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Generator Site Test

S. No.

Test

Surge comparison test

Check the contamination of


respective parts

Purpose of test
Surge comparison test is used to determine
condition of inter turn insulation of the stator
winding.
To check the deposit of moisture and dust on
surface
Test provides an indication of presence of cracks,
contamination and moisture in the insulation IR/PI
test between slip rings and the body is carried out
to check the integrity of the pole sleeve insulation
of the rotor
detection of faults in core inter lamination
insulation by electromagnetic

Site Test

Instrument Req.

Freq.

External Party

Yes

pulse transformer for impulse voltage and


an oscilloscope

During Overhauling

TDPS / Turbo Generator/India


Electrical Works/Gujrat Turbo/Pioneer
Generator/PENTAGON TURBINES (P)
LTD /POWER GEM ENGINEERS

Yes

Visual Inspection and hand touch

During Overhauling

Yes

alkaline, solvent-removable, lipophilic postemulsification, or hydrophilic postTDPS / Turbo Generator/India


emulsifiable ,aerosol spray cans, and may During Overhauling
Electrical Works/Gujrat Turbo/Pioneer
employ acetone, isopropyl alcohol, or a
Generator/PENTAGON
TURBINES (P)
propellant.
LTD /POWER GEM ENGINEERS

Dry penetration Test

ELCID Test on Stator core

Slot wedge test

6
7

Magnetic shunt detection


Coil insulation tests

Condition of bearings & shaft

Off line Rotor Winding Inter


turn Fault Detection

10

Bearing insulation resistance

11

Measurement of Air Gap


between Stator and Rotor

Yes

12

High Voltage Dielectric Test

Yes

13

Open Circuit Test or No-Load


Saturation Test

To check the looseness of winding wedges

To check the Insulation level of the winding


To check the condition f bearing and shaft of
generator
Shorted Turn Detection For Generator Rotor

Yes

Yes

ELCID Evaluation Tester

Visual Inspection and Rubber hammer.

Yes
Yes

During Overhauling

Yes
Yes

During Overhauling

Yes

RSO ( Recurrent Surge Oscilloscope)

During Overhauling

Air Gap Gauge

TDPS / Turbo Generator/India


Electrical Works/Gujrat Turbo/Pioneer
Generator/PENTAGON TURBINES (P)
LTD /POWER GEM ENGINEERS

During Overhauling
During Overhauling

Visual Inspection.

Digital Meggar

Yes

During Overhauling

Yes

Yes

Internally
IS
Capable standard

TDPS / Turbo Generator/India


Electrical Works/Gujrat Turbo/Pioneer
Generator/PENTAGON TURBINES (P)
LTD /POWER GEM ENGINEERS

During Overhauling

During Overhauling

Yes

IS 7132

TDPS / Turbo Generator/India


Electrical Works/Gujrat Turbo/Pioneer
Generator/PENTAGON

TURBINES (P) LTD /POWER


GEM ENGINEERS
Commissioning
Test

Measurement of losses

Yes

Commissioning
Test

14

No load and short circuit


saturation curve and Short
Circuit ratio

Measurement of losses

Yes

Commissioning
Test

15

Dielectric test(tan delta)

To determine the dielectric strength of generator

Yes

Ten Delta Test Kit

3Y

16

Off line Partial Discharge test

Partial discharge test is a diagnostic test for HV


machines as it is capable of revealing incipient
faults in the stator winding structure.

Yes

PD Detector, High Voltage


Capacitor,Oscilloscope.

3Y

Page 1

TDPS / Turbo Generator/India


Electrical Works/Gujrat Turbo/Pioneer
Generator/PENTAGON TURBINES (P)
LTD /POWER GEM ENGINEERS

TDPS / Turbo Generator/India


Electrical Works/Gujrat Turbo/Pioneer
Generator/PENTAGON

TURBINES (P) LTD /POWER


GEM ENGINEERS

TDPS / Turbo Generator/India


Electrical Works/Gujrat Turbo/Pioneer
Generator/PENTAGON TURBINES (P)
LTD /POWER GEM ENGINEERS

IS 5422, IS
7132

IS 5422, IS
7132

IS 5422

Generator Site Test

TDPS / Turbo Generator/India


Electrical Works/Gujrat Turbo/Pioneer
Generator/PENTAGON TURBINES (P)
LTD /POWER GEM ENGINEERS

17

DC leakage current
measurement

Measurement of leakage current by applying DC


voltage in steps is frequently used to indicate the
status of the stator winding.

Yes

DC Voltage generator,clock,and meggar.

3Y

18

Maintenance of Sleeve bearing

To ensure that sleeve bearing not have unilateral


contact.

Yes

by checking visual inspection and hand


touch oil clearance must be measured
using lead wire

3Y

Yes

19

Shaft Voltage measurement

Yes

voltage sensor for detecting shaft voltage

Yes

IS 7132

Yes

IS 5422

Actual Shaft Voltage measurement

20

Vibration measurement on
bearing housing

Yes

Vibration Meter

Unbalancing bearing condition etc.

21

Insulation Resistance test

To measure the insulation resistance of the


winding of generator

Yes

Digital Meggar and Milli ohms meter

HY

Yes

IS 5422

22

Winding Resistance

To measure the resistance of generator winding

Yes

Milli ohms meter

HY

Yes

IS 5422

23

PI test

To check the Insulation level of the winding

Yes

Digital Meggar

HY

Yes

IS 5422

24

Checking of Rotor Rectifier


Assembly

To check the working of rectifier assembly

Yes

Tester/Multi meter for check the continuity


of diode, Spanner and screwdriver

HY

Yes

25

Loose fit of bolt.

Check the Tightness of the bolt

Yes

Spanner and screwdriver

Yes

26

Temperature of respective
parts

Temp. rise limit not be exceed In case the temp.


rises gradually despite running at constant load,
caution is required.

Yes

RTD(for Cont. monitoring), Thermo


camera

FN

Yes

27

Oil Leakage Test

To Check the Oil Leakage from any parts of the


generator

Yes

Visual Inspection

Yes

28

Lubricating condition

Oil flow should indicate no change form that at


normal time, to check the air foam in the oil, and
check the oil level.

Yes

Visual Inspection of inspection lid, looking


in to flow sight and oil level gouge.

Yes

29

Abnormal odor from main body

There should be no abnormal odor compared to


that at normal times

Yes

Resort of sense of smelling

Yes

Page 2

Transformer Site test

S. No.

Test

Purpose of test

Site Test

Instrument Req.

Freq.

External Party

Internally
Capable

Magnetic balance test

This test is done to find out the condition of stacking


of core laminations, tightness of core bolts and
perfection of magnetic circuit

Yes

single phase
supply,voltmeter,lamp

During Overhauling
/ Internal fault

Yes

Measurement of Magnetizing
current

The magnetizing current is measured to test any


fault in the magnetic circuit and winding

Yes

balanced three phase


415V ac supply ,AC
Ammeter

During Overhauling
/ Internal fault

Yes

Measurement of zero
sequence impedance of 3phase transformers.

To measure Zero phase sequence impedance

Yes

Short circuit Current test.

This test is carried out as a check for any loose contact in


the tap changer, lead connections etc

Yes

check' of voltage vector


relationship

to check vector symbol (To ascertain phase


displacement)

Yes

415 V supply

Commissioning
/During
Overhauling /
Internal fault

Volt Amp / Elsytes Control


/India Electrical Works
/Power Gem
Engineer/New Delhi Lab

Measurement of impedance
voltage/ short-circuit
impedance (principal tapping)
and load loss.

To measure losses occurring at rated load , including


I2R loss and stray loss and measured voltage
required to circulate rated current through one
winding when the other winding is short-circuited

Yes

variable voltage source

Commissioning
Test

Volt Amp / Elsytes Control


/India Electrical Works
/Power Gem
Engineer/New Delhi Lab

Measurement of winding
resistance.

To measure resistance of transformer winding

Yes

Digital Meggar and Milli


ohms meter

Ten Delta test.

To determine ratio of the power dissipated in the


insulation in watts to the product of the effective
voltage and current in volt-amperes when test under
a sinusoidal voltage

Yes

Measurement of voltage
ratio

To know correct voltage ratio at each tap.

Yes

10

Polarization Index Test.

Polarization Index Test.

Yes

11

PPA test.

12
13

Leakage test
Sludge test Point
Neutralization Number ( Acid
Number )

14

To Determine contamination of the oil with particle of


matter.
Check leakage of tank
Check Dissolved Contamination
This tests measures the amount of acids that are
contained in the oil.
This test measure the ability of oil to resist the
absorption of moisture in to the oil molecule.
To Estimate the deterioration of the insulation
contamination and physical damage.
The Karl Fisher test measures the exact amount of
free and dissolved water molecules contained in the
oil sample

During Overhauling
Volt Amp / Elsytes Control
/ Internal fault
/India Electrical Works
/Power Gem
During Overhauling
Engineer/New Delhi Lab
/ Internal fault

Ten Delta Test Kit


415 V supply , Voltage
measuring Instrument
Digital Meggar

3Y

3Y

IS standard

I.S2026(Part
I)

I.S2026

[IS 2026
(part I):1977

Yes

IS 2026 (part
I):1977

Volt Amp / Elsytes Control


/India Electrical Works
/Power Gem Engineer

3Y

Yes

Yes

I.S2026
[IS 2026
(part I):1977

Yes

New Delhi Labs/ERDA

Yes
Yes

Y
Y

New Delhi Labs/ERDA


New Delhi Labs/ERDA

Yes

New Delhi Labs/ERDA

IS1448
PART2

Yes

New Delhi Labs/ERDA

IS 6104

Yes

New Delhi Labs/ERDA

Yes

New Delhi Labs/ERDA

IS 2362

15

Interracial Tension test

16

Capacitance and PF / Dissipation


factor

17

Karl Fisher test

18

Flash Point Test

Fire catching Point

Yes

New Delhi Labs/ERDA

IS1448
PART21

19

Oil Power Factor

To Ensure the oil integrity is maintained and as an


indication of changed in quality resulting from
contamination and deterioration.

Yes

New Delhi Labs/ERDA

IS 6262

Page 3

Transformer Site test


To measure the Degradation of paper in the form of
sheets, tapes and other pressed shapes,
Heat,moisture and oxygen .
To measure the radio-influence voltage (RIV)
generated by any internal partial discharge

20

Furanes values test.

Yes

New Delhi Labs/ERDA

I.S2026

21

Partial Discharge.

Yes

New Delhi Labs/ERDA

I.S2026

22

Tighten all bus and ground


connection

To ensure Tightness of all Joints ans bus bars

Alarm / Trip Test

Ensure the Alarm and Tripping of the transformer.

24

BDV of main Tank

To Measure the oil 's ability to with stand electrical


steers with out failure.

25

BDV of OLTC Tank

26

DGA.

To Determine if there is an incipient fault condition or


unusual aging.

Yes

27

Measurement of insulation
resistance.

To determine the insulation resistance from


individual windings to ground or between individual
windings

Yes

Digital Meggar and Milli


ohms meter

HY

Yes

28

Checking for foundation and


cracking and settling

A slight shift or transformer may break bushing or


connecting oil or water lines

Yes

Visual Inspection

Yes

Yes

Spanner and screwdrivers

Yes

Manually

Yes

Yes

23

Yes

BDV Test instrument

HY

Yes

Yes

BDV Test instrument

HY

Yes

HY

Page 4

New Delhi Labs/ERDA

IS: 335.

IS 9434
[IS 2026 (part
I):1977

IS for Transf Oil Specification


INSULATING OILS [IS: 335-1983 OR IEC: 296-1982]
There are no specific lit of type/routine /acceptance tests to be performed on manufactured insulating oil. However, the
manufacturer shall verify the following characteristics by carrying out relevant tests on the insulating oil.
As per IS: 335
(Un-inhibited)

As per IEC: 296


Un-inhibited
Inhibited -IA

Appearance

Clear & transparent and


free from suspended
matter or sediments

Clear & transparent and Clear & transparent and


free from suspended
free from suspended
matter or sediments
matter or sediments

Density
g/cm3

0.89 at 270C

< 0.895 at 200 C

< 0.895 at 200 C

Kinematic viscosity at 270 Max.

27 cSt
at 270C

16.5 cSt
at 40 0C

16.5 cSt
at 40 0C

Interfacial tension Min.


Flash point
Pansky-Marten (closed) Min
Pour point
Max.
Neutralization value
Total acidity
Max.
Inorganic acidity/alkalinity
Corrosive sulpher

0.04 N/m at 270C

0.04 N/m at 250C

0.04 N/m at 250C

1400C

1400C

1400C

-90 C

-300 C

-300 C

0.03mg
KOH/g
Nil

0.03mg
KOH/g
Nil

0.03mg
KOH/g
Nil

Non-corrosive

Non-corrosive

Non-corrosive

30 kV (RMS)
50 kV (RMS)

30 kV (RMS)
50 kV (RMS)

30 kV (RMS)
50 kV (RMS)

0.005

0.005

0.005

30x 1018 ohm-cm


500x 1018 ohm-cm

0.40 mg
KOH/g

0.40 mg
KOH/g

S. No.

Property

5
6

7
8

Electric Strength (Breakdown voltage)


Min.
New unfiltered oil
After filtration

10

11

Dielectric dissipation factor( tand) at 900


Max.
Specific resistivity
At 900 Min.
At 27 0 Min.

12

Oxidation stability
Neutralization value after
oxidation Max.
Total sludge after oxidation Max.

0.10% by weight

0.10% by weight

Page 5

No limit

CT Site test

S. No.

Test
Determination of errors or other
characteristics according to the
requirements of the appropriate
designation or accuracy class.
Measurement of Tand and
Capacitance

IR test on each winding, winding


to earth and between windings.

Checking of winding ratios by


primary injection test set.

7
8

Checking tightness of earthing


connections.

Partial discharge measurement

To check the error of the instrument


transformer both ratio and phase
angle error check the accuracy
class of transformer.
To determine ratio of the power
dissipated in the insulation in watts to
the product of the effective voltage
and current in volt-amperes when test
under a sinusoidal voltage
To determine the insulation
resistance from individual windings
to ground or between individual
windings
Check the winding ratio of current
transformer.

Partial discharge test is a diagnostic


test for HV machines as it is capable
of revealing incipient faults

Checking and Cleaning of Marsh


ling Box.
Checking of insulator for cracks.

11

Measurement of CT Secondary
resistance
Magnetization Characteristics

Site Test

Freq.

External Party

Internal
Capability

IS standard

Datagen Power
System
IS 2705

Yes

Ten Delta Test Kit

3 Yr

Shanthala Power
Limited

Yes

Digital Meggar and


Milli Ohms Meter

Yes

Primary Injection Test Kit

Yes

Spanner and
screwdrivers, Visual
Inception

High Power Lab

Yes

PD Detector, High
Voltage
Capacitor,Oscilloscope
.

New Delhi
Lab/ERDA

Yes

Yes

Yes

In fared Camera

Visual Inspection,
Spanner,screwdriver
and Blower

Visual Inception

Yes

Page 6

IS 2705

Yes

IS 2705

Yes

IS 2705

Yes

Yes

Internal fault/
High Power Lab
Requirement
Internal fault/
High Power Lab
Requirement

Yes

Yes

IS 2705

Yes

Yes

Measure the cracking of insulator


disc

Instrument Req.

3Y

Earthing connection

DGA and testing of other


Oil Testing for internal fault.
parameters of oil
Thermo vision Scanning of CT and To check the Heating of any
Top dome
parts/clamp of PT

10

12

Purpose of test

Yes

IS 2705

Potential Transformer

PT TEST
S. No.

Test

Purpose of test

Determination of errors or other


characteristics according to the
requirements of the appropriate designation to determine whether the errors of the PT are within
specified limits.
or accuracy class.

Measurement of Tand and Capacitance

IR test on each winding, winding to earth


and between winding.

Indicates dielectric loss of the insulation.

Checking tightness of earthing connections.

To determine the insulation resistance from individual


windings to ground or between individual windings
Earthing connection

Freq.

Yes

10

Thermo vision Scanning of PT and Top dome

11

Magnetization Characteristics

IS standard

Yes

IS :3156 Part 1

3Y

Tan Delta Test Kit

3Y

Shanthala Power
Limited

Digital Meggar
Yes

Yes

Spanner and screwdrivers, Visual


Inspection

Yes

IS :3156

Yes

IS:3156

Yes

IS:3156

Check the winding ratio of Potential transformer.


Yes

Primary Injection Test Kit

Yes

IS :3156 Part 1

Yes

IS:3156

Yes

High Power Lab


Yes

Oil Testing for internal fault.

Yes

Measure the cracking of insulator disc

Yes

Visual Inspection

To check the Heating of any parts/clamp of PT

Yes

Thermo Vision Camera

DGA and testing of other parameters of oil


Checking of insulator for crack

Internal Capability

Datagen Power
System

Partial discharge measurement

External Party

High Power Lab

Partial discharge measurement


Checking of winding ratios by primary
injection test set.

Site
Instrument Req.
Test

New Delhi Lab/ERDA

Yes

Page 7

Internal fault/
High Power Lab
Requirement

Lighting Arrester

S. No. Test

Checking of
leakage(Third Harmonic
Resistive Current)

Purpose of test

Site
Instrument Req.
Test

current analyzer (mA)

Yes

Testing by Surge Monitor kitcounter and meter tests

Internally
Capable

Y
Shanthala Power
Limited

Surge Monitor kit-counter

Resistance of bolted
connections

External Party

Shanthala Power
Limited

current analyzer (mA)

Yes

Freq.

Y
Shanthala Power
Limited

Milli volt drop meter


Detects poor contacts
Yes

Yes

HY

Yes

HY

Yes

4
Cleaning of Porcelain Insulator

IR Value

Detects serious flaws, moisture


absorption and cleanliness.

Digital meggar
Yes

Measurement of
Capacitance and Tand

Tan Delta test Kit


Yes

In case of Shanthala Power


requiremen Limited
t

IS
standard

HT MOTOR

S. No.
1

2
3
4

Test
Computerized Digital ELCID of stator core

IR & PI Stator
Tan Delta / Power factor of Stator Winding
AC Impedance on poles

Motor Circuit Analysis

DC HV step voltage / Leakage Current

Purpose of test
Determines healthiness of stator core inter
laminar insulation
Detects serious flaws, moisture absorption and
cleanliness of winding
Evaluation of stress grading, dielectric losses
and homogeneity of the winding insulation
Detects the presence of short circuit turns

Phase angle,current/ frequency


response,resistance,inductance and impedance

Site
Test
Yes

Instrument Req.
ELCID Evaluation Tester

Freq.

Digital Megger

3Y

Yes

Tan delta kit

3Y

Yes

All Test Pro 2000 Motor


circuit analyzer

Internally
IS
Capable standard

India Electric works,Vikas


During Overhauling Electro Engineers,Aditya
Engg Services

Yes

Yes

External Party

Yes

3Y

India Electric works,Vikas


Electro Engineers,Aditya
Engg Services

3Y

Diagnostic Technologies
India Electric works,Vikas
Electro Engineers,Aditya
Engg Services

Detects Insulation weakness and possibility of


warning of breakdown of incipient fault

Yes

3Y

Determines healthiness of turn insulation.

Yes

3Y

Yes

IS-325

Yes

Surge Voltage on Stator Winding


7

PD Test

Evaluation of stress grading system and


location of Partial Discharge sites.

Complete Overhauling of Motor

For preventive maintenance Purpose.

10

Air gap Measurement

11

Maintenance of cooling system

12

Winding Insulation resistance test

PD Detector, High Voltage


Capacitor,Oscilloscope.

3Y

India Electric works,Vikas


Electro Engineers,Aditya
Engg Services

3Y

India Electric works,Vikas


Electro Engineers,Aditya
Engg Services

Yes
TO check the Measurement of the air gap
between stator and rotor
Ensure the working of cooling system.
Detects serious flaws, moisture absorption and
cleanliness of winding.

Yes
Yes

Air gap Guage


Visual Inception,Air Blower

Yes

Digital HT Meggar

Yes

Y
Y

Yes
Yes

Yes

IS-325

16

Lubrication on a scheduled basis, in


conformance with the manufacturer's
Lubrication of Motor Bearing
recommendations, provides optimum bearing
life.
It tends to shake windings loose and
Vibration Measurement of DE/NDE Side.
mechanically damages insulation by cracking,
flaking or abrading the material.
To ensure double earthing of motor.
Earthing Connection Checking
Excessive heat is both a cause of motor failure
Temperature Measurement of DE/NDE side and a sign of other motor problems.

17

VisuaInspection

To check the Motor Condition

Yes

Visual Inspection

18

On line Motor Current Signature Analysis

To determine the healthiness of Motor by giving


all the electrical parameters, Harmonic
analysis, Rotor bar health and bearing problems

Yes

Electrical Signature analyzer

On line

Diagnostic Technologies

19

Acoustics Emission analysis

Motors Generate acoustics signal due to defect


growth in material,loss of lubrication,impact and
friction

Yes

Memo Pro Acoustics


Emission analyzer

On line

Diagnostic Technologies

13

14
15

Yes

Lubrication,Lubrication Gun

HY or Running Hrs.

Yes

Yes

Vibration Meter

FN

Yes

Yes

Visual Inception

Yes

Yes

RTD,Thermo vision Camera

Yes

Yes

Battery Bank
Battery Bank

S. No.

Test

Checking of electrolyte level

Purpose of test

water level in battery

Yes

Yes

Battery Hydro
Meter,multi meter

Yes

VisualInpection, Hand
gloves

Yes

Battery Hydro
Meter,multi
meter,watch,Termo
cam

3Y

Yes

Air Blower,
Multimeter,Screwdrive
r

Yes

Yes

Checking of emergency DC
lighting to control room
Yes

External Internally
IS
Party
Capable standard

Hand gloves and


visual inspection
To ensure the DM

Freq.

Site Test Instrument Req.

Checking of Sp. Gravity and


cell voltage

Visual Inpection

Yes

4
Terminal Tightness of Battery

loosenes of contact

Yes

Capacity Discharge Test of


Battery Set

To Check the Loading Capacity of battery

Yes

Checking of charger panel /


DCDB for electrical
connection tightness and
cleanliness

Yes

Page 10

Extarnal Company Details


S.No.
1
2
3

Name of Company
TDPS
India Electricl Works
Power Engineering Services Pvt. Ltd.

Contact Details.
0807734432-38,0807770541

Web/Mail Address
www.tdps.co.in

91-11-26348020

http://www.spespl.com/

Gujrat Turbo Enterprieses

91-422-2402574

gteturbinecare@yahoo.co.in,
gteturbinecare@gmail.com

Pioneer Generator

91-(11)-28111236, 28112306, 28112372

http://www.processregister.com/Pioneer_Gen
erator_Co/Supplier/sid11453.htm

Pentagon Turbines (P) Ltd

Power Gem Engineers

Volt Amp

New Delhi Lab

10

Datagen Power System

11
12
13
14
15

Shanthala Power Limited


Vikas Electro Engineers
Aditya Engg Services
Diagnostic Technologies
Padmavahini Transformers Pvt Ltd.

16

Karytron Electrical Industries

+91 (80) 4292 1111/ 2780 5974 ,+91 (11)


4153 8031,+91 (40) 2381 5673,

www.pentagonturbines.com

01127154771,47062960,47062960,29236074,2
2618199,22231620 ,27486910
www.powergem.com,pgem@nda.vsnl.net.in
+91-11-224 28331 / 224 39457
www.voltamptransformers.com
01276-268404,011-25534101, 25534102
91-124-4670500,91-124-4670202
91 836 2335936/ 2335934/ 2334908

http://www.newdelhilab.com/

www.datagensystems.com,support@datagen
systems.com
www. shanthala india.com

9810444992 [,95120-2895280
0250-2392060,2392086,2392162

diatech@vsnl.com

422-6531222,09843041222- 09442141222

http://www.padmavahinitransformers.com
http://karytronelectricals.tradeindia.com/Expor
ters_Suppliers/Exporters/hp/13052/home_pag
e.html

91-11-45620856/45620857/65454780

Page 11

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