial
color printer. Personal Computer is required along with
color printer.
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NEW EQUIPMENT REQUIRED FOR
UPGRADATION/REPLACEMENT (3/3)

EQUIPMENT DESCRIPTION Cost

Multi Channel Partial


Discharge measurement Due to un-shielding of 500 kV transformers
sometimes unwanted signal interferes in
test set along with the Partial Discharge measurement.
calibrator for power
Manufacturer’s (CT & PT) raised hue and cry
transformer testing. & show great concern in our test system.

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FUTURE PLAN
OF
HV&SC LAB.

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FUTURE PLAN (1/2)

Since Rawat lab. is the only national testing laboratory of its type in the
entire power sector and has acquired ISO 9001:2008 Certification (23-07-
2005) the laboratory intends to continue its capacity-building to match
growth of national electrical power sector.

Enhancing technical competence to serve as a national R&D Centre /


Centre-of-excellence in the field of Electrical Power Engineering.

May need to have several branches throughout Pakistan.

Earn the status of KEMA laboratory at Regional level.

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FUTURE PLAN (2/2)
Acquire international accreditation / recognition to facilitate export of
made-in-Pakistan electrical equipment and hardware and thereby
facilitate earning of precious foreign exchange for national exchequer.

Emerge as a role model organization to attract qualified persons opting


long-term employment.

Play the key role in setting up Engineering standards of electrical


equipment and related services in Pakistan.

Creation of post of marketing officer to attract the more business in the


field of Electrical power equipment and financial growth of the Lab.

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