HIGH VOLTAGE ENGINEERING

By

Dr. K Durga Syam Prasad

 UNIT V

High Voltage Testing Electrical Apparatus

 UNIT 5

1. Testing of insulators and bushings

2. Testing of isolators and circuit breakers

3. Testing of cables

4. Testing of transformers

5. Testing of surge arresters

6. Radio interference measurements.

3
Ultra High Voltage More than 800 KV

4
 1. INTRODUCTION
⚫ Purpose of the testing: To ensure that the electrical
equipment's are capable of withstanding the overvoltage's
that are met with in service.

1. Testing of insulators and bushings

2. Testing of isolators and circuit breakers

3. Testing of cables

4. Testing of transformers

5. Testing of surge arresters

 2. CLASSIFICATION OF HIGH
VOLTAGE TESTS
⚫Destructive Test

⚫Normally the equipment underwent

destructive test cannot be used in the service.

⚫Test voltage is higher than its normal working

voltage.
⚫Breakdown test.
Con’
t
⚫Non-Destructive Test
⚫Mainly done to assess the electrical
properties, eg. Resistivity, dielectric
constant and loss factor.
⚫The apparatus is not destroyed during the
test and can be used again.
2.2 TYPES OF TESTS
1. Routine Tests
⚫ Made by the manufacturer on every finished piece of
product.
⚫ To fulfills the specifications.
2. Type Tests
⚫ Performed on each type of equipment before their
supply on a general commercial scale – demonstrate
performance characteristics.
⚫ No need to repeat the test unless changes are made in
the design of the product.
Con’
t
3. Maintenance Tests
⚫Usually carried out after
maintenance/repair of the equipment.
⚫Conducted according to schedule
provided.
⚫Purpose of the test : To ensure the
equipment lifetime is achieved.
Types of
tests

The range of
high voltage
tests depends on
the nature of
the equipment
being tested
3.0 TEST
VOLTAGES

Direct
power-
frequency voltage
alternating s
voltages (DC)
(AC)

impuls
e
voltage
s.

TEST
Con’
t
⚫Test with Direct Voltage (DC).
⚫Mainly to test equipment used in HVDC
transmission systems.

⚫Rate of voltage rise above 75% of its

estimated final value should be about 2%
per second.
1. Testing of insulators and bushings

TESTS ON INSULATORS
 Type Test To Check The Design Features
 Routine Test To Check The Quality Of The
Individual Test Piece.
 High Voltage Tests Include
(i) Power frequency tests
(ii) Impulse tests

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14
TESTS ON INSULATORS
POWER FREQUENCY TESTS
(a) Dry and wet flashover tests:
 A.C voltage of power frequency is applied across the
insulator and increased at a uniform rate of 2% per second of
75% of there estimated test voltage, to such value that a
breakdown occurs along the surface of the insulator.
 If the test is conducted under normal conditions without any
rain –dry flashover test.
 If the test is conducted under normal conditions of rain –wet
flashover test
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(b) Dry and wet withstand tests(one minute)

 The test piece should withstand the specified

voltage which is applied under dry or wet
conditions for a period of one minute with insulator
mounted as in service conditions.
 The test piece should withstand specified voltage

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IMPULSE VOLTAGES

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 IMPULSE TESTS ON INSULATORS
 Impulse withstand voltage test:
 This test is done by applying standard impulse
voltage of specified value under dry conditions
with both positive and negative polarities of the
wave.
 If five consecutive waves do not cause a
flashover or puncture, the insulator is deemed to
have passed the test. If two applications cause
flashover,
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the object is deemed to have failed.
 Impulse flashover test:
This test is done by applying standard
impulse voltage of specified value. Usually,


the probability of failure is determined for

40% and 60% failure values or 20% and 80%
failure values, since it is difficult to adjust the
test voltage for the exact 50% flashover
values.
The average value of the upper and the lower
limits is taken.


The insulator surface should not be damaged

by these tests.


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 Pollution Testing:
Because of the problem of pollution of outdoor electrical


insulation and consequent problems of the maintenance

of electrical power systems,
The normal types of pollution are
(i)dust, micro-organisms, bird secretions, flies, etc.,
(ii) industrial pollution like smoke, petroleum vapours,
dust, and other deposits,
(iii)coastal pollution in which corrosive and salt layers are
deposited on the insulator surfaces,
(iv) desert pollution in which sand storms cause deposition
of sand and dust layers,
(v)ice and fog deposits at high altitudes and in polar
countries.

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 These pollutions cause corrosion, non-uniform
gradients along the insulator strings and surface of
insulators and also cause deterioration of the material.
 Also, pollution causes partial discharges and radio
interference.
 The popular test that is normally done is the salt fog
test.
 In this test, the maximum normal withstand voltage is
applied on the insulator and then artificial salt fog is
created around the insulator by jets of salt water and
compressed air.
 If the flashover occurs within one hour, the test is
repeated with fog
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TESTING ON BUSHINGS

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TESTING ON BUSHINGS
Power frequency tests
(a ) Power Factor-Voltage Test:
 Set up as in service or immersed in oil.
 Conductor to HV and tank to earth.
 Voltage is applied up to the line value in increasing steps and then
reduced.
 The capacitance and power factor are recorded in each step.
(b) Internal or Partial discharge Test:
 To find the deterioration or failure due to internal discharges
 Conducted using partial discharge arrangements
 Performance is observed from voltage Vs discharge magnitude.
 It is a routine test.
(c ) Momentary Withstand Test at Power frequency
 Based on IS:2009
 The bushing has to withstand the applied test voltage without flashover
or puncture for 30 sec.
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TESTING OF BUSHINGS
(d) One Minute withstand Test at Power Frequency
 Most common & routine test
 Test is carried in dry &wet for one minute.
 In wet test, rain arrangement is mounted as in service.
 Properly designed bushing should withstand without flashover for one
minute.
(e) Visible Discharge Test at Power Frequency
 Conducted based on IS:2009
 Conducted to determine radio interference during service
 Conducted in dark room
 Should not be any visible discharges other than arcing horns/ guard
rings.

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TESTING OF BUSHINGS
Impulse voltage tests:
 Full wave Withstand Test
 The bushing is tested for either polarity voltages
 Five consecutive full wave is applied
 If two of them flashed over, then 10 additional applications are
done.
 If the test object has withstood the subsequent applications of
standard impulse voltage then it is passed the test.
Chopper Wave withstand Test
 Sometimes done on HV bushings (220kV, 400kV and above)
 Switching surge flashover test is included for HV bushings.
 This is also carried out same as above full wave test.

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TESTING OF BUSHINGS
Temperature Rise and Thermal Stability Tests
 To observe the temperature rise and to ensure that it
doesn’t go into ‘thermal runaway’ condition.
 Temperature rise test is done at ambient temperature
(below 400C) at a rated power frequency.
 The steady temperature rise should not exceed 450C.
 Test is carried out for long time & increase in
temperature is less than 10C/hr.
 This test is enough to produce large dielectric loss and
thermal in stability.
 Thermal stability test is done for bushing rated for 132
kV above.
 Carried out on the bushing immersed in oil at max.
service temperature with 86% of normal system voltage.
 This is a type test for low rating and routine test for high
ratings.

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27
TESTING OF ISOLATORS AND CIRCUIT
BREAKERS
Isolator:
 Off-load or minimum current breaking mechanical switch.
 Explained according to “IS:9921 Part-1, 1981”.
 Interrupting small currents(0.5A): Capacitive currents of
bushings, busbars etc.,
Circuit Breaker:
 Onload or high current breaking switch
Testing of Circuit Breaker:
 To evalute,
 Constructional & operating characteristics
 Electrical characteristics

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TESTING OF ISOLATORS AND CIRCUIT
BREAKERS
Electrical Characteristics:
 Arcing voltage
 Current chopping characteristics
 Residual currents
 Rate of decrease of conductance of the arc space and the plasma
 Shunting effects in interruption
Physical Characteristics:
 Arc extinguishing medium
 Pressure developed at the point of interruption
 Speed of contact travelling
 Number of breaks
 Size of the arcing chamber
 Material and configuration of the circuit interruption

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TESTING OF ISOLATORS AND CIRCUIT
BREAKERS
Circuit Characteristics:
 Degree of electrical loading
 Applied voltage
 Type of fault
 Time of interruption
 Frequency
 Power factor
 Rate of rise of recovery voltage
 Re-stricking voltage
 Decrease in AC component of the short circuit current
 DC component of the short circuit current

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TESTING OF ISOLATORS AND CIRCUIT
BREAKERS
 Dielectric tests:
 Consists of over voltage withstand tests of power
frequency, lightning and switching impulse voltages
 Tested for internal & external insulation with CB in both
the open & closed position.
 Voltage in Open position >15% of that of closed position.
 During test, CB is mounted on insulators above ground to
avoid ground flash over.
 Impulse tests:
 Impulse test and switching surge tests with switching
over voltage are done.

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TESTING OF ISOLATORS AND CIRCUIT
BREAKERS
 Thermal tests:
 To check the thermal behaviour of the breakers
 Rated current through all three phases of the switchgear
is passed continuously for a period long enough to
achieve steady state conditions
 Temperature rise must not exceed 40°C when the rated
normal current is less than 800 amps and 50°C if it is 800
amps and above
 Contact resistances between the isolating contacts and
between the moving and fixed contacts is important.
These points are generally the main sources of excessive
heat generation.

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TESTING OF ISOLATORS AND CIRCUIT
BREAKERS
 Mechanical Test:
 To ensure the open and closing with out mechanical failure
 It requires 500(some times 20,000) operations without
failure and with no adjustment of the mechanism.
 A resulting change in the material or dimensions of a
particular component may considerably improve the life
and efficiency of the mechanism.

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TESTING OF ISOLATORS AND CIRCUIT
BREAKERS
Short circuit tests:
 To check the ability to safely interrupt the fault currents.
 To determine the making and breaking capacities at
different load currents
 Methods of conducting short circuit tests,
i. Direct tests
i. Using the power utility system as the source.
ii. Using a short circuit generator as the source
ii. Synthetic Tests

34
TESTING OF ISOLATORS AND CIRCUIT
BREAKERS
Direct tests -Using the power utility system as the source:
 To check the ability to make or break in normal load conditions or
short circuit conditions in the network itself
 Done during limited energy consumption
 Advantages:
1. Tested under actual conditions in a network
2. Special cases (like breaking of charging current of long lines, very short line
faults etc.,) can be tested
3. Thermal & dynamic effects of short circuit currents and applications of safety
devices can be studied
 Disadvantages:
1. Can be tested only in rated voltage and capacity of the network
2. Test is only at light load conditions
3. Inconvenience and expensive installation of control and measuring equipment
is required in the field.
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TESTING OF ISOLATORS AND CIRCUIT
BREAKERS
Direct Testing-Short circuit test in laboratories:
 To test the CBs at different voltages & different SC currents
 The setup consists of, Back up
breaker Making
 A SC generator Reactor Switch

 Master CB
Test device
 Resistors G

 Reactors and
CT

 Measuring devices Short Circuit Circuit

Testing Gen Capacitance

 The make switch initiates the circuit short circuit & master
switch isolates the test device from the source at the end of
predetermined time.
 If the test device failed to operate, master CB can be tripped.

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TESTING OF ISOLATORS AND CIRCUIT
BREAKERS
Synthetic Testing of CBs:
 Heavy current at low voltage is applied
 Recovery voltage is simulated by high voltage, small current
source
 Procedure:
 Auxiliary breaker 3 and test circuit breaker T closed, making switch 1 is
closed.  Current flows through test CB.
 At time t0, the test CB begins to open and the master breaker 1 becomes
to clear the gen circuit.
1 3 4 5 6
2

Ic Iv

Vc Cc C0 Cv
T

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TESTING OF ISOLATORS AND CIRCUIT
BREAKERS
 At time t1, just before zero of the gen current, the trigger gap 6
closes and high frequency current from capacitance Cv flows
through the arc of the gap
 At time t2, gen current is zero. Master CB 1 is opened
 The current from Cv will flow through test CB and full voltage will
be available
 At the instant of breaking, the source is disconnected and high
voltage is supplied by auxiliary CB 4
1 3 4 5 6
2

Ic Iv

Vc Cc C0 Cv
T

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TESTING OF CABLES
Different tests on cables are
i. Mechanical tests like bending test,dripping and drainage
test, and fire resistance and corrosion tests
ii. Thermal duty tests
iii. Dielectric power factor tests
iv. Power frequency withstand voltage tests
v. Impulse withstand voltage tests
vi. Partial discharge test
vii.Life expectancy tests

39
TESTING OF CABLES
Dielectric power factor tests:
 Done using HV Schering Bridge
 The p.f or dissipation factor ‘tan’ is measured at 0.5, 1.0, 1.66 and 2.0
times the rated phase-to-ground voltage of the cable
 Max. value of p.f and difference in p.f b/w rated voltage and 1.66 times
of rated voltage is specified.
 The difference between the rated voltage and 2.0 times of rated voltage
is also specified
 A choke is used in series with the cable to form a resonant circuit.
 This improves the power factor and rises the test voltage b/w the cable
core and the sheath to the required value when a HV and high capacity
source is used.

40
TESTING OF CABLES
High voltage testing on Cables:
 Power frequency HV A.C, DC and impulse voltages are applied to test
the withstanding capability
 Continuity is checked with high voltage at the time of manufacturing
 Routine test:
 Cable should withstand 2.5 times of the rated voltage for 10 mins
without damage in insulation
 Type test:
 Done on samples with HVDC & impulses
 DC Test:1.8 times of the rated voltage (-ve) applied for 30 mins.
 Impulse Test: 1.2/50µS wave applied. Cable should withstand 5
consecutive impulses without any damage
 After impulse test, power frequency & power factor test is conducted
to ensure that no failure occurred during impulse test.
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TESTING OF CABLES
Partial Discharge test:
i. Discharge measurement:
 Life time of insulation depends on the internal discharges. So, PD
measurement is important.
 In this test, weakness of insulation or faults can be detected
 Fig(i) and (ii) shows the connection to discharge detector through
coupling capacitor. F

C HV
(i)
D.D

F
F

C HV
Equivalent Circuit of Cable for discharges

(ii)

D.D
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TESTING OF CABLES
 If the coupling capacitor connected, transient wave will be
received directly from the discharge cavity and second wave from
the wave end i.e., two transient pulses is detected
 In circuit shown in fig (ii), no severe reflection is occurred except a
second order effect of negligible magnitude.
 Two transients arrive at both ends of the cable-super imposition
of the two pulses detected-give serious error in measurement of
discharge
ii. Location of discharges
 Voltage dip caused by discharge or fault is travelled along the length &
determined at the ends
 Time duration b/w the consecutive pulses can be determined
 The shape of the voltage gives information on the nature of discharges

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TESTING OF CABLES
iii. Scanning Method:
 Cable is passed through high electric field and discharge location is
identified.
 Cable core is passed through a tube of insulating material filled with
distilled water
 Four ring electrodes (two @ ends+two @ middle) mounted in contact
with water.
 Middle electrode given to HV. If a discharge occurs in the portion b/w the
middle electrodes, as the cable is passed b/w the middle electrode’s
portion, the discharge is detected and located at the length of cable.
iv. Life Test
 For reliability studies in service.
 Accelerated life tests conducted with increased voltages to determine the
expected life time.
1  K-Constant depends on Field condition and material
- 
n
Em Kt  n- Life index depends on material

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TESTING OF TRANSFORMERS
 Transformer is one of the most expensive and important
equipment in power system.
 If it is not suitably designed its failure may cause a lengthy and
costly outage.
 Therefore, it is very important to be cautious while designing its
insulation, so that it can withstand transient over voltage both
due to switching and lightning.
 The high voltage testing of transformers is, therefore, very
important and would be discussed here. Other tests like
temperature rise, short circuit, open circuit etc. are not
considered here.
 However,these can be found in the relevant standard
specification.

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TESTING OF TRANSFORMERS
 Induced over voltage test:
 Transformer secondary is excited by HFAC(100 to 400Hz) to about twice the
rated voltage
 This reduces the core saturation and also limits the charging current
necessary in large X-mer
 The insulation withstand strength can also be checked
 Partial Discharge test:
 To assess the magnitude of discharges
 Transformer is connected as a test specimen and the discharge
measurements are made
 Location and severity of fault is ascertained using the travelling wave theory
technique
 Measurements are to be made at all the terminals of the transformer
 Insulation should be so designed that the discharge measurement should be
much below the value of 104 pC.

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TESTING OF TRANSFORMERS
Impulse Testing of Transformer:
 To determine the ability of the insulation to withstand transient
voltages
 In short rise time of impulses, the voltage distribution along the
winding will not be uniform
 The equivalent circuit of the transformer winding for impulses is
shown in Fig.1.

Fig.1: Equivalent circuit of a transformer for impulse voltage

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TESTING OF TRANSFORMERS
 Impulse voltage applied to the equivalent sets up uneven voltage
distribution and oscillatory voltage higher than the applied
voltage
 Impulse tests:
 Full wave standard impulse
 Chopped wave standard impulse (Chopping time: 3 to 6S)
 The winding which is not subjected to test are short circuited and
connected to ground
 Short circuiting reduces the impedance of transformer and hence
create problems in adjusting the standard waveshape of impulse
generators

48
TESTING OF TRANSFORMERS
Procedure for Impulse Test:
 The schematic diagram of the transformer connection for impulse
test is shown in Fig.2

Fig.2: Arrangement for Impulse test of transformer

 The voltage and current waveforms are recorded during test.
Sometimes, the transferred voltage in secondary and neutral current
are also recorded.

49
TESTING OF TRANSFORMERS
Impulse testing consists of the following steps:
i. Application of impulse of magnitude 75% of the Basic Impulse Level (BIL) of
the transformer under test.
ii. One full wave of 100% of BIL.
iii. Two chopped wave of 115% of BIL.
iv. One full wave of 100% BIL and
v. One full wave of 75% of BIL.
 During impulse testing the fault can be located by general
observation like noise in the tank or smoke or bubble in the
breather.
 If there is a fault, it appears on the Oscilloscope as a partial or
complete collapse of the applied voltage.
 Study of the wave form of the neutral current also indicated the type
of fault.

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TESTING OF TRANSFORMERS
 If an arc occurs between the turns or from turn to the ground, a
train of high frequency pulses are seen on the oscilloscope and
wave shape of impulse changes.
 If it is only a partial discharge, high frequency oscillations are
observed but no change in wave shape occurs.
 Impulse strength of the transformer winding is same for either
polarity of wave whereas the flash over voltage for bushing is
different for different polarity.

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TESTING OF SURGE DIVERTERS
(i ) Power frequency spark over test
 It is a routine test.
 The test is conducted using a series resistance to limit the current
in case a spark over occurs.
 It has to withstand 1.5 times the rated value of the voltage for 5
successive applications.
 Test is done under both dry and wet conditions.
(ii ) 100% standard impulse spark over test
 This test is conducted to ensure that the diverter operates
positively when over voltage of impulse nature occur.
 The test is done with both positive and negative polarity
waveforms.
 The magnitude of the voltage at which 100% flashover occurs is
the required spark over voltage.
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TESTING OF SURGE DIVERTERS
(iii) Residual voltage test:
 This test is conducted on pro-rated diverters of ratings in the range 3 to 12 kV
only.
 Standard impulse wave of 1/50µS is applied, voltage across it is recorded.
 Magnitude of the current 2 X Rated current
 A graph is drawn b/w current magnitude and voltage across pro-rated unit and
residual voltage is calculated
 V1=rating of the complete unit
 V2=rating of the prorated unit tested
 VR1=residual voltage of the complete unit
 VR2=residual voltage of the prorated unit
 V1/V2= VR1/ VR2
 V1/= V2 .(VR1/ VR2)
 Let, VRM – Max. permissible residual voltage of the unit
Multiplying factor, r = (VRM /V1)
Diverter is said to be passed when VR2<rV2
53
TESTING OF SURGE DIVERTERS
HIGH CURRENT IMPULSE TEST ON SURGE DIVERTERS
 Impulse current wave of 4/10µS is applied to pro-rated arrester in
the range of 3 to 12kV.
 Test is repeated for 2 times
 Arrester is allowed to cool to room temperature
The unit is said to pass the test if
i. The power frequency sparkover voltage before and after the test
does not differ by more than 10%
ii. The voltage and current waveforms of the diverter do not differ in
the 2 applications
iii. The non linear resistance elements do not show any puncture or
flashover

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TESTING OF SURGE DIVERTERS
Other tests are
i. Mechanical tests like porosity test, temperature cycle tests
ii. Pressure relief test
iii. voltage withstand test on the insulator housing
iv. the switching surge flashover test
v. the pollution test

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