TRE - 72064N - TIS Rev-01

TEST INSTRUCTION SCHEDULE OF 95KVp/ 1000mA EC_HVR
FOR ESP
PROJECT: 1x660MW BHUSAWAL THERMAL POWER STATION UNIT-6
Owner: Maharashtra State Power Generation Co. Ltd.
Owner Consultant: Development Consultants Private Ltd.
BHARAT HEAVY ELECTRICALS LIMITED JHANSI
TITLE: TEST INSTRUCTION SCHEDULE OF 95KVp/ 1000mA EC_HVR FOR ESP
DRAWING NO TRE/72064N/TIS REV 01

BHARAT HEAVY ELECTRICALS LIMITED, JHANSI
MAHARASHTRA STATE POWER

GENERATION CO. LTD.
BHUSAWAL T.P.S UNIT-6: 1 X 660 MW
DEVELOPMENT CONSULTANTS PVT. LTD.
CONSULTING ENGINEERS. VASHI, NAVI MUMBAI
Doc No.: TRE/72064N/TIS REV: 01

RATING: 95 KV peak, 1000 mA (average) DC, High Voltage Rectifier Transformer (HVR) for E.S.P
(Mark V)
Test Instruction Schedule

The following tests shall be performed on the above HVR transformer - generally in accordance with IS-
2026-1977 (wherever applicable) and Functional Test Procedure TP: 109.
Routine Tests [Generally as per IS-2026]

A. Outside the tank (in air): Before the connection of the transformer with rectifier, AC Reactor, DC
Choke etc. and done internally by BHEL.
1. Core: 2 KV ACrms withstand test at 50 Hz for 1 minute.
2. Winding Resistance: HV and LV windings.
3. Ratio Test.
B. Inside the tank (under Oil): After the connection of the transformer with rectifier, AC reactors, RF
choke etc.
i) Check for Oil:
a) BDV - 30 KV (min)
b) PPM - 50 ppm (max)
c) Resistivity - record for reference
d) Tan Delta - record for reference
ii) Insulation resistance between H-L, H-E & L-E
iii) Applied voltage test between

a) L-E at 3 KV for 1 minute at 50 Hz.
b) H-E at 10 KV for 1 minute at 50 Hz.
iv) Induced over voltage test at 1.5 x Normal volts at 100 Hz for 1 minute (1.5 x 373.5 V).
v) No load loss and no load current at 50 Hz at

a) 373.5 Volts (i.e. 415 – 10% V) (Guaranteed Loss = 450 W + IS Tol.)
b) 415 Volts (Loss is Guaranteed at 373.5 V)
c) 456.5 Volts (i.e. 415 + 10%)
vi) Load loss and impedance voltage at rated DC output current
(Guaranteed Loss = 4000 W + IS Tol.)
vii) DC Voltage measurement between AS1 and AS2 at rated mA current after shorting AS2 to
ground.
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TRANSFORMER ENGINEERING
GENERATION CO. LTD.

(Mark V)
viii) DC Voltage measurement between AS2 and AR in no load condition of transformer at

a) 70 KV DC output
b) 95 KV DC output
ix) Check on critical dimensions:
a) Between rollers (Dimension A & B)
b) (-) ve bushing flange to center line of HVR (Dimension C)
c) Height of (–) ve bushing from ground level (Dimension D)
Functional Tests [as per Functional Test procedure TP-109]

i) Resistive and Capacitive Load test from 0 to rated load inline with clause 2.3.0 of TP-109.
ii) Time over ride test (T/O test) in line with clause 2.4.0 of TP-109.
iii) Current Regulation test in line with clause 2.5.0 of TP-109
a) Line Regulation test
b) Load Regulation test
iv) Semi pulse Operation at different Charge Ratios: The transformer shall be tested at charge ratio
of 1, 3, 31 & 159 in line with clause 2.6.0 of TP-109.
v) S & T Control test in line with clause 2.7.0 of TP-109.
vi) Spark test inline with clause 2.8.0 of TP-109.
vii) Spark Simulation test inline with clause 2.9.0 of TP-109.
viii) Resistive load test from ‘0’ to rated load inline with clause no. 2.12.0 of TP-109.
ix) Fault Annunciation test on HVR inline with clause no. 2.10.0 of TP-109: For the following
components individual test records shall be verified. After assembling with HVR wiring
continuity shall be checked.
a) Buchholz relay
b) Oil Temperature Indicator
c) Magnetic Oil Level Gauge
Page 2 of 9
GENERATION CO. LTD.

(Mark V)
TYPE TESTS [On one unit only]

i) TEMPERATURE RISE TEST:-
Temperature rise test shall be conducted by Short circuit method. Alternating voltage at 50 Hz shall be
applied to LV winding keeping HV shorted - to feed total losses corresponding to rated DC current of
1000 mA. (i.e. No-Load Loss of transformer + Load Loss of Transformer at 75 °C + Diode Loss + Loss of
AC Reactor). Power supply shall be obtained from MG set of test plant.
Top oil temperature rise shall be monitored by a thermometer placed in oil filled thermometer pocket
provided on the tank cover. Input power shall be maintained at a steady value equal to total losses.
The test shall be continued until 4 consecutive hourly readings of top oil temperature rise are obtained
with variation of not more than 1° C per hour. The voltage shall then be adjusted to flow full load rated
current (1000mA) for one hour. LV hot resistance shall then be measured for determination of winding
temperature.
HV winding hot resistance measurement is not possible since it is connected with rectifiers.
The temperature rise shall be computed from the hot winding resistance of the LV winding.
Guaranteed Values:
Top oil Rise : 50 °C
Winding Rise : 55 °C
ii) LIGHTNING IMPULSE TEST:-

Full wave lightening impulse test shall be conducted. The impulse test sequence shall be applied to HV
winding and the LV winding shall be earthed along with the tank. The impulse shall be negative
polarity and shall be applied in following sequence.
a) One reduced full impulse (50 % to 75 %)

b) Three 100 % full impulse
The full standard lightening impulse shall be 250 KVp, 1.2 ± 30 % / 50 ± 20 % microsecond.
Impulse test shall be conducted on the transformer only and HV Rectifier, HF Choke, AC Reactor, HV
Resistor Board shall be disconnected & removed from the tank before impulse test.
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GENERATION CO. LTD.

(Mark V)
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GENERATION CO. LTD.

(Mark V)
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GENERATION CO. LTD.

(Mark V)
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(Mark V)
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GENERATION CO. LTD.

(Mark V)
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GENERATION CO. LTD.

(Mark V)
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TRE - 72064N - TIS Rev-01

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TEST INSTRUCTION SCHEDULE OF 95KVp/ 1000mA EC_HVR

PROJECT: 1x660MW BHUSAWAL THERMAL POWER STATION UNIT-6

Owner: Maharashtra State Power Generation Co. Ltd.

Owner Consultant: Development Consultants Private Ltd.

BHARAT HEAVY ELECTRICALS LIMITED JHANSI

TITLE: TEST INSTRUCTION SCHEDULE OF 95KVp/ 1000mA EC_HVR FOR ESP

DRAWING NO TRE/72064N/TIS REV 01

MAHARASHTRA STATE POWER

Doc No.: TRE/72064N/TIS REV: 01

Test Instruction Schedule

Routine Tests [Generally as per IS-2026]

iii) Applied voltage test between

v) No load loss and no load current at 50 Hz at

Doc No.: TRE/72064N/TIS REV: 01

Test Instruction Schedule

viii) DC Voltage measurement between AS2 and AR in no load condition of transformer at

Functional Tests [as per Functional Test procedure TP-109]

Doc No.: TRE/72064N/TIS REV: 01

Test Instruction Schedule

TYPE TESTS [On one unit only]

ii) LIGHTNING IMPULSE TEST:-

a) One reduced full impulse (50 % to 75 %)

Doc No.: TRE/72064N/TIS REV: 01

Test Instruction Schedule

Doc No.: TRE/72064N/TIS REV: 01

Test Instruction Schedule

Doc No.: TRE/72064N/TIS REV: 01

Test Instruction Schedule

Doc No.: TRE/72064N/TIS REV: 01

Test Instruction Schedule

Doc No.: TRE/72064N/TIS REV: 01

Test Instruction Schedule

Doc No.: TRE/72064N/TIS REV: 01

Test Instruction Schedule

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