PD Test Report (CGP-2)
PD Test Report (CGP-2)
For
IOCL GUJARAT
Document ID : RPT_IOCL_GR_CGP2_CM_TST_V004
This document is for restricted circulation. No part of this document shall be reproduced, stored in retrieval system or transmitted
in any form or by any means – recording, photocopying, electronic and mechanical without prior permission of NCEPL.
Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO : 26807898 Dated: 06/02/21)
Reference:
Tender No JC20ELT221
Customer Details:
Contents
1 Executive Summary ................................................................................................... 4
3 Methodology ............................................................................................................... 6
a) PD-74 ..................................................................................................................................................................... 6
b) PD-30 ..................................................................................................................................................................... 6
c) Prycam Portable ..................................................................................................................................................... 6
d) PD-13 ..................................................................................................................................................................... 6
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Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO : 26807898 Dated: 06/02/21)
1 Executive Summary
Background:
Navitus Controls & Equipment (P) Ltd (NCEPL) received a contract from IOCL Gujarat refinery for online partial
discharge monitoring of 33 kV cables, HT transformer & motor termination box, Transformer main tank, 33 kV,
11 kV, 6.6 kV switchgears. The contract has defined the test procedures and also mentioned the type of
sensors that are to be used for testing each of the target assets. However, NCEPL not only complied with the
stated procedures and the type of sensors specified against each type of the asset but also deployed additional
sensors to achieve better sensitivity for the tests performed. The following table describes the sensors specified
in the contract and the additional tests performed by NCEPL team for achieving higher sensitivity and data
comparison among various sensors for better accuracy.
11 KV & 33 KV SWGR- 66
6.6 KV SWGR- 23
11 KV & 33 KV Trafo terminal box- 11
NCEPL team has followed a proven testing methodology and have collected the On Line PD data of these
target assets for detail analysis. Depending on the outcome of the analysis, NCEPL team has classified the
assets into different categories based on their criticalities. NCEPL team has also provided specific
recommendations against each type of criticality. Recommendations provided are based upon NCEPL
experience against various types of discharges.
The progression of PD is a complex activity and depends on many factors making it almost impossible to
predict the time to failure for these PD pulses. It is through repeated testing IOCL has to determine the trend
analysis and a fast-increasing trend is what is most critical and requires immediate intervention. Hence it is
helpful to have the failure history of the target assets before any On Line PD Monitoring is performed on an
asset.
The assets with criticality ORANGE should be immediately inspected. The detailed recommendations were
provided in the detailed report later in the document. However, the criticality marked in YELLOW shall also be
inspected as per the recommendations. Failure history shall be shared for more accurate criticality assignment.
Conclusion:
th
NCEPL team has completed the 7 phase of the testing and shall undertake the next phase in close
coordination with the IOCL team. Meanwhile, NCEPL urges IOCL to open the assets marked critical and look
for physical marks/ traces of PD in these assets. If found these deteriorations need to be fixed and the assets
can be re-tested after that.
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Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO : 26807898 Dated: 06/02/21)
Navitus Controls & Equipment (P) Ltd (NCEPL) received an order from M/S India Oil Corporation
Limited, Gujarat refinery for the online partial discharge testing of the following:
1. Condition assessment of HT 11/33 kV switchgears- 1200 EA
2. Localization of PD activity in 11/33kV switchgears- 100 EA
3. Online PD testing of 6.6kV switchgears- 1848 EA
4. Localization of PD activity in 6.6 kV switchgears- 50 EA
5. Online PD testing of 33 kV cables- 880 EA
6. Cables, cable joints & end termination- 360 EA
7. Diagnostic testing of HT cables- 20 EA
8. 72 hrs continuous monitoring of PD in critical cables- 10 EA
9. Online PD testing of transformer terminal box & motor terminal box- 2240 EA
10. PD monitoring of transformer main tank through UHF drain valve sensors- 10 EA
11. Diagnostic testing of transformers- 8 EA
12. Condition monitoring of HT/ LT motors- 5 EA
13. Diagnostic testing of VCBs of HT panels- 10 EA
Testing modalities were defined by IOCL in the tender as follows:
1. For 11 & 33kV switchgears, PD monitoring shall be done in UHF range using UHF sensors.
2. For PD localization, HFCT/ UHF/ Ultrasonic/ offline PD test shall be carried out for locating the PD in
the switchgear (33 kV & 11kV)
3. For 6.6 kV switchgears airborne acoustic & TeV technology shall be used for PD identification &
localization.
4. For 33kV cables, cable terminations and the whole cable shall be tested through EMI/ HFCT based
sensors & TeV or UHF sensors at the terminals.
5. Critical cables shall be subjected to 72 hrs of continuous monitoring.
6. 6.6 kV transformer terminal box & motor terminal box shall be monitored using air-borne acoustic &
TeV. PD testing has also been done using EMI based sensors for HT motors.
7. PD identification inside the transformer tank shall be done through UHF drain valve sensors.
8. Location of PD in transformers shall be done through four acoustic & one HFCT sensor technology.
NCEPL engineers used multiple On Line PD Testing equipment to ascertain the test results as per the
technology requirement guided in the work order/ tender. The equipment that were used are:-
PD-13 (Acoustic & HFCT based device for location analysis in switchgears
Failure history of each asset tested (if any) shall be provided by IOCL for more accurate
prediction. The failure history (or previous PD test readings) of the assets shall be mandatory
for providing recommendations after the first round of test.
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Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO : 26807898 Dated: 06/02/21)
To conclude NCEPL would like to thank IOCL for giving this opportunity to undertake the On
Line PD Testing for their critical Cables/ Transformers & Switchgears.
3 Methodology
NCEPL deployed four partial discharge monitoring devices for comprehensive PD monitoring of the
assets listed in the work order of IOCL to NCEPL. The devices are:-
a) PD-74
b) PD-30
c) Prycam portable
d) Prycam Grids
e) PD-13
f) PD-71
a) PD-74
PD-74 is an HFCT based Cable PD monitoring device. It has three channels viz: Acoustic channel,
High frequency channel & Ultra high frequency channel. It has the following features:-
Real-time PD measurement with provision for Acoustic, HF & UHF range of measurements
in one single unit.
Provision for both Wideband & Narrow band spectrum measurement & analysis.
PRPD, 3D & PD Expert features are available in the unit itself. No requirement of laptop at
site as the unit has a well-defined HMI.
Apart from cables it can also be used for PD measurements in GIS, AIS & HV Switchboards.
b) PD-30
The PD-30 has the following features:-
PD-30 is a TeV& Acoustic measuring instrument.
Data archiving capability in the acquisition unit itself. So it can be easily handled at site for
data acquisition & viewing.
PD-30 is suitable for Cables & HT switchgear.
c) Prycam Portable
The Prycam portable is an EMI antenna based PD monitoring device. It captures PD signals in high
frequency range. The device has the following features:-
Traffic light indication (Green/Yellow/Red) in the power cycle providing an easy
understanding of the health of the asset (Basic mode).
PRPD, Spectrum, Pulse characteristics using waveform analysis, PRPD data filter, Pulse
count, intensity & amplitude for more refined and detailed analysis if the Traffic light is Red
(Advanced/Premium mode).
Data saving option along with the feature for uploading the data in Prysmian cloud for data
retrieving & analysis at a later stage using any i-pad with Prycam software installed with all
the data & photographs from any location.
d) PD-13
NCEPL followed testing methodology at stipulated in the tender and scope of work from IOCL.
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Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO : 26807898 Dated: 06/02/21)
However, NCEPL also performed additional tests to diagnose/ corroborate a defect once some suspicious PD
activity is observed from the tests stipulated by IOCL.
The additional tests performed by NCEPL (asset specific) upon capturing some suspicious discharges are as
follows:
Type of asset Tests performed as per Additional tests Ideal methodology for
SOW in the tender performed by NCEPL data corroboration
(additional)
11 kV s/w gears UHF based PD test AA & TeV Contact type acoustic test
in addition along with EMI
test for data corroboration
6.6 kV s/w gears AA & TeV UHF based PD test at the Contact type acoustic test
panels where highly in addition along with EMI
suspicious activities were test for data corroboration
observed
Transformer terminals AA & TeV test EMI test
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Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO : 26807898 Dated: 06/02/21)
The list of the critical PDs observed and physically corroborated to avoid failure in the near future are as follows:-
Substation Name Feeder Name Voltage rating Date of PD Type of PD detected & Remarks
identification rectified
CGP-II SWBD-101 33 kV 28-03-2023 PD Sound in the amplitude of After replacing the breaker, we tested
Panel no-16 (19/78) comes from front side of the panel again and found panel is
Panel name- the panel. We inform this to IOCL free from PD.
33 KV Distribution and opening the panel IOCL found
SWBD HT 104 looseness in JAW contact.
CGP-II SWBD-104 33 kV 27-03-2023 PD found from Cable termination After opening the panel IOCL found
Panel no-2 Chamber in the amplitude of broken stands in CT’s equipotential
Panel name- (17/74). wire. After repair work we tested the
S/S-39 (BUS-B) panel again and No major PD sound
was observed.
SS-28 SWBD-252 6.6 KV 24-03-2023 PD found from Cable termination After opening the panel IOCL found
Panel no-34 Chamber in the amplitude of CT’s equipotential wire is completely
Panel name- (25/84). disconnected from CT. After repair
Motor FDR 1010- work we tested the panel again and
KM-02A found panel is completely free from
PD.
SS-8C SWBD-HT 6.6 KV 29-03-2023 PD found from Cable termination After opening the panel IOCL found
Panel no-11 Chamber in the amplitude of PD marks between Y and B phase
Panel name- (17/112). Cable.
I/C FROM HT S/S
Well-B To C FDR-15
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Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO : 26807898 Dated: 06/02/21)
2 2 DTR-1 4 5 0
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Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO : 26807898 Dated: 06/02/21)
15 5 AIR COMP-016 4 8 0
INCOMER-1 (FROM 33/6.9KV
16 6 3 6 0
TRAFO)
17 8 BUS PT (SECTION-1) 4 3 0
18 10 TRUNKING PANEL 4 6 0
19 11 BUS PT (SECTION-2) 3 8 0
33 kV Switchgear Panel
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Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO : 26807898 Dated: 06/02/21)
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Test Report for On Line Partial Discharge Testing at IOCL Gujarat
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Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO : 26807898 Dated: 06/02/21)
50 12 Incomer-2 From HT-101B 4 5 0 -30.8 7
51 13 S/S-38 (BUS-A) 5 4 0 -33.2 13
Re-Test for new
52 14 S/S-39 (BUS-A) 5 7 9 -32.6 11 Noise PD Inception
Re-Test for
53 15 GRE-3 6 12 0 -33.2 17 Minor acoustic PD
Trending
Re-Test for new
DTR-5 (Outgoing to PMCC-3
54 16 5 4 0 -35.6 4 Noise PD Inception
I/C-1)
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Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO : 26807898 Dated: 06/02/21)
ACOUSTIC TEV
Noise
SL. Panel Observation and
Date level Feeder Name Pulses Amplitu Action
No. No. Amplitude Trend
ambient per de
(dBµV)
second (dBmV)
SS-CGP 2 (33 KV Switchboard HT-101)
NCEPL immediately inform this
to IOCL. On Opening the Panel
Form Moderately High PD found
33 KV Distribution Switch IOCL Found Mechanical
1 28-03-2023 2 16 front 19 78 0 from the front side of the
board HT 104 problem in Breaker Jaw
door panel.
contact. IOCL Perform
necessary repair work.
SS-CGP 2 (33 KV Switchboard HT-103)
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Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO : 26807898 Dated: 06/02/21)
2nd Re-test for trending on of 33 kV Switch Gear
ACOUSTIC TEV
Noise
SL. Panel Observation and
Date level Feeder Name Pulses Amplitu Action
No. No. Amplitude Trend
ambient per de
(dBµV)
second (dBmV)
SS-CGP 2 (33 KV Switchboard HT-101)
After repair work, Minor
33 KV Distribution Switch
1 28-03-2023 2 16 12 98 0 PD from the front side of Re-test for trending
board HT 104
the panel found.
SS-CGP 2 (33 KV Switchboard HT-104)
. On Opening the Panel IOCL
Increases in PD Value
Found one of the CT’s
2 27-03-2023 2 2 SS-39 (BUS-B) 17 74 21 from previously tested on
Equipotential Wire is
25-03-2023
disconnected from HT BUS.
ACOUSTIC TEV
Noise
SL. Panel Observation and
Date level Feeder Name Pulses Amplitu Action
No. No. Amplitude Trend
ambient per de
(dBµV)
second (dBmV)
SS-CGP 2 (33 KV Switchboard HT-104)
After repair work, Some Minor
1 28-03-2023 2 16 SS-39 (BUS-B) 7 24 9 No Critical PD Found PD found from the front side of
the panel found.
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Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO : 26807898 Dated: 06/02/21)
Transformer
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Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO : 26807898 Dated: 06/02/21)
PD from
40/45 Cable
11 GTR-6 34500/11000 V 11 KV 1 90.0 53.4 46.2 3
MVA termination
Chamber
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at
Test Report for On Line Partial Discharge Testing at IOCL Gujarat
Refinery (WO No.- 26807898 Dated: 06/02/21
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at
S/S-CGP-2 (GTR-6)
Test Data
PRPD
Frequency Spectrum
Pulse Shape
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