Electrical Power Equipment Maintenance and Testing Second Edition By Paul Gill

www.TechnicalBooksPdf.com POWER ENGINEERING Series Editor H Lee Willis Quanta Technology Raleigh, North Carolina Advisory Editor Muhammad H Rashid University of West Florida Pensacola, Florida Power Distribution Planning Reference Book, H Lee Willis Transmission Network Protection: Theory and Practice, Y G Paithankar Electrical Insulation in Power Systems, N H Malik, A A Al-Arainy, and M I Qureshi Electrical Power Equipment Maintenance and Testing, Paul Gill Protective Relaying: Principles and Applications, Second Edition, J Lewis Blackburn Understanding Electric Utilities and De-Regulation, Lorrin Philipson and H Lee Willis Electrical Power Cable Engineering, William A Thue Electric Systems, Dynamics, and Stability with Artificial Intelligence Applications, James A Momoh and Mohamed E El-Hawary Insulation Coordination for Power Systems, Andrew R Hileman 10 Distributed Power Generation: Planning and Evaluation, H Lee Willis and Walter G Scott 11 Electric Power System Applications of Optimization, James A Momoh 12 Aging Power Delivery Infrastructures, H Lee Willis, Gregory V Welch, and Randall R Schrieber 13 Restructured Electrical Power Systems: Operation, Trading, and Volatility, Mohammad Shahidehpour and Muwaffaq Alomoush 14 Electric Power Distribution Reliability, Richard E Brown 15 Computer-Aided Power System Analysis, Ramasamy Natarajan www.TechnicalBooksPdf.com DK4058_C000.indd i 11/20/2008 10:17:56 AM 16 Power System Analysis: Short-Circuit Load Flow and Harmonics, J C Das 17 Power Transformers: Principles and Applications, John J Winders, Jr 18 Spatial Electric Load Forecasting: Second Edition, Revised and Expanded, H Lee Willis 19 Dielectrics in Electric Fields, Gorur G Raju 20 Protection Devices and Systems for High-Voltage Applications, Vladimir Gurevich 21 Electrical Power Cable Engineering, Second Edition, William Thue 22 Vehicular Electric Power Systems: Land, Sea, Air, and Space Vehicles, Ali Emadi, Mehrdad Ehsani, and John Miller 23 Power Distribution Planning Reference Book, Second Edition, H Lee Willis 24 Power System State Estimation: Theory and Implementation, Ali Abur 25 Transformer Engineering: Design and Practice, S.V Kulkarni and S A Khaparde 26 Power System Capacitors, Ramasamy Natarajan 27 Understanding Electric Utilities and De-regulation: Second Edition, Lorrin Philipson and H Lee Willis 28 Control and Automation of Electric Power Distribution Systems, James Northcote-Green and Robert G Wilson 29 Protective Relaying for Power Generation Systems, Donald Reimert 30 Protective Relaying: Principles and Applications, Third Edition, J Lewis Blackburn and Thomas J Domin 31 Electric Power Distribution Reliability, Second Edition, Richard E Brown 32 Electrical Power Equipment Maintenance and Testing, Second Edition, Paul Gill www.TechnicalBooksPdf.com DK4058_C000.indd ii 11/20/2008 10:17:57 AM ELECTRICAL POWER EQUIPMENT MAINTENANCE AND TESTING SECOND EDITION Paul Gill Boca Raton London New York CRC Press is an imprint of the Taylor & Francis Group, an informa business www.TechnicalBooksPdf.com DK4058_C000.indd iii 11/20/2008 10:17:57 AM CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2009 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U.S Government works Printed in the United States of America on acid-free paper 10 International Standard Book Number-13: 978-1-57444-656-2 (Hardcover) This book contains information obtained from authentic and highly regarded sources Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint Except as permitted under U.S Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers For permission to photocopy or use material electronically from this work, please access www.copyright.com (http:// www.copyright.com/) or contact the Copyright Clearance Center, Inc (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400 CCC is a not-for-profit organization that provides licenses and registration for a variety of users For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe Library of Congress Cataloging-in-Publication Data Gill, Paul, 1942Electrical power equipment maintenance and testing / Paul Gill 2nd ed p cm ISBN 978-1-57444-656-2 (alk paper) Electric power systems Testing Electric power systems Maintenance and repair I Title TK401.G55 2008 621.31’0420287 dc22 2008029371 Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com www.TechnicalBooksPdf.com DK4058_C000.indd iv 11/20/2008 10:17:57 AM Liability This textbook and instructions offered in it are designed to acquaint students and readers with accepted good practice for maintenance, operation, and testing of electrical equipment and/or systems This book does not purport to be complete nor is it intended to be specific for the products of any manufacturer, testing procedures, or maintenance routines The publisher, the author, companies, and other organizations referenced in this book will not accept any responsibility and liability whatsoever for work undertaken on the basis of this text The sole purpose of this book is to impart knowledge on the subjects covered in the book All work undertaken based on this text is the sole responsibility of the reader and user of the book The manufacturer’s operating, maintenance, and testing procedures are the only reliable guide in any specific instance and, therefore, they should be consulted before undertaking any work on electrical equipment The contents of this book not represent a U.S Nuclear Regulatory Commission (USNRC) position on the subjects covered in the book v www.TechnicalBooksPdf.com DK4058_C000.indd v 11/20/2008 10:17:57 AM www.TechnicalBooksPdf.com DK4058_C000.indd vi 11/20/2008 10:17:57 AM Dedication In memory of my parents—Jasbir Singh and Amar Kaur To my wife Patricia—for her patience and understanding to make this work possible To my children/spouses—Shaun/Debra, Rajan/Larie, Jason/Deanna, and Rania/Alden and to my beautiful grandchildren Collin, Andrew, Ryan, Timothy, Owen, Henry, Jack, Maya, Chani, Paul, and Lauryn who keep me young and bring boundless joy to my journey in life www.TechnicalBooksPdf.com DK4058_C000.indd vii 11/20/2008 10:17:57 AM www.TechnicalBooksPdf.com DK4058_C000.indd viii 11/20/2008 10:17:57 AM Contents Series Introduction xxix Foreword xxxi Preface xxxiii Acknowledgments xxxvii Chapter Maintenance Strategies, Dielectric Theory, Insulating Materials, Failure Modes, and Maintenance Impact on Arc-Flash Hazards 1.1 Introduction 1.2 Why Maintain and Test .1 1.3 Overview of Electrical Maintenance and Testing Strategies 1.3.1 Key Factors in EPM Optimization Decisions 12 1.3.2 General Criteria for an Effective EPM and Testing Program 12 1.3.3 Qualifications of EPM Personnel 13 1.3.4 Optimization of PM Intervals 14 1.3.5 Trending of Test Results 15 1.3.6 Systematic Failure Analysis Approach 15 1.3.6.1 Postmaintenance Testing 16 1.3.6.2 Engineering Support 16 1.3.6.3 Summary 17 1.4 Planning an EPM Program 18 1.4.1 Maintenance Management Considerations 18 1.4.1.1 Responsibilities 19 1.4.1.2 Inspection 19 1.4.1.3 Scheduling 19 1.4.1.4 Work Orders 20 1.4.1.5 Record Keeping 20 1.4.2 Technical Requirements 20 1.4.2.1 Survey of Plant Equipment 20 1.4.2.2 Listing of Plant Equipment in the Order of Critical Importance 23 1.4.2.3 Plan to Perform EPM on Regular Frequency 24 1.4.2.4 Development of Instruction and Procedures for the EPM Program 24 1.4.3 What Should Be Included in the EPM Program 25 1.4.3.1 EPM and Testing 25 1.4.3.2 Electrical Repairs 25 1.4.3.3 Analysis of Failures 25 1.4.3.4 Trending of Maintenance and Testing Data 26 1.4.3.5 Computerized Maintenance Management System 26 ix www.TechnicalBooksPdf.com DK4058_C000.indd ix 11/20/2008 10:17:57 AM Index 949 laminated cable, 331 MI cables, 304–305 paper, 302–303 rubber and rubber-like compounds (polymeric insulation), 303–304 teflon, 305 varnished cambric, 303 Insulation shield system, 305 Insulation system, of machines, 127 Integral-horsepower motor, 550 Interfacial tension (IFT) test, 201 Inverter duty motors, 642 IR, see Insulation resistance K Karl Fisher method, see Water content test L Laminated shielded cables, field test voltages for, 119 Large-apparatus induction motors, 552 LC filters, see Tuned inductor and capacitor (LC) filters Leakage current, 616 definition, 120 vs time, 121, 134–135 vs voltage, 119–120, 133–134 Leakage flux, 570 Leakage impedance, 244–245 Lenz’s law, 242 Lightning arresters insulating quality of, 188 maintenance procedures for, 136–137 PF tests of, 171 test connections, 136 Linear loads, PQ problems categories arcing devices, 728 electrostatic discharges (ESDs), 728 power electronic devices, 727 saturatable devices, 727 impedance characteristics, 730 PF characteristics, 735–739 power disturbances sources, 727 Line filters, see Noise filters Liquid-filled transformers acceptance test, 265–267 construction process, 236 cooling methods, 236–237 DC hi-pot test voltage on, 113 diagnostic guide, 273–275 drying-out methods heat alone, 271–272 heat followed by vacuum, 272–273 inspection, 264 installation, 263–264 insulation systems, 112 maintenance, 267–271 storage, 272 Load cycle, 561 Load reactors, 643 Load-time rating, of machines and generators, 561–562 Lock-rotor torque, 566 Low-voltage breakers service life continuous current rating, 444–445 endurance requirements electrical operations, 449 MCCB, 450 overload switching, 448 maximum voltage rating/ nominal voltage class, 444 rated short-circuit current NEMA AB-1-2002 and UL 489-2002 standards, 445 power factor, 446 short circuit current rating/ panelboards, MCC and switchgear assembly, 447 Low-voltage circuit breakers fused power circuit breakers, 434 low-voltage equipment selection and application continuous current rating, 444–445 endurance requirements, 448–450 maximum voltage rating/nominal voltage class, 444 panelboards, MCC, and switchgear assembly, 447 short-circuit current rating, 445–447 low-voltatge fuses anti-single phase protection feature, 441 www.TechnicalBooksPdf.com DK4058_C015.indd 949 11/8/2008 12:38:22 PM Index 950 current and noncurrent limiting fuses, 440 single-phase interrupters, 441 MCCB and insulated-case circuit breakers, 433 overcurrent protective devices direct-acting trip, 434–435 monitoring and protection packages, 439 static and electronic-trip units, 435–439 power circuit breakers electrical maintenance factors, 458–459 mechanical maintenance factors, 456–458 spring-operated, storedenergy mechanisms, 433 tripping action, 434 Low-voltage fuses anti-single phase protection feature, 441 current and noncurrent limiting fuses, 440 single-phase interrupters, 441 Low-voltage protective device testing ground fault sensing and relaying equipment testing fielding training preparation, 475 field testing, 475–477 molded-case breaker trips protective trip testing, 471–472 verification testing, 472–474 overcurrent trip units electromechanical trips, 466–468 solid-state trip units, 468–470 overload relays, 474 Low-voltage switches, 441–442 Low-voltage switchgear indoor and outdoor switchgear, 431 maintenance and care air disconnect switches, 464 corona, 453–454 energized and deenergized equipment, 451 heat, 452 insulators, 465 MCCB, 460–463 moisture, 452–453 physical damage, 451–452 power fuses, 464–465 tracking, 453 original equipment manufacturer (OEM), 432 three-phase AC system, 431 Lubrication, of machines, 596 M Machine insulation system, 178, 573 Machine windings, cleaning and varnishing of, 593–596 Magnetic flux, 630 Magnetomotive forces, 551 MCCB low-voltage circuit breakers, 433 mechanical and electrical factors circuit breakers, 461 insulation resistance measurement, 462 mechanical operation and connection test, 461–462 UL listed components repair/ replacement, 460–461 MCT-1600, CT test set model, 528–529 Medium-voltage circuit breakers, 172 PF tests procedure for, 173 problems in, 188–189 Medium-voltage switchgear construction features metal-clad, 378, 382 metal-enclosed interrupter, 382 station-type cubicle, 382–383 control power requirements AC and DC, 415 AC tripping methods, 418 capacitor trip, 416–418 circuit breaker closing methods, 418–419 circuit breakers, tripping methods, 416–417 DC battery trip, 416 power circuit breakers, 393–396 short-circuit and power circuit breaker ratings AC and DC effective values, 384 AC component currents, 386 asymmetrical current wave, 385–386 www.TechnicalBooksPdf.com DK4058_C015.indd 950 11/8/2008 12:38:22 PM Index 951 available short circuit/first half-cycle current, 387–388 average and instantaneous value, 384 closing angle, 386–387 current-limiting fuses, 388 DC component, 385 decay, 386 fault at zero, asymmetrical current wave, 387 let-through current, 389 operating time, 383 random closing, 387 total current, 385 X/R ratio, 389–390 voltage and insulation ratings, 378 Megavolt-amperes (MVA), 390–391 Megger DF test equipment Delta-3000 test set, 151 formulas for calculating PF or DF, 151–152 general instructions for operation of, 152–153 simplified circuit diagram of, 150 Megger DLRO 200, microohmmeter, 407–408 Megger S1-5010, insulation resistance measurement test, 403–404 Megger Vidar instrument DC, 394, 401 vacuum bottle integrity, 399 Megohm value, insulation resistance measurement test, 403 Metal rolling mill motor, 551 Mineral insulated (MI) cables, 304–305 Mitigation devices and methods, harmonic solutions preventive measures, 820–821 remedial measures circuit detuning, 821 delta–delta and delta–wye transformers, 823 isolation transformers, 823 line reactors, 823 passive harmonic filters, 821–823 Mobile cartridge-type filter, model BA-2FC2-20, 216 Model CB-100, 150 Molded-case breaker trips low-voltage protective device, 470 primary current injection method, 471 protective trip testing INST (magnetic) test, 472 overload (thermal element) test, 471 verification testing INST trip tolerance, 473 UL standard 489 and NEMA AB-1, 472 Motor control centers (MCCs), 27 Motor current signature analysis (MCSA), Motors, insulation systems DC overpotential test, 133 insulation resistance test of field-winding test procedures, 128–129 individual stator winding test, 130–133 overall stator test, 129–130 overall system test, 130 leakage current vs time test, 134–135 step-voltage test, 133–134 Motors and generators applications of, 559–560 electrical integrity, 560–562 mechanical integrity, 562 insulation systems for, 572–576 maintenance of balancing, 602–603 belts, gears, and pinions, 603–604 brushes, 600–602 failure mechanisms, 576–577 general inspection, 577–580 induction motor, 588–592 lubrication, bearings, and oil seals, 596–600 machine windings, 593–596 recommendations for, 580–588 synchronous motors and generators, 592–593 NEMA classification of, 549–559 other insulation test methods series resonant testing, 662–663 very low frequency testing, 660–662 predictive maintenance guide on, 604–605 air gap, 630 www.TechnicalBooksPdf.com DK4058_C015.indd 951 11/8/2008 12:38:22 PM Index 952 insulation condition, 615–621 power circuit, 611–615 power quality, 605–611 rotor condition, 625–630 stator condition, 621–625 rotating machines/rotating apparatus, 549 terminal markings for, 556 testing of, 643–649 conductor insulation tests, 657 dissipation factor tan δ test, 653–654 high-potential test, 650–652 insulation resistance and dielectric absorption tests, 650 motor and generator component tests, 657 partial discharge test, 654–656 PF test, 652–653 slot discharge test, 657 voltage surge comparison test, 658–660 torque–speed curve, 565 vibration analysis for, 663–664 Multispeed motor, 556, 568 N National Electrical Code (NEC), 15, 193, 302 National Electrical Manufacturers Association (NEMA) standards, 229, 239, 252, 377, 393 classification of motors and generators, 549 application, 550–551 electrical type, 551–553 physical protection and methods of cooling, 554–555 size, 550 variability of speed, 555–556 terminal marking of machines, 556–559 MG1-2006 standards for motors and generators, 549 power circuit breakers, standard voltages and operating ranges, 416 National Electric Energy Testing, Research and Application Center (NEETRAC), 298 National Fire Protection Association (NFPA) 14, 70 flash protection, 830 National Electrical Code (NEC)-2008, 829 potential electric arc-flash hazards, 830 NEMA standard CP1-2000, 139 Neoprene, elastomer compound, 304 Network transformers, 239 NFPA, see National Fire Protection Association NFPA 70E arc flash protective equipment, 835–837 electrical hazard analysis, 831 Electrical Safety in Workplace-2004, 830 flash-hazard analysis, 834–835 flash protection, 837 live parts boundaries approach, 831–834 Noise filters, 808 Noncondenser-type bushings, 167–168 Nondestructive testing, 146 Nonlinear loads, PQ problems categories arcing devices, 728 electrostatic discharges (ESDs), 728 power electronic devices, 727 saturatable devices, 727 PF characteristics, 736 power disturbances sources, 727 types current source inverter (CSI) drives, 734–735 fluorescent lighting, 732–733 switch-mode power supplies (SMPS), 735 variable frequency drives (VFDs), 733 VSI drives, 733 V–I characteristics harmonic generating characteristics, 742 harmonics sensitivity, 743 www.TechnicalBooksPdf.com DK4058_C015.indd 952 11/8/2008 12:38:22 PM Index 953 HD terminology, 731–732 noise sensitivity, 743 phase sequence of harmonics, 739–742 power factor (PF) characteristics, 735–739 types, 732–735 voltage flicker sensitivity, 743 Normal mode noise, 724–725 O Occupational safety and health administration (OSHA), 14 Oil circuit breakers, 398–399 components of, 173 insulation test on, 173–174 PF tests procedure for, 174–175 interrupter assembly, 176 problems in, 189 TLI test, 175–176 Oil-filled power, PF test results of, 185 Oil seals, installation of, 599–600 On-Line Monitoring Corporation, 297–298 Online monitoring systems, transformers bushings and lightning arrestors, 296–298 DGA testing, 292–296 diagnostics, 296 On-site circuit breaker maintenance safety checklists low voltage checklist equipment/breakers examination, 859–860 precautions racking, 861 preparation, 859 medium-voltage checklist equipment breakers examination, 862–863 precautions racking, 863–864 preparation, 861–862 Oscillating wave (OSW) Testing apparatus, 354 description, 353 procedure, 354 Overall stator winding test procedures, 129 test connection for, 130 Overall system test procedure, 130 test connection for, 131 Overcurrent protective devices direct-acting trip electromagnetic force, 435 series trip, electromechanical and dashpot trip device, 434 short-circuit current flow, 435 monitoring and protection packages, 439 static and electronic-trip units current measurement, 436 current sensor, 438 current transformer sensor, 435 digital communication network, 437 flux-shift device control, 438 harmonic current generation, 436 microprocessor trip element, 437 Micro-VersaTrip plus, 438 semiconductor-integrated circuits usage, 435 signal monitoring, 436 Overcurrent trip units electromechanical trips mechanical checking, 466 overcurrent test, 466–468 solid-state trip units primary current injection test, 468–469 secondary current injection test, 469–470 Overhead cable conductors, 300 Overload duty, 562 P Paper-insulated lead-covered (PILC) cable, 301 Partial discharge current, 99–100 Partial discharges (PD) testing characteristics, 341 data analysis and documentation, 344–346 diagnostics tests, 351 magnitude calibration, 343 multiterminal testing, 342 off-line PD diagnostics, 351–352 on-and off-line detection system, 342 www.TechnicalBooksPdf.com DK4058_C015.indd 953 11/8/2008 12:38:22 PM Index 954 online PD diagnostics, 351 sensitivity assessment, 343 voltage stress, 343–344 Part-winding-start motor, 550 PD inception voltage (PDIV), 333 PE, see Polyethylene Peak value/crest, 384 Percent full-load amperes (% FLA), 613 Personal protective equipment (PPE), 91 PF correction capacitors, see Powerfactor correction capacitors PF Live Plus, online monitoring system, 297–298 PF testing basic test connections grounded-specimen test mode, 154 guard-specimen test mode, 154–155 ungrounded specimen test mode, 155 of cables precautions for, 180 shielded and sheathed cables, 181 unshielded and unsheathed cables, 181–182 of circuit breakers, 171 medium-voltage circuit breakers, 172–173 OCBs, 173–176 and DF tests, 146 equipments manufacturers of, 149 Megger DF test equipment test circuit modes of, 154–155 factors influencing humidity and surface leakage current, 149 temperature, 148 of lightning arrestors, 171–172 on machine winding insulation test connections for, 179 using PF tip-up test, 178, 180 principles of capacitive current, 147 resistive current and dielectric losses, 148 safety cautions with, 155 apparatus insulation, 156 HV test cable, 157 safety switches, 157 of SF6 breaker, 177 of transformer bushing, 164 hot-collar test, 167–168 test connections, 166–167 of transformer oils and fluids, 170–171 of transformers autotransformer, 163 conditions for, 158 PTs, 163–164 three-winding transformers, 161–163 two-winding transformers, 158–161 PF tip-up test, machine winding insulation, 178 Phase-to-ground insulation, 178 Phase-to-phase insulation, 656 Phase-to-phase voltages, 607 Polarity testing, in TTR testing, 281 Polarization current, 616 Polarization index (PI), 620 Polarization recovery voltage test composites, 286 measuring instrument, 287–288 polarization spectra, 290–291 power transformers, 288–289 Polyethylene (PE), thermoplastic compound, 304 Polyphase motors, 551–552, 557–559 Polyvinyl chloride (PVC), thermoplastic compound, 304 Potential transformers (PTs), 163 Power cable conductors, 300 Power circuit breakers electrical maintenance factors insulation resistance, AC dielectric and low-frequency tests, 459 primary circuit resistance check, 458–459 mechanical maintenance factors arc chute and interphase, 458 contact erosion, 457 contact pressure and alignment, 456–457 current-carrying components lubrication, 458 operating mechanism, 456 www.TechnicalBooksPdf.com DK4058_C015.indd 954 11/8/2008 12:38:22 PM Index 955 selection and application installation, 394 limits, 393 maintenance, 395–396 receiving, handling, and storage, 393–394 steps, 392 Power factor (PF), 390, 564, 567 Power-factor correction capacitors capacitance of, 190–191 design, 182 tests checking before placing in service, 137 factors affecting, 137 NEMA standard CP1-2000, 139 serviceability, 137–139 Power line conditioners enhanced isolation transformer, 813 ferroresonant type, 813–814 magnetic synthesizers, 814 motor generator (M-G) transform, 814–815 tap switching, 814 types, 812–813 Power quality (PQ) concept and fundamentals comprehensive definition, 716–717 electrical disturbances types, 717–725 definition, 715 harmonics capacitor banks, 753–756 current distortion factor (CDF), 744–745 electronic equipment, 758 insulation stress, 747 lighting devices, 759 load disruption, 747–748 metering devices, 758 protective relays, 757 rotating machines, 751–753 switchgear, 756–757 thermal stress, 745–747 total harmonic current distortion (THD), 744–745 transformers, 748–751 voltage distortion categories, 744 linear loads, 729 load current waveforms, 730 nonlinear loads, V–I characteristics harmonic generating characteristics, 742 harmonics sensitivity, 743 HD terminology, 731–732 noise sensitivity, 743 PF characteristics, 735–739 phase sequence of harmonics, 739–742 types, 732–735 voltage flicker sensitivity, 743 solutions and power treatment devices HDs, 817–823 problem categories, 807 voltage disturbance and noise, 807–817 wiring and grounding, 823–825 sources external, 726 grounding design and installation, 728 internal, 726 lightning strikes, 726–727 linear and nonlinear loads, 727–728 load switching and surges, 727 power system faults, 726 wiring design and installation, 728–729 types, 715 Power supply system, 607 Power transformer applications, 240 graphical representation of, 244 polarization recovery voltage test, 288–289 Power treatment devices harmonic distortion (HD) industry standards, 818 mitigation devices and methods, 820–823 negative aspects, 817 system harmonics evaluation, 818–820 problem categories, 807 voltage disturbance and noise isolation transformers, 812 noise filters, 808 power line conditioners, 812–815 www.TechnicalBooksPdf.com DK4058_C015.indd 955 11/8/2008 12:38:22 PM Index 956 TVS suppressors (TVSS), 808–809 UPS, 815–817 voltage regulators, 809–812 wiring and grounding, 823–825 Preventive maintenance program, 2, 127 Programma TM-1800, circuit breaker analyzer, 413 Protective device testing, 30–31 Protective relays, power systems application and principles back up relaying, 516 current/voltage/balance relays, 517–518 differential relaying, 518–519 directional relays, 517 distance relaying, 518 overcurrent relays, 516–517 over–under voltage relays, 516–517 pilot wire relaying, 519 primary relaying, 515 classification of, 510 construction and types electromechanical and induction relays/firstgeneration relays, 511 microprocessor relays/fourthgeneration relays, 513–514 solid-sate relays/thirdgeneration relays, 513 static relays/second-generation relays, 512–513 tests types acceptance, 519–520 commissioning and startup tests, 520 maintenance tests, 520 troubleshooting, 520–521 Pulse height analyzer, 656 Pulse width modulated (PWM) switching, 561 PVC, see Polyvinyl chloride PWM inverters, 638 R Radio frequency current transformer, 656 Radio noise meter, 656 Random closing, circuits, 387 Rated short-circuit current NEMA AB-1-2002 and UL 489-2002 standards, 445 power factor, 446 RC snubber networks, 642–643 Reactance grounded system, 665 Recovery voltage meter (RVM) 5462, 287–289 Rectifier transformers, 240 Reliability-centered maintenance (RCM) airborne ultrasonic and lubrication oil analysis, analysis, 11 condition monitoring techniques, 8–9 implementation, 10–11 infrared thermography, 7–8 maintenance strategies, methods, 3–4 mix and reactive, 5–6 plant databases, 11–12 PM, condition and vibration monitoring, proactive maintenance, RCFA and FMEA, 10 specification, 9–10 target systems and components, Resistance grounded system, 665 Resistance temperature detector (RTD), 569 Resonant grounded system, 665; see also Ground-fault neutralizers Reversing hot mill motor, 551 Ripple currents, 571 Ripple effect, 570 Root cause failure analysis (RCFA), Root-mean-square (rms) effective value, 384 Rotating apparatus, energyconversion device, 549 Rotating machinery, PF testing contamination detection, 190 2500 V PF test set and 10 kV PF test set, 177 Rotor influence check (RIC), 626–627 Round cell battery, 421 Routine inspection sheet (RIS), 522 www.TechnicalBooksPdf.com DK4058_C015.indd 956 11/8/2008 12:38:22 PM Index 957 Rule of thumb, 139 Run-to-failure (RTF), 2–3 S Schering bridge, 653 SEL 421, high-speed line protection relay, 514–515 Self-cooled dry-type transformers, 236 Series-wound motor, 551, 553 Service-factor duty, 561 SF6 breaker, PF test procedures capacitances, 177 problems in, 189–190 Shielding and semiconducting tape, 305 Short-time duty, 561 Shunt-wound motor, 553 Silicone insulating fluid filtering, 219–220 receiving and handling, 218–219 safety precautions, 220 storage and periodic inspection, 219 Silicone rubber, thermosetting compound, 304 Single-phase transformers additive polarity, 247 insulation resistance of windings, 110 subtractive polarity, 246–247 test connections for insulation resistance of, 108 Single-phase windings, 659 Single-voltage motors, 557 Sleeve bearings, 596–598 Slip, calculation of, 565 Small (fractional) machine, 550 Soil resistivity measurements, see Four-point measurement method Solid insulation testing, 29–30 Solidly grounded system, 666 Special-purpose motor, 550 Specific insulation resistance, 120 Spill prevention, control, and countermeasure (SPCC), 227 Squirrel-cage induction motors, 551 Squirrel-cage induction rotor, 627 Start-up/commissioning test, 28 Static and digital relays commissioning methods and practices, 534 bus protection scheme, 536–537 communications means, 535 line protection system, 536 transformer differential scheme, 538–539 test methods, 534 Static relays, testing and commissioning of, 531 Static-trip units current measurement, 436 current sensor, 438 current transformer sensor, 435 digital communication network, 437 flux-shift device control, 438 harmonic current generation, 436 microprocessor trip element, 437 Micro-VersaTrip plus, 438 semiconductor-integrated circuits usage, 435 signal monitoring, 436 Stator insulation system, 654 Step-voltage test, 105 of cables, 119–120 of motors and generators, 133–134 of transformer, 111 Strand shielding (semiconducting tape), 305 Surface leakage current, 99 Surge arrestors, insulating quality of, 188 Surge capacitors design, 182 main capacitance of, 190 Surge impedance, 642 Sweep frequency response analysis (SFRA) testing, 283–285 Swirl effect, 628 Switchgear bus and enclosure, 400 electrical distress areas, 402 maintenance procedures, 401–402 Switchgear maintenance air disconnect switches, 464 corona, 453–454 energized and de-energized equipment, 451 heat, 452 www.TechnicalBooksPdf.com DK4058_C015.indd 957 11/8/2008 12:38:22 PM Index 958 insulators, 465 MCCB, 460–463 moisture, 452–453 physical damage mechanical stress, 451 thermal cycling and strains, 452 power fuses, 464–465 tracking, 453 Symmetrical current wave, 384–385 Synchronous generators, temperature rise for, 569 Synchronous motor, 551, 568 System neutral grounded system, 666 T TDMS 2000 L DGA monitoring system, 293–294 Temperature coefficient, 618 Temperature correction factors, 102, 104 Temperature vs insulation resistance curve, 619 Terminal markings for AC motors and generators, 556 of machines, 556–557 Terminal voltage, 608–610 Testing and test methods, electrical power equipment circuit breaker time–travel analysis, 31 fault gas analysis, 31–32 grounding electrode system, 31 infrared inspection, 32 insulating liquids, 30 protective device, 30–31 routine maintenance, 28–29 solid insulation, 29–30 special maintenance, 29 start-up/commissioning type, 28 Testing methods, cable AC hi-pot testing, 336–337 AC resonance testing definition, 346 variable frequency, 347–348 GCA testing, 350 hi-pot withstand testing DC hi-pot test, 349 60 Hz hi-pot test and AC resonant test, 349 VLF hi-pot test, 349–350 insulation resistance and DC hi-pot testing, 335–336 PD testing characteristics, 341 data analysis and documentation, 344–346 diagnostics tests, 351 magnitude calibration, 343 multiterminal testing, 342 off-line PD diagnostics, 351–352 on-and off-line detection system, 342 online PD diagnostics, 351 sensitivity assessment, 343 voltage stress, 343–344 PF and DF testing, 337–338 VLF testing advantages and disadvantages, 341 cosine-rectangular waveform, 340 diagnostic testing, 338–339 sinusoidal waveform, 340 Test Procedures for Synchronous Machines, 569 T-frame motors, voltage variation effects, 609 Thermal stress, harmonics copper losses, 745–746 dielectric losses, 747 iron losses, 746–747 Three-phase machine insulation, 178 Three-phase short circuit, 389 Three-phase transformers configurations, 248–249 polarity of, 247 terminal marking, 249–250 Three-winding transformers DC testing of, 108 insulation circuit of, 161 PF tests on, 162 test connections for insulation resistance of, 109 Time-based maintenance (TBM) strategy, Time-delay units, electromechanical relays, 511–512 Time-domain reflectometer (TDR) method, 371–372 www.TechnicalBooksPdf.com DK4058_C015.indd 958 11/8/2008 12:38:22 PM Index 959 Torkel programmable load unit battery load tester, 426 Torque characteristics of various motors, 567 for motors, 565 produced by electric motor, 565 Total fault gas analysis (TCGA), 204, 206 Total harmonic distortion (THD), 606 Touch potential measurement method, ground resistance step potential, 703 touch potential, 702 values, 704 vs fall-of-potential measurements, 703 Transformer bushing classification of, 164 PF tests on core insulation and tap insulation, 164–167 insulation of bushing without tap, 165, 167 noncondenser-type bushings, 167–168 problems in, 185, 187 Transformer core ground testing, 286 Transformer correction factor (TCF), 500, 502 Transformer differential protection scheme primary injection test, 539 testing levels, 538 Transformer excitation current test, 168–170, 185 Transformer insulating fluids, PF test of, 170–171, 187 Transformers applications distribution transformer, 238–239 network and arc-furnace transformers, 239 rectifier and power transformers, 240 characteristics basic impulse insulation level (BIL), 253 cooling properties, 251–252 kVA and voltage ratings, 251 short-circuit conditions, 252 sound and impedance levels, 252–253 components iron core, 242 primary winding, 241 secondary winding, 241–242 connection and circuit diagram, 240 construction techniques core construction, 238 tank construction, 237 copper and core losses, 242 definition, 235 fundamental concepts equivalent and vector diagram of, 243 leakage impedance, 244–245 percentage equivalent circuit, 245–246 voltage vs current, 244 insulating medium dry-type transformers, 236 liquid-filled transformers, 236–237 online monitoring systems bushings and lightning arrestors, 296–298 DGA testing, 292–296 diagnostics, 296 preventive maintenance dry-type transformers, 255–263 installation, acceptance, and maintenance, 253–255 liquid-type transformers, 263–275 single-phase transformers additive polarity, 247 subtractive polarity, 246–247 testing AC hi-pot test, 276 alternative TTR test, 279–280 DC winding resistance, 285–286 FRA testing, 282–285 induced potential test, 281–282 polarity, 281 polarization recovery voltage test, 286–291 transformer core ground test, 286 TTR capacitor, 280–281 TTR test, 277–279 three-phase transformers configurations, 248–249 polarity, 247 www.TechnicalBooksPdf.com DK4058_C015.indd 959 11/8/2008 12:38:22 PM Index 960 terminal marking, 249–250 Transformers, DC testing of DC hi-pot test cautions and considerations in, 112–113 procedure for, 111–112 for routine maintenance, 113 dielectric absorption test, 110 insulation resistance measurement test connections for, 107–108 test procedures, 107 variables affecting, 106 Transformers, harmonics effects, 748 K-factor data sources, 751 dry-type, 750 normalized method, 749–750 UL method, 749–750 overheating, 751 Transformers, PF testing prerequisite conditions for, 158 problems in, 185 of three-winding transformer, 162 two-winding transformers HV and LV bushing, 159 test connection arrangements for, 160–161 Transformer turns ratio (TTR) testing dry-type transformer, 259 liquid-filled transformer, 266–267 Triangular wave, current-limiting fuse, 389 TTR capacitor testing, 280–281 Tuned inductor and capacitor (LC) filters, 642 Two-winding transformers insulation system, 158–159 PF tests on HV and LV bushing, 159 test connection arrangements for, 160–161 U Underwriters laboratory (UL) method, 748–750 Ungrounded specimen test mode, 155 Ungrounded system BÍ fault to ground, 667 definition, 666 grounded neutral systems, 668 grounding impedance type, 675 wye-zigzag grounding transformer, 674 normal condition, 667 Uninterruptible power supply battery system, 480 electrochemical pretesting, 484–486 mechanical inspection, 481–482 precharge electrical inspection, 482–484 configuration, 815 rotary UPS (RUPS) system, 816 static UPS (SUPS) system, 815–816 testing background, 477–478 combined test, 480 preinstallation checks and tests, 478–480 U.S Federal Aviation Administration (FAA), 354 U.S Nuclear Regulatory Commission (NRC), 355 UST mode, see Ungrounded specimen test mode Utility-type cable, 301 V Vacuum breaker, 396, 400 Vacuum circuit breaker checks, 399 vacuum bottles and disconnect fingers, 400 Vacuum dehydrator, model BA-D-H1800, 216 Valve-regulated lead–acid (VRLA), 421 Variable current inverters (VCI), 638 Variable frequency drives (VFDs), 604–605, 635 application guide for, 641–643 classifications of, 638 Variable speed drive (VSD), 635 Variable voltage inverters (VVI), 638–639 Varying-speed motor, 556 www.TechnicalBooksPdf.com DK4058_C015.indd 960 11/8/2008 12:38:22 PM Index 961 VDE electrode, see Dielectric breakdown voltage test Very low-frequency (VLF) testing advantages and disadvantages, 341 cosine-rectangular waveform, 340 diagnostic testing, 338–339 sinusoidal waveform, 340 Viscosity, insulating fluids, 224 VLF test, 146 Voltage/potential transformers (VTs), 500 accuracy classes, 502 ANSI standard burdens for, 502 ratings of, 502 Voltage regulators buck–boost regulators type, 810–811 constant type, 811 constant voltage transformers (CVTs), 811–812 line type, 809–810 tap changer type, 810 Voltage source inverter (VSI), 639 Voltage waveform, 639 Volumetric leakage current, 100 Wecosol insulating fluid, 220 drying, reprocessing, 222 receiving and handling, 221 sampling, 221–222 Wiring and grounding, power quality continuity of conduit/enclosure grounds, 824 dedicated feeders and direct path routing, 825 equipment grounding conductor impedance, 824–825 grounding electrode resistance, 825 isolated ground (IG) and conduit ground systems, 825 load phase and neutral currents, 824 measurements, 823–824 neutral conductor impedance, 825 N–G bonds, 824 separately derived system (SDS), 825 Wound-rotor motors, 551 X XLPE, thermosetting compound, 304 W Water content test, 202 Water treeing, 331–332 Z Zero sequence harmonics, 637 www.TechnicalBooksPdf.com DK4058_C015.indd 961 11/8/2008 12:38:22 PM www.TechnicalBooksPdf.com DK4058_C015.indd 962 11/8/2008 12:38:22 PM www.TechnicalBooksPdf.com ... Maintenance and Testing, Second Edition, Paul Gill www.TechnicalBooksPdf.com DK4058_C000.indd ii 11/20/2008 10:17:57 AM ELECTRICAL POWER EQUIPMENT MAINTENANCE AND TESTING SECOND EDITION Paul Gill Boca... Protection: Theory and Practice, Y G Paithankar Electrical Insulation in Power Systems, N H Malik, A A Al-Arainy, and M I Qureshi Electrical Power Equipment Maintenance and Testing, Paul Gill Protective... Principles and Applications, Third Edition, J Lewis Blackburn and Thomas J Domin 31 Electric Power Distribution Reliability, Second Edition, Richard E Brown 32 Electrical Power Equipment Maintenance and