CBM Manual For PE

Condition Based Maintenance Manual for
Distribution Substation (PE)
September 2015
Asset Management Department

Distribution Division,
Tenaga Nasional Berhad
Wisma TNB Jalan Timur,
Petaling Jaya Selangor
Disclaimer: This Condition Based Maintenance Manual for Distribution Substation (PE) is a
document providing technicians, engineers, and managers of the Distribution Division of Tenaga
Nasional Berhad with an understanding of Condition Based Maintenance methodology. The
information in this document has been prepared in good faith and represents the Asset
Management Department’s intentions and opinions at the date of issue. The Asset Management
Department may change any information in this document at any time.
ii
Acknowledgement
We would like to express our deepest gratitude to the management of the
Distribution Division, for giving us the opportunity to develop the Condition
Based Maintenance Manual for Distribution Substation (PE).
Special thanks to Mr. Zahari bin Dollah, Mr. Roshimee Mustapha, Mr.
Mohammad Khuzairee b. Ibrahim, Ms. Komal Deep Kaur, Mdm. Noor Hanisa
bt Ali, Ms. Nursyahira Sharif, as well as the SL1M trainees, Ms. Sumaiyah bt
Mohamad Sani and Mr. Aizuddin b. Abd Rahim from Asset Management
Department, for their valuable contribution and assistance in developing this
manual.
The project team would also like to express our gratitude to Technical Experts
Mr. Young Zaidey B. Yang Ghazali and Mr. Sharizal B. Shamuri from Asset
Management Department and not forgetting Mr. Pairolani Bin Hj. Hashim
from ILSAS for their valuable input and guidance to develop this manual.
Our appreciation also goes to TNBR QATS staffs headed by Mr. Zulfadly Zardi
and team comprising Mdm. Nurul Farhana Yanti bt A.Ghani, Mr. Mohd
Fakhrurrazi bin Husain and Mr. Abu Sufian bin Abu Bakar for providing
information and data of equipments for maintenance testing.
We would also like to express our appreciation to TNB representatives from

the states comprising of Pn.Noradzlin bt Mat Zuki, Mr.Pershanta Kumar A/L
J.Raman, Mr.Paventhan A/L Salliah, Mr.Ng Wai Kean, Mr.Ganesh Kumar A/L
Balakrishnan, Ms. Nor Afni Bt. Mohamad Rudzalan, Mr. Khairulanwar Bin
Othman, Mr. Mohd. Hafizan Bin Mohd Yahya and Mr. Mohd. Khairil Bin Omar
for their continuous efforts and patience towards the successful completion
of this manual.
Thank you.
Pn. Hjh. Rosila bt. Dato’ Hj. Senan

General Manager
Asset Management Services
Asset Management Department
Distribution Division, TNB
iii
Foreword
VP Distribution Division,
Datuk Ir. Baharin Din
As Malaysia progresses to achieve Vision 2020, the

volume of substations installed in the distribution
system has also increased in tandem with the country’s
rapid economic development. With continuous
expansion of the distribution main intake substation
and its ever challenging environment, it is vital that the spirit of “do it right at
the first time” be instilled among the TNB personnel and appointed
contractors.
Although various technical and engineering circulars and guidelines have been
issued from time to time, it is found that discrepancies in standard practices
of Condition Based Maintenance for switchgear and transformer among states
are still widespread, thus affecting the performance and lifespan of the
switchgear and transformer. In view of this, it is timely that such a practical
handbook on Condition Based Maintenance of Distribution Substation (PE) is
produced for easy reference throughout TNB Distribution Division.
TNB Distribution Division through Distribution Asset Management

Department, in collaboration with ILSAS, TNBR QATS and TNB staff
representative from states have taken a step forward to develop this manual
which incorporates the latest technological changes in maintenance testing.
Therefore, I would like to take this opportunity to congratulate the project

team from the Asset Management Department, as well as ILSAS, TNBR QATS
and TNB staff representative from states for their impressive effort in
developing this useful Condition Based Maintenance Manual for Distribution
Substation (PE).
Thank you.
iv
Contents
Chapter 1 Introduction ..........................................................
. 1
1.1 Overview .................................................................................................... 1
1.2 Objec ves .................................................................................................. 2
1.3 Scope of This Manual................................................................................. 3
Chapter 2 Maintenance of Assets ..........................................

. 7
2.1 Overview .................................................................................................... 7
2.2 Methodology ............................................................................................. 8
2.3 Maintenance Scope ................................................................................... 9
2.3.1 Electrical Assets ...................................................................................... 9
2.3.2 Civil and Mechanical Work ................................................................... 11
Chapter 3 Switchgear ..........................................................

. 12
3.1 Preliminaries
.................................................................................................. 12
3.1.1 Air Insulated Switchgear (AIS).............................................................. 13
3.1.2 Ring Main Unit (RMU): Oil/Gas ............................................................ 16
3.2 Maintenance 20
3.2.1 Overview .............................................................................................. 20
3.2.2 Maintenance Intervals ......................................................................... 21
3.2.3 Tier 1 .................................................................................................... 22
3.2.3.1 Thermography .................................................................................... 23
3.2.3.2 Airborne Ultrasonic ............................................................................. 26
3.2.3.3 Internal Par al Discharge (TEV) .......................................................... 29
3.2.3.4 Visual Inspec on ................................................................................. 33
3.2.4 Tier 2 ................................................................................................... 36
v
3.2.4 Tier 2 .................................................................................................... 36

3.2.4.1 Insulation Resistance .......................................................................... 37
3.2.4.2 Oil Dielectric Test for OLU/HFU ........................................................... 43
3.2.4.3 Trip Test (On-Line Timing).................................................................... 47
3.2.4.4 Circuit Breaker Timing ........................................................................ 53
3.2.4.5 Vacuum Checks .................................................................................... 57
3.2.5 Tier 3 .................................................................................................... 62
3.2.5.1 PD Locator........................................................................................... 63
3.2.5.2 Power Frequency/AC Pressure Test ................................................... 65
3.2.5.3 Dielectric Dissipa on Factor (DDF ) Tan δ .......................................... 69

3.2.5.4 Contact Resistance .............................................................................. 73
3.2.6 Maintenance Test Summary for Switchgear........................................ 78
3.3 Maintenance Servicing Procedures ......................................................... 79
3.3.1 Off-Line Maintenance Services & Checks (for AIS Only) ...................... 79
3.3.2 Off-Line Maintenance Services (RMU) ................................................ 82

3.3.3 Fun onal Checks and Tests (for AIS only) .......................................... 84
3.3.4 Mechanical Interlock Checks (AIS) ...................................................... 84
Chapter 4 Transformers ....................................................... 87

4.1 Overview .................................................................................................. 87
4.2 Transformer Categories .......................................................................... 87
4.3 Distribu on Transformer Arrangement................................................... 87
4.4 Maintenance Tes ng .............................................................................. 90
4.4.1 Overview .............................................................................................. 90
4.4.2 Maintenance Intervals......................................................................... 92
vi
4.4.3 Tier 1 ....................................................................................................

.... 95
4.4.3.1 Visual Inspec on ............................................................................. 95
4.4.3.2 Infrared Thermography .................................................................. 95
4.4.3.3 Ultrasonic Scanning ........................................................................ 101
4.4.4 Tier 2 .................................................................................................... 103
4.4.4.1 ........................................................... 103
4.4.4.2 Insula on Resistance (IR) ................................................................ 104
4.4.5 Tier 3 .................................................................................................... 110
4.4.5.1 Turns Ra ..................................................................................... 110
4.4.5.2 Winding Resistance ........................................................................ 113
4.4.5.3 Oil Quality Analysis (OQA) ......................................................... 115
4.4.5.4 Dissolved Gas Analysis (DGA) ......................................................... 126
4.4.6 .................................................................... 133
4.4.6.1 Replacement/Retro-filling of Oil (Draining, Flushing and Refilling)..133
4.4.6.2
Resistance Tests ............................................................................ 134
4.4.6.3 Repair Work ................................................................................... 134
4.4.6.4 Maintenance Test Summary for Transformers ............................... 137
Chapter 5 Maintenance Management System ...................... 140

5.1 Overview of Maintenance Management System .................................... 140
5.2 Data Record & Monitoring ...................................................................... 142
5.3 Overview of ERMS-PM............................................................................. 143
5.3.1 Maintenance Planning/Upda n vity for PE 11KV......................... 143
5.3.2 ERMS - PM ............................................................................................ 144
vii
5.4 Appendices ............................................................................................... 149

Appendix 5-1: List of TNBD’s Business Areas and Sta n Codes ....................... 149
Appendix 5-2: Fun onal Loca on Naming Conven on – Level 2, 3 & 4........... 153
Appendix 5-3: Fun onal Loca on Naming Conven on – Level 4 & 5 .............. 154
Appendix 5-4: Fun onal Loca on Naming Conven on – Level 4, 5 & 6........... 155
Appendix 5-5: Example of Fun onal Loca .................................................. 156
Chapter 1 Introduction 1
1
Chapter 1 Introduction
1.1 Overview
Distribu on network assets are developed, operated and maintained to
provide distribu on of power to the consumers. In TNB Distribu on, these
assets that consist of various equipment are grouped as follows:-
Primary Systems
Secondary Systems (prote on relays and telecontrol equipment)
Electrical distribu on equipments are generally designed for a certain

economic service life. Equipment life is dependent on opera ng environment,
maintenance program and the quality of the original manufacture and
installa on. Beyond this service life period they are not expected to render
their services up to expecta on with desired efficiency. Equipment currently
in opera on in the distribu on grid system consists of various type and make.
In managing these assets, it is prudent for TNB to balance the cost and the risk
involved in maintaining the assets.
In line with industries pra ces in managing the asset and with the increasing
expecta on for maintenance to deliver improved performance, Distribu on
Division has prepared this Cond on Based Maintenance Manual for
Distribu on Substa on (PE).
2 Distribution Substation ( PE)
1.2 Objectives
1
The objec ves of this manual are as follows:-
Provide a standard maintenance level requirement and prac ces in TNB’s

Distribu on Division.
Op ize the maintenance cost and performance (reliability and
availability) of Distribu on network assets.
Assist State Maintenance Unit to plan, implement and monitor the
prescribed inspe on and maintenance strategies.
Ensure maintenance pra ces comply with statutory requirements.
Ensure equipment health, personnel and public safety, and security of
supply.
Assist in achieving Distribu on Division’s business plans and targets.
To ensure the effe ve implementa on of this manual in Distribu on Division

maintenance pra ce, subsequent procedures and work instru ons are to be
prepared by Asset Management Department. These documents shall
provide:-
Method, instru ons and checklist to carry out inspe on and

maintenance task.
Recommenda ons on the corre ve ac ons will be taken a er observing
findings/ results during inspec on and maintenance.
1.3 Scope of This Manual

1
The scope of this manual covers primary equipment in substations including
electrical and non-electrical.
Equipment in operation consists of a large population with variety of

manufacturers which can be difficult to maintain as the maintenance
procedures may be different from one to another. Thus this manual is
intended to serve majority of the equipment installed in TNB Distribution
system. Nevertheless, specific recommendations or instructions from the
manufacturer need to be adhered to where required
Chapter 2 – This chapter describes standard maintenance practices in TNB

Distribution Division for electrical and non-electrical assets.
Chapter 3 – Switchgear is the key components in the power system, hence it is

appropriate for analysis under a risk assessment program. Switchgear failure
can have significant economic impact due to long lead times in procurement,
manufacturing and installation in addition to high equipment cost. The
maintenance testing of switchgear can be divided into 3 Tiers.
Chapter 4 – In this chapter, it is clearly explain on the built up of transformer

and steps to perform transformer oil sampling. Maintenance testing of
transformer also divided into 3 Tiers assessment. Besides that, equipment
specifications, test procedures and test results on maintenance testing of
transformer explained.
Chapter 5 – Information about all observations during inspections, repair and

replacement work are properly recorded and documented in the ERMS-PM.
Besides that, steps to upload information of equipment into the system also
shown in this chapter.
4 Distribution Substation (PE)
1 In order to determine the maintenance interval of the equipment, the

Frequency Multiplier based on the equipment condition in the Maintenance
Frequency Matrix (Table 1-1) is to be multiplied with the Maintenance
Interval for Switchgear (Table 1-2) and Transformer (Table 1-3) as required by
PSI ENGR-750-36 and ENGR-750-36-QR-02 respectively. The maintenance
frequency matrix is only applicable for Tier 1.
Table 1-1: Maintenance Frequency Matrix

Frequency Multiplier
Equipment Reliability Based on Equipment Condition
Requirement
Good Average Poor
Score for Substation
7-8 5-6 0-4
Condition
Multiplying Factor 1 0.5 0.25
Table 1-2 : Maintenance Interval for Switc hgear under in-Service Condition
1
Frequency
Diagnostic Techniques
OLU/HFU VCB RMU SF6
Tier 1
Thermography 12 month 12 month 12 month

12 month 12 month 12 month
Airborne Ultrasonic
Internal Par al Discharge (TEV)
Visual Inspec on (Electrical)
Tier 2
Insula on Resistance
18 months 24 months 36 months
(Bushing/Busbar)
- -
Circuit Breaker Timing 24 months
- -
Vacuum Checks 24 months
18 months -
Oil Dielectric -
Tier 3
Par al Discharge Locator & - Condi on Condi on
Monitoring Based Based
SF6 Gas Analysis (Gas Purity, - Condi on
-
Dewpoint & SO2) Based
- Condi on Condi on
Contact Resistance
Based Based
- Condi on Condi on
Power Frequency/ Pressure Test
Based Based
Dielectric Dissip on Factor (DDF) - Condi on
-
Tan δ Based
1 Table 1-3 : Maintenance Interval for Distribution Transformer under In-

Service Condition
Diagnostic Techniques Frequency
Conservator Hermetically
Tier 1
Tank Seal
Visual Inspec on 12 months 12 months
Load Profiling For Cri cal Transformers 12 month 12 month
Infrared Thermography 12 months 12 months
Ultrasonic Scanning 12 months 12 months
Oil Breakdown Voltage (BDV) 12 months -
Quality
Analysis Moisture/Water Content 24 months -
(OQA)
Tier 2
Insula on Resistance (IR) 24 months 24 months
Con nuity Test 24 months 24 months
Tier 3
Online Par al Discharge (PD) Condi on Based Condi on Based
IMPORTANT:
Multiply test frequency dura on in Table 1-2 and Table 1-3 by the factor
in Table 1-1: Maintenance Frequency Matrix .
Chapter 1 Maintenance of Assets 7
Chapter 2 Maintenance of Assets

2.1 Overview
Maintenance of asset is one of the key life cycle activities under the asset
management plan according to PAS 55-2:2008. The scope of maintenance of
assets covers all work electrical, and non-electrical work to sustain the
2
condition of the asset.
Life Cycle Activities
Functional Acquire/Create
Policies, Utilize
Strategies,
Standards, Maintain
Process and
Procedures Renew/Dispose
Figure 2-1 : Life Cycle Activities
While practicing time based maintenance for Civil and Mechanical Assets, TNB
has adopted and implemented a condition based maintenance strategy for all
electrical assets.
2.2 Methodology
The guidelines review and formulation was carried out based on
manufacturers’ recommendation, statutory requirement and TNB’s operation
and maintenance experience.
2 In general, the inspection and maintenance plan for the assets are categorized
based on Tiers that have been categorized as:-
The maintenance interval or frequencies are categorized into calendar time,

operational number and as required. Calendar time used is months and years.
The time interval is normally determined by the statutory requirement, type
of equipment and condition of equipment to be maintained. For operational
number, it is determined by the manufacturer’s recommendation.
2.3 Maintenance Scope

The scope of maintenance covers works related to the following:
1. Electrical Assets
2. Civil and Mechanical Assets
2.3.1 Electrical Assets 2

Condition based maintenance (CBM), shortly described, is maintenance when
need arises. This maintenance is performed after one or more indicators show
that equipment is going to fail or that equipment performance is
deteriorating.
Condition based maintenance was introduced to try to maintain the correct

equipment at the right time. CBM is based on using data to prioritize and
optimize maintenance resources. Observing the state of the system is known
as condition monitoring. Such a system will determine the equipment's
health, and act only when maintenance is actually necessary. Developments in
recent years have allowed extensive instrumentation of equipment, and
together with better tools for analyzing condition data, the maintenance
personnel of today are more than ever able to decide the right time to
perform maintenance on some piece of equipment. Ideally condition-based
maintenance will allow the maintenance personnel to do only the right things,
minimizing spare parts cost, system downtime and time spent on
maintenance.
CONDITION BASED
MAINTENANCE
ONLINE CONDITION OFFLINE CONDITION CORRECTIVE

ASSESSMENT ASSESSMENT MAINTENANCE
Figure 2-2: Category of Condition Based Maintenance

for Primary Equipment
CONDITION BASED
MAINTENANCE
2 ONLINE CONDITION OFFLINE CONDITION CORRECTIVE

TIER 1
TIER 2 PLANNED
TIER 2
TIER 3 UNPLANNED
TIER 3
Figure 2-3: Category of Condition Based Maintenance for Switchgears
CONDITION BASED
MAINTENANCE
ONLINE CONDITION OFFLINE CONDITION CORRECTIVE

TIER 1 TIER 2 PLANNED
TIER 3 TIER 3 UNPLANNED
Figure 2-4: Category of Condition Based Maintenance for Transformers

2.3.2 Civil and Mechanical Work

Preven ve maintenance is carried out at predetermined intervals determined
by AMD. It is intended to reduce the probability of failure. Rou ne/Scheduled
maintenance is carried out at a fixed interva me, opera ons).
Correc ve maintenance is carried out a failure or unacceptable cond on

has occurred and intended to restore an item to a state in which it can
perform its required fun on.
2
CIVIL AND MECHANICAL

WORK
PREVENTIVE CORRECTIVE
MAINTENANCE MAINTENANCE
ROUTINE/
SCHEDULE IRREGULARITY EMERGENCY
Figure 2-5 : Category of Civil and Mechanical Work

Chapter 3 Switchgear
3.1 Preliminaries
Switchgear is key components in the power system and appropriate for
analysis under a risk assessment program. Switchgear failure can have
significant economic impact due to long lead mes in procurement,
manufacturing and installa on in add on to high equipment cost.
Determining the exis ng cond on of switchgear is an essen al step analyzing
the risk of failure.
3 Switchgear types available in the distribu on system are categorized as
follows:
Air Insulated switchgear (AIS) : VCB,OCB

Ring main units (RMU) : OLU, HFU, SF6
The distribu on system has predominantly indoor air insulated switchgear.

Ring main units (RMU) are popular at 11kV system for the purpose of
providing economical ring re ula on systems. Although oil RMUs are
available, they are gradually being phased out by the gas insulated RMUs.
Chapter 3 Switchgear 13
3.1.1 Air Insulated Switchgear (AIS)

Air insulated switchgear comprises the busbars, circuit breakers and cable
termination compartments insulated by air at atmospheric pressure. Busbars
may or may not be insulated and are supported by specially designed resin
moulds. The breaker compartment houses the circuit breaker with its
different arc quenching mediums. The circuit breaker type is differentiated by
its arc extinction medium such as vacuum, SF6 gas and dielectric oil.
In vacuum circuit breakers, the fixed and moving contacts are housed
permanently inside a sealed vacuumed ceramic bottle. The arc is quenched as
the contacts are separated in vacuum. In the MV switchgear range, vacuum is
the most predominant insulating medium for circuit breaking.
3
Figure 3-1 : Typical Arrangement of 11 kV Air Insulated Switchgear (AIS),

Vacuum Circuit Breaker
(3) (4)
(1) (2)
3 (5)
(12)
(6)
(7)
(8)
(11) (10) (9)

1. Metering Compartment 7. Multi Core Cable Box
2. Railing 8. Earth bar
3. Drawout VT Truck 9. Arc protection
4. Pressure Relief Flap 10. Heater
5. Busbar 11. Vacuum Circuit Breaker
6. Cable termination 12. Air Filter
Figure 3-2 : Cut-out View of Air Insulated Switchgear (AIS),
Vacuum Circuit Breaker
Table 3-1 : Description in Rating of Circuit Breaker for 11 kV
Voltage Level 11 kV
Equipment Circuit Breakers with

Single Busbar Panels
Voltage (kV) 12
Main Busbar Current (A) 2000
Rated Current 630 / 1250 / 2000
Rated Insulation Level 75 kV Peak / 28 kV Power
Frequency 3
Short Time Current 20 kA/25 kA @ 3 sec
Construction Metal Clad
Short Circuit Breaking 20 kA / 25 kA
Current (A)
Closing Operation Motor Charged Spring
Tripping System Shunt Trip
Tripping Control Source DC 30 V / 110 V
Opening Time < 50 msec
Making Time < 60 msec
Typical Dimension (mm) W – 600/800
D – 2200/2250
H – 2300
Relay & Control Switchgear
3.1.2 Ring Main Unit (RMU): Oil/Gas

In TNB, the RMU is the switching equipment used extensively in the 11kV and
22kV system as it suits the system configuration and protection practice.
Additionally, the RMU offers the following advantages:
a) Economical
b) Ease of maintenance
c) Space saving
d) Suitable for indoor and outdoor use
The suitability of indoor and outdoor applications depends on the degree of
3 protection of the RMU (Ingress Protection (IP) rating). IP42 is suitable for
indoor while outdoor applications require a minimum of IP54.
In general, the RMU is a combination of two units of switches, which

comprises of Load Break Switch, Switch Fuse and circuit breaker. RMU has
extensible and non-extensible type.
For the insulation, RMU can either use oil or Sulphur Hexafluoride (SF 6) gas.
The insulation is responsible to clear the arc during operation. Other than
that, the insulation will also assist in cooling the bus-bar and the blade inside
the same chamber. The typical ratings for the RMU are given in the following
table.
Table 3-2 : Description in Rating of RMU for 11 kV

DESCRIPTION RATING
Voltage level 12kV
Con nuous normal current 630 A
Short- me Withstand
Load break switch 20kA 3 sec
Earthing switch 2.1kA 1 sec
Making capacity
Load break switch 50 kA peak
5.4 kA peak
Earthing switch
Power frequency withstand Voltage

3
Across earth and between poles
28 kV
Across isol ng distance 32 kV
Lightning impulse withstand Voltage
Across earth and between poles 75 kV
Across isol ng distance 85 kV
A typical ring main unit (RMU) comprises of two fault-make load-break ring
feeder/ earth switches and one or more tee-off transformer fused switch or
circuit breaker. All live parts, including switching components are housed
within the oil filled or SF6 gas filled enclosures. Gas filled enclosures are
considered sealed for life for normal opera ng cond ons.
Each ring switch is a fully fault making, load breaking device which can be
operated in three pos ons ‘On’, ‘Off’ and ‘Earth’. In some design, cable test
terminals are available with the earth removed by lowering the interlocked
earth bar a ached to the hinged box of the unit depending on the switchgear
model.
The Tee off feeder may be either a fused switch or a circuit breaker employing
rota ng arc device or vacuum interrupters as a means of interrup ng fault or
load currents. The fused switch is normally located outside the gas
compartments while the circuit breaker is housed in the gas filled chamber.
The integrity of the quenching medium is the main concern for these RMU
and careful monitoring will ensure its lifespan extension.
Figure 3-3 : An example of SF6 Ring Main Unit

Figure 3-4 : Cut-out View of a Sample of RMU

3.2 Maintenance Testing
3.2.1 Overview
Switchgear maintenance testing can be performed in 3 stages or tiers as
described below.
NOTE: Tier 3 inspections are intended to confirm or refute the need for more
extensive maintenance, rehabilitation, or switchgear replacement.
3.2.2 Maintenance Intervals

Table 3-3: Maintenance Test Frequency for Switchgear
Frequency
Diagnostic Techniques
OLU/HFU VCB RMU SF6
Tier 1
Thermography 12 month 12 month 12 month

Airborne Ultrasonic
Internal Partial Discharge (TEV)
Visual Inspection (Electrical)
Insulation Resistance
Tier 2
3
18 months 24 months 36 months
(Bushing/Busbar)
Oil Dielectric Test 18 months - -
- -
Trip Test (On-line timing) 24 months
-
Circuit Breaker Timing (Off-line Test) 24 months -
- -
Vacuum Checks 24 months
Tier 3
Partial Discharge Locator & - Condition Condition
Monitoring Based Based
- Condition
SF6 Gas Leakage Emission -
Based
- Condition Condition
Power Frequency/ Pressure Test
Based Based
Dielectric Dissipation Factor (DDF) - Condition Condition
Tan δ Based Based
- Condition
Contact Resistance -
Based
Note: In order to determine the maintenance interval of Tier 1 for next

maintenance activity of each test, the maintenance interval should be multiplied
with the maintenance frequency multiplier in Table 1-1 based on condition
indicated by the test results.
3.2.3 Tier 1
Table 3-4 : Maintenanc e Testing of Switchgear in Tier 1
Maintenance Tools &
Function Team
Tests/Condition Equipment
1. Thermography To check if there is any FLUKE Ti 32 Vendor,
loose contact or any high Maintenance
resistance surface Team
between any electrical
contact
2. Airborne To check if there is any UltraProbe, Vendor,

Ultrasonic external/surface - partial UltraTEV+ Maintenance
3 discharge Team
3. Internal Partial To check if there is any UltraProbe, Vendor,

Discharge (TEV) internal partial discharge UltraTEV+ Maintenance
Team
4. Visual Check any defected of the N/A -visual Vendor,

Inspection switchgear Maintenance
Team
3.2.3.1 Thermography
Thermography is an important factor in determining the condition of the

terminations and busbar joints. Performing periodical thermography tests can
provide an early indication of a potential problem. These tests can identify
internal arcing, bad electrical contacts, hot spots, partial discharge, or
overheating of conductors.
Figure 3-5 : Example of Thermography Test Equipment

3.2.3.1.1 Equipment Specification
Table 3-5 : Equipment Specification for Thermography Test

Item Specification
1. Object Temperature Measuring
-20°C ~ +600°C
Range
2. Measurement Accuracy ±2% of reading or ±2°C
3. Thermal Sensitivity < 0.05°C @ 30°C
4. Field of View/Min. Focus Dista nce 24° x 18°/0.5m

Focal Plane Array (FPA), uncooled micro
5. Detector Type
bolometer, 320 x 240 pixels.
7.5 ~ 13 µm, built-in atmospheric filter
3 6. Spectral Range
with cut-on @ 7.5 µm
7. Operating Environment Temperature -15 ~ +50°C
3.2.3.1.2 Test Procedures
1. Switch off all heaters at least 3 hours (if applicable) before any scanning
as the heat from the heaters can mask hot spots in the equipment
scanned.
Note: Ensure all heaters are switch on after testing
2. Before scanning, record the loading in Amps and Voltage for each piece of
equipment scanned and status of breaker position (ON/OFF/ISOLATED).
3. Key in manually the background/ambient temperature into the camera

with emissivity (ε = 1.00). This is to obtain the temperature compensation
of radiated heat from different materials.
Note: Any external light sources that may be reflected from the
surfaces scanned may cause wrong interpretation of data, for example,
reflection from light sources, sunlight, heat reflection, etc. Ensure there
are no cold drafts or winds blowing directly at then equipment scanned.
3.2.3.1.3 Result and Condition
Table 3-6 : Result & Condition for Thermography Test (Enclosed Metal Clad)
Result (∆T) Condition
0 °C Good
1 ~ 5 °C Fair
>5°C Poor
Table 3-7 : Result & Condition for Thermography Test (Non-enclosed)

Result (∆T) Condition
0 °C Good
1 ~ 24 °C Fair 3
>25°C Poor
Note:
For any temperature difference, further inspe on and analysis is
required. Record and monitor load and ambient temperature.
3.2.3.2 Airborne Ultrasonic
Airborne ultrasonic test is used to identify surface partial discharge. Surface

partial discharge is divided into corona discharge, arcing and tracking.
Corona, arcing, and tracking are ultrasound-producing phenomena that can
be heard directly through the panels without opening the doors and exposing
the operator to high voltage. Panels are typically not hermetically sealed
meaning that ultrasound will pass through the edges of the panel where air
gaps exist. Ultrasound, like audible sound, needs a medium to transport itself.
That medium can be air, steel, or both.
Arcing produces a high frequency ultrasonic signal that is airborne, but when
it comes in contact with the metallic surface of the switchgear, a portion of
3 that signal is refracted through to the other side. Detecting that signal can be
done with an airborne sensor positioned in one of the openings at the panel
covers with the bolt removed or with a contact magnetic sensor directly
touching the panel body.
Figure 3-6 : Example of Airborne Ultrasonic Test Equipment

3.2.3.2.1 Equipment Speci cation
Table 3-8 : Equipment Speci cation for Airborne Ultrasonic Test

Item Speci cation
1. Measurement Range -7 dBµV to 68 dBµV
2. Resolution 1 dB
3. Accuracy ±1 dB
4. Transducer Sensitivity -65 dB (0 dB = 1 volt/µbar rms SPL)
5. Transducer Centre Frequency 40 kHz
6. Heterodyning Frequency 38.4 kHz
3.2.3.2.2 Test Procedures 3

1. Before scanning, set the equipment reading limit based on below.
Table 3-9 : Limit for Ultrasound

Colour Limits For Ultrasound
< 0 dB
≥ 1 dB
2. For Ring Main Unit (RMU) and Air Insulated Switchgears (AIS), scan all
the compartments directly using flexible probe.
3. Open the compartment doors for accurate dete on with the

necessary PPE. If the compartment cannot be opened due to safety
reasons, look for small opening or remove one screw which will provide
an opening into the compartment depending on the switchgear type.
4. Point the scanning instrument into the compartment at different areas

where discharge may occur. Place the instrument as close as possible to
the opening.
5. Listen for abnormal sound e.g. crackling, buzzing or frying sounds. Aim
the scanner at each spot for a while before moving on to another spot
so that intermittent discharges will also be captured.
6. Record results in decibel (dB) and store any abnormal sounds for
further analysis by software where necessary. The instrument will
capture both mechanical vibration noise and partial discharge.
7. During the course of scanning, eliminate external noise sources that

may interfere with the scanning e.g. electric ballast in fluorescent light
fittings, exhaust fan.
8. Also take note, not to scan during a rainy day.
3 Note: Internal discharge in insulators will not be detected by this system.
3.2.3.2.3 Test Result and Action
Table 3-10 : Result and Action for Airborne Ultrasonic Test

Result*
Action
dB Characteristic
< 0 dB Normal condition, proceed scheduled test as

No Sound
plan.
≥ 1 dB Tracking,
Serious level, areas of the fault deemed to
Arcing
be serious nature. Shutdown and repair of
the equipment within 2 weeks would be
≥ 4 dB Corona required to avert fire or failure.
*Note:
If ultrasound characteristic (Arcing, Tracking) detected for less than 0
dB, it is considered as serious level. Shutdown and repair of the
equipment within 2 weeks would be required to avert fire or failure.
3.2.3.3 Internal Partial Discharge (TEV)
The partial discharge creates current spikes in the conductor and also in the
earthed metal surrounding the conductor. TEVs are a very convenient
phenomenon for measuring and detecting Internal Partial Discharges as they
can be detected without making an electrical connection or removing any
panels.
Each discrete partial discharge is the result of an electrical breakdown of an

2
air pocket within the insulation. These discharges erode insulation and
eventually result in insulation failure.
Table 3-11: Indication of Pulse/Cycle

Pulse / Cycle Indication 3
0.05 ~ 10 Internal Discharge
10 ~ 50 Surface Tracking
> 50 Interference
TEV Sensor
Colour Display Ultrasonic

Sensor
External
On/Off Button Sensor Socket
Keypad
Headphone
Socket
Charger Socket Charging LED
Figure 3-7 : Example of Internal Partial Discharge Test Equipment

Table 3-12 : Equipment Specification for Internal Partial Discharge Test

Item Specification
1. Frequency Range 20 kHz ~ 100 kHz
2. Response Time < 10 ms
3. Indicators dB, Frequency, and Bar Graph
4. Sensitivity Detect 0.005” (0.127 mm) diameter leak @

5 psi (.34 bar) at a distance of 50 feet
(15.24 m)
5. Headset Deluxe noise attenuating headphones.

3 Over 23 dB of noise attenuation
6. Operating Environment 0 ~ 50°C
7. Sensor Capacitive
8. Measurement Range 0 ~ 60 dBmV

9. Resolution 1 dB
10. Accuracy ±1 dB
11. Max Number of Pulses/Cycle 655
12. Min Pulse Rate 10 Hz
1. Before scanning, set the equipment reading limit based on below.
Table 3-13 : Limit for TEV

Colour Limits For TEV
< 20 dB
20 ~ 29 dB
> 29 dB
2. Measure and record ambient temperature, humidity and background

noise (dB) for surrounding environment.
3. Point the scanning instrument into the compartment at the different

areas where discharge may occur. Place the instrument as close as
possible to the opening.
the scanner at each spot for a while before moving on to another spot so
that interm ent discharges will also be captured.
5. Record results in decibel (dB) and store any abnormal sounds for further
analysis by so ware where necessary. The instrument will capture both 3
mechanical vibra on noise and par al discharge.
6. During the course of scanning, eliminate external noise sources that may
interfere with the scanning.
Table 3-14 : Result and Action for Internal Partial Discharge Test (TEV)
Result (dB) Action
≤ 20 Normal monitoring frequency can be maintained.
20 < dB magnitude ≤ 28 Monitoring frequency should be revised to 3 months.
≥29 Make arrangement for further test. Refer Table 3-15

Note:
Care must be taken where work is performed in ht corners,

where the proximity of other earth planes will affect the reading. If
possible maintain a distance of more than 30 cm from metal work
which runs perpendicular to the sensor faceplate.
Strong electromagne fields from mobile phones, RF transm ers,

VDUs and un-screened electronics in the frequency range DC to 1
GHz can have an effect on the readings. A measure of local fields
can be obtained by holding the tester in free-air at least 1 meter
away from any condu ng surface.
3
Table 3-15 : Guide to Interpretation For TEV Reading ≥ 29dB

TEV Reading Conclusion
1. Background Suspect Internal PD. Further Inves g on required :-

(ambient) reading < 1. PD Locator
20Db 2. Sequen al Switching
3. Visual Inspec on
2. Background Further Inves g on is required to detect source of TEV
(ambient) reading > reading either from internal PD or surrounding by using PD
20dB Monitor for a period of one (1) week.
3.2.3.4 Visual Inspection
Visual inspe on is a common method of quality control, data acquis n, and

data analysis used in maintenance of facil es. Visual Inspe on checklist can
be obtained from ENGR-750-36. Typical methods of visual inspe on are as
follows:
1. Audit of The Substation
Subs on earthing installed properly
No water logged cable trenches / cable cellar
No li er in subs on / cable trench / cable cellar
No ceiling leak /no water ingress from windows Ven l on
No adverse effects from environmental pollu on
Adequate ligh ng
No exposed unterminated power cables
Cement quality especially the area in front of the switchgear
3
2. Veri cations of Switchgear External Condition
Any anomalies, smell, etc
No water marks on the panels
Protec on relay are in healthy condi on i.e.: no alarm indic on
All covers and door bolted properly
No discolora on at the panel
Opening and interpanel gaps sealed
3. DC Power Supplies
Good b ery condi on
Ba ery output voltage (>28.5V when AC OFF )
4. Safety Equipment and Signage

Fire figh ng systems func oning properly
Portable fire ex nguisher in placed
Single line diagram and CPR are in placed
5. Switchgear Accessories
Complete set of tools for breaker opera on
Complete set of tools for earth switch opera on
6. Switchgear, Transformer, LVDB & Substation Earthing

Con nuous earth connec ons between all switchgear/Transformer/LVDB
Con nuous earth connec on to substa on earth
3.2.3.4.1 Switchgear Checklist
Items to be inspected during visual inspe on are specified in a detailed

checklist/test sheet. A summarized switchgear visual inspe on checklist is as
below:
1. Switchgear Panel
• Standard Feeder Name
3
• Standard Breaker Number
• AMPs Meter
• MCB ‘ON’
• Heater ‘ON’, Amps Reading
• Abnormal Sound
• SF6 Gas Pressure (RMU) Oil Level (RMU)
• Panel Earthing
• Panel Door Tightly Closed
Table 3-16 : SF6 Gas Pressure Reading by OEM

Pressure
SF6 Gas Pressure Indication Action to be taken
(kPA)
Normal
Green 130 ± 5 -
Operating
De-energize and perform

Abnormal
Red < 125 Tier 3 Test – SF6 Gas
Operating
Leakage Detector
2. Cable
• Cable Earthing
• Cable Clamp
• Cable Entry to switchgear compartment properly sealed
3. Earthing
• Oxid on/Loose Connec on/Vandalised
4. EFI
Table 3-17 : EFI Checking List

REGIME ACTIVITIES
EFI Box observation
Lense LED
EFI Control Box
Printed Circuit Board (PCB) Observation
Animals/Insects trespassing
Physical Moisture
Observation Wiring
Well ed at terminal block
Oxid
CT
on at terminal
3
Vandalism
Check the connec on of CT at cable termin on
Test the volt
Battery Testing
Change the b ery if its weak
DIP Switch Testing Check on the se ng of DIP switch
Note :
1. Check for an -vermin at various loca ons in the substa on.
2. Record visit in the Log Book available at the substa on
3. Abnormali es need to recorded in VI check list
3.2.4 Tier 2
Table 3-18 : Maintenance Testing of Switchgear in Tier 2
Tools &
Maintenance Test Team
Function Equipment
1. Insulation Insulation resistance checks IR Test Set Vendor,

Resistance are carried out to give an Maintenance
(Bushing/ indication of the relative Team
Busbar) quality of the insulation
system of an equipment
3
2. Oil Dielectric To check the break down Oil Test Set Vendor,
voltage of the oil which is Maintenance
used as insulation Team
3. Trip Test (On- To test the breaker in the Trip Test Set Maintenance
Line Timing) energized state so that the Team
performance of the first trip
can be analyzed
4. Circuit Breaker To ignite movement which Timing Test Set Vendor,
Timing may smoothen harden Maintenance
moving parts. Also to check Team
the opening and closing
time of a circuit breaker and
to identify which is the
sluggish part through time
profiling
5. Vacuum Check the integrity of the Vacuum Vendor,
Checks vacuum bottle to ascertain Checker Maintenance
the ability of the breaking Team
chamber to inhibit
flashovers
3.2.4.1 Insulation Resistance
Insulation resistance (IR) checks are carried out to give an indication of the
relative quality of the insulation system of an equipment.
Figure 3-9 : Example of Insulation Resistance Test Equipment
Table 3-19 : Equipment Specification for Insulation Resistance Test

For Switchgear
Item 12 kV
1. Measuring Range 0 ~ 2000 MΩ/
1000 ~ 100000 MΩ
2. Accuracy Insulation ± 20% of reading
Resistance
Output Voltage 5000 ± 5%
3. Operating Environment -10 ~ +40°C at maximum relative humidity
Step 1 – De-energize Test Object
1. De-energize the equipment or section of equipment to be tested. Always

comply with TNB safety regulations and procedure when working with
equipment connected to high voltage mains.
2. Do not disconnect voltage leads whilst a test is being carried out.
Step 2 – Set-up And Connect The Insulation Resistance Tester
1. Ensure the correct test instrument is used for the object to be tested by
checking the test voltage. Refer for guidelines on the test voltages.
3 Table 3-20 : Minimum Rating Insulation R esistance Test For Switchgear
Rating of Equipment Test Voltage DC
12 kV 2.5 kV
2. Ensure the object is earthed before connecting to test instrument.
3. Connect earth lead of the tester to earthing point of the object. Then
proceed with measuring lead of the instrument to the line terminal of
test instrument.
4. Ensure the object is earthed “OFF” before testing.
5. The object is now ready for testing.
Note: Testing method is depending on switchgear model.

Figure 3-10 : Insulati on Resistance for Breaker Busbar, Phase to Earth
Figure 3-11: Insulation Resistance for Breaker Busbar, Phase to Phase

3
Figure 3-12: Insulation Resistance for Circuit Breaker Truck (Open Position)
Figure 3-13: Insulation Resistance for Circuit Breaker Truck (Close Position)
Figure 3-14: Insulation Resist ance for RMU, Phase to Earth
Figure 3-15: Insulation Resistance for RMU, Phase to Phase

Step 3 – Record and Analyze of Insulation Resistance Tester
1. Ensure steps 1 and 2 are completed before taking any measurements.
2. Activate the switch to apply the test voltage.
3. Read the value of the insulation resistance and record in test format.
4. Analyze results obtained and compare results with previous

measurement. Trend the data.
3.2.4.1.3 Test and Condition

3
Table 3-21 : Result and Condition for Insulation Resistance Test
Result Condition
≥ 1 GΩ Good
< 1 GΩ Poor
3.2.4.2 Oil Dielectric Test for OLU/HFU
The insula ng oil in OLU/HFU serves three essen al purposes:-
(i) Provide adequate insula on

(ii) Ensure efficient heat transfer from the source to the atmosphere
(iii) Perform arc quenching fun ons.
The obje ve of dielectric test is to check the break down voltage of the oil
which is used as insula on integrity. This breakdown voltage is ind ve of
the amount of contaminant in the oil and samples for tes ng should be
obtained from OLU/HFU er a heavy fault or series of faults and at regular
intervals. 3
Check colour, odour and dielectric strength of insula ng oil.
Check for oil leaks at the seals and gasket.
Figure 3-16 : Example of Oil Dielectric Test Equipment

Table 3-22 : Equipment Specification for Oil Dielectric Test

Item Specification
1. Input 120 V, 60 Hz, 7 A
1. Output Voltages 0 ~ 60 kVrms (0 ~ 30 kV at 61.8 kHz
Customized Voltage Between 10 and 60 kVdc
Ripple Max 3%
2. Operating Environment (Humidity) 0 ~ 40°C (80% RH at 40°C –
noncondensing)
3. Distortion < 5%
3 3.2.4.2.2 Test Procedure
Step 1 – Obtain Switchgear Oil Sample
1. Always comply with TNB safety regulations when working with

2. De-energize the OLU/HFU from which a sample of the insulating oil will
be taken for testing.
3. Prepare a clean container to hold the oil sample.
4. Ensure sufficient oil is taken with no contamination.
Step 2 – Set-up the Oil Test Set
1. Clean the test instrument, the test chamber, test vessel/container and
the cover from dirt and oil. Rinse with part of the oil sample to be tested
if necessary. Exterior surfaces may be wiped with a clean cloth damped
with an alcohol based cleaning fluid or other cleaning fluids
recommended by the manufacturer.
2. Clean the electrodes and all parts that come in contact with the oil
sample until they are thoroughly clean. Rinse with part of the oil sample
if necessary.
3. Pour the oil sample into the container slowly up to the oil mark indicated
without spilling and without the formation of air bubbles. Be careful not
to introduce any contaminants into the oil sample.
4. Set the gap between the electrodes according to the requirement of the
test undertaken. Confirm the gap has been set properly and lower
electrodes into the oil sample.
5. The oil sample is now ready for testing of its dielectric properties.
Step 3 – Conducting a Test
1. Ensure step 1 and 2 above are completed before conducting this test.
2. Power up the test instrument.
3. Select the desired test sequence and initiate test. After the initial stand
time for the oil and test set is complete, a high voltage will be applied
between the electrodes according to the test sequence selected. These
test sequences are based on National specifications. 3
Table 3-23: Oil Test Standards
Standard Test AS 1767 CEI 10-1 ASTM D1816 ASTM D877
Specification BS5874 TOCT 6581
Selected BS148 VDE 0370
BS 5730 STAS 286
IEC 156
IP 295
NFC 27
SABS 555
UNE 21
Electrode Shape
Electrode
2.5mm 2.0mm 2.5mm
Spacing
4. Option : Test sequence 1

• The oil sample is subjected to a defined voltage for duration of 1
minute to see if it will withstand that voltage.
• After 1 minute, the voltage is then removed.
• If oil breakdown occurs before the 1 minute is up, the test voltage is
switched off.
5. Option : Test sequence 2

• The oil sample is subjected to a defined voltage for a period of 1 minute
as in test sequence 1 above.
• However, in this sequence, the voltage continues to rise at a steady
rate after one minute until oil breakdown occurs or until the maximum
value of the test voltage is reached.
• The test voltage is switched off immediately when oil breakdown
occurs and the breakdown voltage is displayed.
• The same oil sample is then stirred slowly for a period of time after
which the test voltage is re-applied to get another breakdown value.
• The process is repeated several times and the average breakdown
value is then calculated
3
6. Record or obtain a print out of the test results. Analyze results.
3.2.4.2.3 The Result and Action
Table 3-24 : Result and Action for Oil Quality

Result Action
Breakdown voltage Retain oil and perform sampling at normal
more (>) 30 kV interval.
Breakdown voltage less Replace oil or perform asset replacement.
(<) 30 kV Refer circular A15/2011
3.2.4.3 Trip Test (On-Line Timing)
This test is performed to test the breaker in the energized state so that the
performance of the first trip can be analyzed. By performing this test, the
current profile allows diagnosis of potential defects in the trip coil mechanism
and also highlights problems within the main circuit breaker contacts. Each
Circuit Breaker type has a characteristic profile similar to that shown in
Figure 3-17.
Deviations from this profile can be easily detected by comparing profiles from
first trip operations with subsequent or previous trip coil profiles. The same
methodology can be applied to the close coil operation.
Figure 3-17 : Sample Circuit breaker characteristic profile

Figure 3-18 : Circuit Breaker Analyser
Figure 3-19 : Example of Trip Test (On -Line Timing) Equipment

Table 3-25 : Equipment Speci cation for Trip Test (On -Line Timing)
Item Speci cation
1. Measurement Voltage 0 ~ 265 Vdc
Range Current 0.2 ~ 20 Adc
2. Measurement Resolution 0.03%
3. Basic Accuracy 0.5%
4. Dynamic Error Motion 1%
Speed 3%
5. Time Base Accuracy 0.02%
6. Measurement Interval 0 ~ 1000 ms
7. Able To Capture Online Test With - Main mechanis ming
Graphic - Trip latch ming
- Trip coil ming
3
- S on b ery and wiring
- Auxiliary switch contac ming
- Main contac ming
8. Operating Environment -10 ~ 50°C
9. Closing Closing Voltage At 100% rated voltage
Characteristic Closing Time ≤ 80 ms
Chatter Time 11 kV ≤ 8 ms, 36 kV ≤ 12 ms
10. Tripping Tripping Voltage At 100% rated voltage
Characteristic Tripping Time ≤ 50 ms
Di rent Contact ≤ 5 ms
Time
Test Equipment Set-up
1. Turn on the test instrument.
2. Key in the breaker identification and test number details as follows :-

• Substation name
• Breaker Serial Number
• Breaker type or model
• Date of testing
• Test Number (Note for some instruments the test number is
automatically incremented)
3 3. To obtain optimal results, the level should be set to as low a value as

possible. For most applications, 0.2 A is sufficient. However, should
unwanted signals be superimposed on the dc current, it may be necessary
to raise the trigger level above the noise floor to get accurate results.
Refer to instrument operation guide to change the trigger level.
Connecting the Test Instrument
1. Open the LV metering compartment of the breaker to be tested.
2. To capture a TRP operation, identify a dc current path where the trip coil
current will flow when a TRIP command is given.
3. To capture a CLOSE operation, identify a dc current path where the

closing coil current will flow when a CLOSE command is given.
4. Fit the DC current probe around this wire. The respective trip or closing
coil currents are captured using a Hall Effect clamp on probe.
5. For best results, fit the DC current probe around the negative return of
the DC circuit of the trip or close coil.
6. Connect the voltage monitoring leads at the positive and negative supply
of the trip coil to monitor voltage drop across the trip coil when it is
energized.
7. Connect the clip-on CT to the secondary wiring of the protection relay.

8. Keep a safe distance from the switchgear once the set-up is complete and
is ready to receive a breaker TRIP or CLOSE command.
Note: CT measurements will only be captured if the breaker is carrying

load current. Refer to the test instrument manual for the minimum
secondary CT current captured.
IMPORTANT:
Remember to operate the breaker electrically. No current profile will be

available if the breaker is tripped/closed using mechanical/manual
method.
3
Making a Breaker TRIP/CLOSE Measurement
1. Give a TRIP/CLOSE command when the Central Control Centre for the
TNB region gives the green light. This opera on should be performed by
authorized TNB switching personnel.
2. The TRIP/CLOSE Command can be effected from any one of the following
loca ons :-
• The trip/neutral/close selector switch at the switchgear
• SCADA remote control
• Breaker control switch or pushbu on at the remote control panel
3. When the breaker is tripped/close, save the trip coil current profile and
other data for further analysis and for archiving the data to library for
breaker performance trending purposes.
Figure 3-30 : Circuit Connection of Making a Breaker TRIP/CLOSE
Table 3-26 : OEM Declared Closing and Tripping Time for 12 kV

Items SIEMENS ABB EPE TOPRANK TAMCO
CLOSE (t) < 75 ms < 70 ms < 60 ms < 70 ms < 50 ms
OPEN (t) < 65 ms < 55 ms < 50 ms < 50 ms < 35 ms
Note: If closing and tripping time obtained is more that OEM declared
time, then servicing and lubrication of circuit breaker needs to be
performed.
3.2.4.4 Circuit Breaker Timing
The circuit breaker is designed to clear a fault by quickly interrupting the fault
current, thus minimizing damage to the electrical circuit through which the
fault current flows. However, once put in service, the breaker may remain
idle for long periods of time i.e. the mechanical parts are not operated until it
is taken out for maintenance or until a fault occurs. Breaker tests to analyze
its performance can be carried out either with the breaker still online or off-
line.This test can be performed under both energized and de-energized
switchgear. The advantage of this analysis is to detect failure of the driving
shaft, gear assembly and spring.
3
Table 3-27 : Equipment Specification

Item Specification
1. Measurement Voltage 0 ~ 265 Vdc
Range Current 0.2 ~ 20 Adc
2. Measurement Resolution 0.03%
3. Basic Accuracy 0.5%
4. Dynamic Error Motion 1%
Speed 3%
5. Time Base Accuracy 0.02%
6. Measurement Interval 0 ~ 1000 ms
7. Able To Capture Online Test With Graphic - Main mechanism timing
- Trip latch timing
- Trip coil timing
- Station battery and wiring
- Auxiliary switch contact timing
- Main contact timing
8. Operating Environment –10 ~ 50 °C
9. Closing Closing Voltage At 100% rated voltage
Characteristic Closing Time ≤ 80 ms
Chatter Time 11 kV ≤ 8 ms, 36 kV ≤ 12 ms
10. Tripping Tripping Voltage At 100% rated voltage
Characteristic Tripping Time ≤ 50 ms
Different Contact Time ≤ 5 ms
Figure 3-21 : Circuit Breaker Timing Test Equipment
Figure 3-22 : Circuit Breaker Timing Connection

Step 1 – De-energize and Isolate Circuit Breaker

2. If the breaker is withdrawable, trip the circuit breaker and rack the
breaker out to test or disconnected position.
3. Ground the breaker under test on one side.
Step 2 – Set-up and Connect the Test Instrument
1. Connect the breaker to the test set according to instructions given by the 3
manufacturer.
2. For each measurement or breaker operation sequence, reconnect the

test set according to instructions given by the test equipment
manufacturer.
3. If the contact travel/stroke is required, connect the measuring

transducers.
Figure 3-23 : Breaker Off -Line Timing Test Set-up

Step 3 – Conducting A Test
1. Conduct the following breaker tests :-

a) Breaker ming test for CLOSE-OPEN sequence.
b) Breaker ming test for OPEN-CLOSE sequence.
c) Breaker ming for OPEN-DELAY - CLOSE-OPEN sequence.
d) Breaker ming for CLOSE-OPEN-CLOSE sequence.
2. Record or print out results.
3. Analyze results for :-

Contact closing me
Contact opening me
3 Contact travel
Contact cha ering or bounce
Trip coil current profile
Close coil current profile
3.2.4.4.3 The Result and Action
Table 3-28 : Result and Action for Circui t Breaker Timing

Result Action
Below recommended Normal. Trip Test can be maintained at 24
value as in Trip Test months.
Above recommended Indicates serious problem. Require immediate
value as in Trip Test evalua on, add onal tes ng and servicing.
Note: Refer Table 3-28 for recommended value.

3.2.4.5 Vacuum Checks
Vacuum check is carried out to:-
(i). Check if all there is any vacuum leak to ensure the integrity of the
vacuum interrupter.
(ii). Detect dirt on the poles of the vacuum bottle and on the exterior
surface which makes it unsafe during operation.
(iii). Check for sufficient distance between the two poles of the vacuum
bottle to see if frequent operations have caused misalignment to the
breaker mechanism.

3
Table 3-29 : Equipment Specification for Vacuum Checks
Item Specification
1. Output Standard Voltages, Switchable 0 ~ 60 kVDC
Customized Voltage Between 10 and 60 kVDC
Ripple Max 3%
Figure 3-24 : Vacuum Test Set for Circuit Breaker

Table 3-30 : Vacuum Checker Function Equipment

No. Item Function
1 High Voltage For connec on of the test voltage and ground to the
Cable vacuum breaking chamber.
2 CANCEL Lamp Lights up when:
the test interval has exceeded one minute.
a one minute test is conducted less than two
minutes a er the latest test.
the HIGH-VOLTAGE indicator malfunc ons.
3 HIGH-VOLTAGE Shows that the high voltage is applied
Warning Lamp
4 Test Voltage 10 ~ 60 kVDC. One of these voltages is customized and
Selector specified by the customer when ordering.
3 5 Protective Earth
(Ground)
For grounding purpose.
Terminal.
6 Large Test Clip Provides for quicker connec on and more efficient
Connectors tes ng process
7 TEST Safety Both knobs must be turned simultaneously to apply high
Control Knobs voltage to the test object.
8 ACCEPTABLE Lights up when the breaking chamber test result is
Green Lamp posi ve
9 DEFECTIVE Lights up when the breaking chamber test result is
Red Lamp negative, when the flashover threshold voltage

1. Always comply with TNB safety regula ons when working with
2. Proceed with shutdown procedures. It is important to make sure there is

no feedback supply to VCB panel.
3. Rack out truck from the panel.
Step 2 – Set-up and Connect Vacuum Tester
1. Visually inspect the vacuum bo le for cracks and dents.

2. Clean the surface of the vacuum bottle and the connected linkages
thoroughly. Use a dry lint free cloth or industrial paper travel. Avoid using
any cleaning solvents. Denatured alcohol may be used if required.
3. Check the insulation resistance of the vacuum bottle. If the value drops
below 1000 MΩ (corrected to 20°C), discontinue vacuum test and consult
the manufacturer for advises. If value is good, continue test set-up.
4. Ensure that the vacuum interrupter is in the OPEN position.
5. Ensure vacuum tester is in OFF position and is grounded properly.
6. Connect the part negative DC clamp of the high voltage cable to the
control mechanism side of the breaking chamber.
7. Connect the positive DC clamp of the high voltage cable to the other
3
terminal on the breaking chamber.
8. Connect the vacuum tester to the main power.
Figure 3-25 : Vacuum Test Set -Up
Step 3 – Conducting A Test
1. Ensure step 1 and 2 above are completed before conducting this test.
2. Select test voltage to 25kVDC.

Table 3-31: Test V oltage for Vacuum Checks

Switchgear Rated Voltage 12 kV
Vacuum Test Voltage 25 kVDC
Note: For guide on test voltage refer to IEC 694 and ANSI C37-06
standards.
3. Turn the power for the vacuum tester to the ON position.
4. Confirm that the test investment is powered up properly.
3
5. Observe the indication lights. If the “defective” indication lights up or if
the test set trips, the breaking chamber is considered defective.
Note: If metallic discharge sounds are heard during the test but the
discharge is not sustained or bridges the gap between electrodes
permanently, the object under test is accepted as non-defective.
6. When the test is completed, turn OFF the power supply.
7. Discharge the vacuum interrupter after test.
Note: A full time 10 second test is required after that. There must be a
pause of 2 minutes before starting the next test. This pause permits
proper resetting of the vacuum tester’s internal timer counter.
Step 4 – Disconnection After Testing
1. Check that the power switch is at the OFF position.
2. Remove the ground connection and connect it to the metallic part of the
high voltage cable before removing it from the circuit breaker.
3. Remove the additional earth loop from the circuit breaker.

Note:
When a DC test voltage is used, electrostatic charges can build up on:-
a) Adjacent insulated parts

b) The metallic centre section of the breaking chamber
c) The entire centre parts of dual breaking chamber
Ensure a lapse of at 10 seconds for the ground connection to take

effect. When a ground connection is established it takes (depending on
surface conditions) about 10 seconds for statically charged parts to
assume ground potential.
3
Table 3-32 : Test Result From Vacuum Checks Equipment

Green Light Acceptable
Red Light Defective
3.2.5 Tier 3
Table 3-33 : Maintenance Testi ng of Switchgear in Tier 3

Tools &
Maintenance Tests Function Team
Equipment
1. SF6 Gas Leakage To identify and pinpoint SF6 Leak OEM

Checks the location and Detector
magnitude of leak
2. Power Frequency / To access the ability of AC/DC High Maintenance

Pressure Test switchgear or object Voltage team
under test to withstand Pressure
and voltages in excess Test
of its rated voltage at
3 power frequency for a
duration of 1 minute to
assess the ability of the
object to withstand this
voltage
3. Dielectric To analyze integrity and Tan δ Test TNBR

Dissipation Factor quality of high voltage Set
(DDF) insulation systems by
Tan δ measuring the dielectric
dissipation factor and
power factor
4.PD locator To identify and pinpoint PD Locator Vendor,

the location of PD Diagnostic
Team
5. Contact Resistance To measure the Contact Vendor,

Test resistance of electrical resistance Maintenance
joints and other high test set team
current links
3.2.5.1 PD Locator
The PD Locator is used to identify and locate the early warning signs of PD
activity that signals the start of insulation degradation that could ultimately
lead to disruptive failures.
Figure 3-6 : Sample of PD Locator
Table 3-34 : Equipment Specification for PD Locator

Item Specification
1. Sensor Capacitive
2. Measurement Range 0 ~ 60 dBmV
3. Resolution 1 dB
4. Accuracy ±1 dB
5. Max Number of Pulses/Cycle 655
6. Min Pulse Rate 10 Hz
1. Measure and record ambient temperature, humidity and background

noise (dB) for surrounding environment.

possible to the opening.
that intermittent discharges will also be captured.
3 4. Record results in decibel (dB) and store any abnormal sounds for further
analysis by software where necessary. The instrument will capture both
mechanical vibration noise and partial discharge.
5. During the course of scanning, eliminate external noise sources that may
interfere with the scanning.
Table 3-35 : Result and Action for Partial Discharge Locator

Result Action
TEV dB magnitude
Perform immediate shutdown and repair of the equipment.
> 29
Note: If the source of PD is found to be external then the condition of high

TEV should be recorded for the partial substation. Hence the source of PD
is not created within the switchgear.
3.2.5.2 Power Frequency/AC Pressure Test
To access the ability of switchgear or object under test to withstand voltages

in excess of its rated voltage at power frequency for a duration of 1 minute to
assess the ability of the object to withstand this voltage.
Figure 3-26 : Example of Power Frequency Test Equipment
Figure 3-27 : Identification of Button at Power Frequency Test Equipment

3
Figure 3-28 : Identification of Transformer
Table 3-36 : Equipment Specification for Power Frequency Test
Item Specification
1. Measuring Range Voltage 0 ~ 80 kVac (rms)
Secondary Current 0 ~ 60 mA (rms)
2. Current Current Rating 13 mA
Short-circuit Current Max. 50 mA (1 minute)
3.2.5.2.2 Test Procedure

2. Ensure that the test object is de-energized.
3. If the test object is a withdrawable breaker, trip the breaker, then rack
the breaker out to ‘Test’ or ‘Disconnected’ position.
4. If the breaker is fixed, trip all incoming supplies connected to the

incoming side of the breaker. It is also important to ensure there is no
feedback supply to the outgoing side of the breaker. 3
Step 2 – Set-up and Connect High Voltage Test Set
1. Connect the test set to the object under test as shown in .
2. Ensure that the ground leads are connected and that the test object is
properly earthed.
3. Connect the test set to the Mains but do not power-up until the test set-
up is completed and is ready for testing.
Figure 3-29 : Power Fr equency Test Set-up

1. Ensure step 1 and 2 above are completed before conducting any tests.
2. Turn the voltage control knob of the variable transformer to the zero
output voltage position.
3. Turn ON the power for the test equipment. Just before the application of
the test voltage, ensure that the earth connection at the test object is
disconnected.
4. Raise the test voltage until the desired value is reached then apply this
voltage for at 1 minute. For guidance on test voltage, refer to .
3 Table 3-37 : Power Frequency Withstand Test Voltages

Rated Voltage 12 kV
Test Voltage At Power Frequency For
28 kV
1 min – New/Commissioning
Test Voltage At Power Frequency For
22 kV
1 min – Existing/In Service
5. If the test set does not trip due to disruptive discharges and the “PASS”
indication is given, the test is complete and the object under test is
considered to be in good condition.
6. If the test instrument trips due to disruptive charges, the test object is
considered defective.
Note: Any discharge sounds that are heard during the test are of no
importance. The results shall solely be based on the “acceptable” or
“defective” indication.
7. Some test sets will give the value of the leakage current measured during
the test. Record this value if it is available.
8. When the test is completed, return the voltage control knob to the zero
voltage position.
9. Ensure discharge the test object after test accordingly.

Table 3-38 : Result and Action for Power Frequency Test

Result Action
Normal. The monitoring frequency of

Leakage current ≤ 0.5mA
24 months can be maintained.
Interrupter
Perform Tier 3 test – Dielectric
Leakage current > 0.5 mA
Dissipation Factor (DDF) Tan δ.
Normal. The monitoring frequency of
Leakage current ≤ 10mA
24 months can be maintained.
Busbar (AIS)
Perform Tier 3 test – Dielectric
Leakage current > 10mA
Dissipation Factor (DDF) Tan δ.
3
3.2.5.3 Dielectric Dissipation Factor (DDF) Tan δ
To analyze integrity and quality of high voltage insulation systems by

measuring the dielectric dissipation factor (tan δ) and power factor. Damage
or changes in the insulation can be detected easily and corrective action taken
before a breakdown occurs. This test gives very reliable results about the
degree of degeneration of insulators by measuring the loss of capacitance or
the increase in power loss. Insulators act as capacitors between line and earth
and between lines. However, contaminants introduce a resistive component
and the greater the contamination, the greater the power losses.
Figure 3-30 : Example of DDF Test Equipment

Table 3-39 : Equipment Specification for DDF Tan Delta

Item Specification
1. Measurement Range Test Specimen Capacitance, Cx 50 pF ~ 1.99 μF
Max Resolution 0.01 pF
Dissipation Factor Tan δ 0 ~ 9.99
Max. Resolution 1 x 10-4
Power Factor (PF) 0 ~ 1.00
Max. Resolution 1 x 10-4
Inductance, Lx 31 A < Lx < 15 A
Test Voltage UTest 0 ~ 1200 kV
Max. Resolution 0.001 kV
3 Test Specimen Current, Ix

Max. Resolution
Max 15.00A
0.001mA
2. Accuracy Capacitance ± 0.05% rdg ± 1 dig
(Limits of Error) Dissipation Factor ± 1% rdg ± 1 x 10-4
Power Factor ± 1% rdg ± 1 x 10-4
Inductance ± 0.5% rdg ± 2 dig
Test Specimen Current ± 1% rdg ± 2 dig
Test Voltage ± 1% rdg ± 2 dig
Test Frequency ± 0.02% rdg
3. Operating Environment Temperature + 5 ~ +40°C
1. De-energize the object to be tested. Always comply with TNB guidelines.
2. Ensure there is no power supply connected to both sides of the test

object and that there is no feedback.
Step 2 – Set-up and Connect the Test Instrument
1. Connect the control cable.
2. Connect the live and return cable.
3. Connect the mains cable.

4. Connect the HIGH VOLTAGE GROUND terminal on the power supply to a

good earth ground.
5. Plug the high voltage cable into the HIGH VOLTAGE TO TEST OBJECT
socket.
6. Plug the safety switch connector into the switch socket.
7. Plug the line cord cable into the mains socket on the power supply.
8. Check that all connections are properly made.
9. Connect the test set to the mains supply.
Figure 3-31 : Dielectric Dissipation Test for Breaker
Figure 3-32 : Dielectric Dissipation Test for Bushin g

1. Ensure Step 1 and 2 are completed before conducting this test.
2. Ensure that the HIGH VOLTAGE GROUND is properly connected.
3. Connect the measuring lead between the bushing’s semi-conductive plain

and the test instrument.
4. Connect the high voltage lead to the bushing’s centre conductor.
5. Select the test voltage and adjust to the required level. Voltage applied is
up to 10 kV but not more than phase voltage.
6. If the mains power is not on, turn it on.

3 7. Select the parameters to be recorded (Dissipation/Capacitance/Voltage).
8. Enter the temperature of the test object so that the tan delta & power
factor values displayed are automatically compensated for 20°C. If there
is no built in conversion feature, key in the compensation table values.
9. In both cases we are applying a high-voltage to the insulation (up to 10 kV

but no more than normal L-G voltage) and measuring the phase angle of
the resulting current.
10. Turn on the high voltage to apply the test voltage to the object under
test.
11. Capture the results and print.
Table 3-40 : Result and Action for DDF Tan Delta

Result Action
% deviation from name plate Normal. The monitoring frequency of 24
value ≤ 5 months can be maintained.
% deviation from name plate Perform immediate shutdown and repair of

value > 5 the equipment.
3.2.5.4 Contact Resistance
Contact resistance test measures the resistance of electrical connections such

as terminations, joints and connectors. These can be connections between
any two conductors such as busbar sections, cable connections and vacuum
interrupter. This test is used primarily to verify that electrical connections are
made properly and can detect problems such as loose connections, adequate
tension on bolted joints, eroded contact surfaces and contaminated/corroded
contacts. It is important to perform this test especially on contacts that carry
large amount of current as higher contact resistance leads to higher losses
and lower current carrying capacity.
Figure 3-33 : Example of Contact Resistance Test Equipment

Table 3-41 : Equipment Specification for Contact Resistant Test

Item 0 ~ 100 A 0 ~ 200 A
1. Measuring Range 0 ~ 1999 µΩ 0 ~ 19.99 mΩ
2. Resistance Resolution 1 µΩ 10 µΩ
Inaccuracy ± 1% of reading + 1 digit
3. Output Current 0 ~ 200 A
Open Circuit 4.7 Vdc
Voltage
Current Shunt 10 mV/100 A ± 0.5%, max 20 mVout, max
Output 10 V to protective earth (ground)
5.Testing Done Open Connection Injecting voltage
3 Close Connection Injecting current
1. De-energize the equipment or section of equipment to be tested. Always

comply with TNB safety regulations when working with equipment
connected to high voltage mains.
2. Ensure the power supply to both sides of the breaker or isolator contact
or joints is turned OFF and that there is no feedback supply.
3. Ground the object under test on one side.
4. Do not disconnect current leads or open the device under test whilst the
micro-ohmmeter is still connected to it.
Step 2 – Set-up And Connect Micro-Ohmmeter
1. For this set-up, select the required set-up diagram.
2. Ground the micro-ohmmeter.
3. Ensure the micro-ohmmeter’s ON/OFF switch remains OFF when

connections to the test object are carried out.
4. Connect the micro-ohmmeter to the mains supply.
5. The test shall be conducted one phase at a time.
6. Connect the two current cables from the test set across the contacts or
joints so that the current generated by the micro-ohmmeter will flow
through the contacts to be measured.
7. Similarly, connect the two sensing cables (using the same polarities as
used for current cables) on two sides of the contacts or joints and as close
to the targeted object as possible.
Figure 0-7: Connection diagram for Circuit Breaker (Close Position)
IMPORTANT:
Follow closely the instructions given by the micro-ohmmeter

manufacturer. For example in the case of Programme test equipment,
the sensing cables must be connected inside the current cables.
Otherwise test data may be incorrect.
Step 3 – Inject Current And Take Measurements.
1. Select the desired current range.
2. Turn the current control knob down to zero.
3. Turn on the test set to start current injec on. Check the Power “ON”
ind on to ensure the test set is powered up properly. The test
instrument is now ready for use.
4. Sta ng from zero, slowly turn the control knob to increase the current
output of the test set un it reaches the desired current value.
5. The micro-ohmmeter will measure the voltage drop across the breaker or
3 disconnector contacts and will automa cally calculate the actual
resistance in micro-ohms. Take the reading displayed on the screen, and
then turn the current down to zero again.
Note: High current must only flow for a short me interval. Never leave
the instrument una ended whilst it is on and in high-current mode.
Step 4 - Record And Evaluate Test Result
1. Record test results for each phase of the contact, disconnector or joint in
the test sheet.
2. Compare obtained results with the acceptable range given by the

manufacturer.
Table 3-42 : Rating for Contact Resistance Test (Interrupter)
Type Rating Resistance

630 A 30 ~ 55 µ Ω
TAMCO
1250 A 20 ~ 35 µ Ω
12 kV
2000 A 10~ 20 µ Ω
630 A
800 A Refer NETA Std
Others Guideline (Sub-Clause
1250 A 7.6.2.3.3.3)
2000 A
3
Note:
Compare obtained results with the acceptable range given by the
manufacturer. The varia on value should not more than 20% from
previous result or by comparison with similar conne ons (IEC
62271-1:2007 clause 6.4.1 – measurement of the resistance of
circuit/main circuit.
If the value exceeds this range, check for loosened, improperly

htened threaded joints or corrosion/oxida on at joints.
3.2.6 Maintenance Test Summary for Switchgear
Table 3-43 : Maintenance Test Summary for Switchgear

Recommended
Action Plan
Maintenance Test Measurement
If more than specified limit,
Thermography Tier 1 ∆T<10°C
Inspect/Repair/Replace
Airborne If more than specified limit,
Tier 1 <1dB
Ultrasonic Inspect/Repair/Replace
Internal Partial If more than specified limit,
Tier 1 <29dB
Discharge (TEV) Inspect/Repair/Replace
If Red – Refill gas and Monitor. If

Yellow (eg.Toprank RMU)
contact inside SF6 cubicle not
3 Gas Pressure
Checks
Tier 1 Green good, require to inspect &
rectify
If re-occur, De-energized to
locate gas leak, perform tier 3
If less than specified limit
Insulation
Tier 2 > 1GΩ inspect & rectify. If required
Resistance
perform tier 3 test.
Replace oil or perform asset
Oil Dielectric Test Tier 2 > 30kV replacement. Refer circular
A15/2011
Trip Test Closing < 60ms If more than specified limit –

Tier 2
Shutdown to inspect and rectify.
(On-Line Timing) Tripping < 60ms
Circuit Breaker If more than specified limit –
Closing < 60ms
Timing (Off-Line Tier 2 Refer to OEM
Test) Tripping < 50ms & if require inspect to rectify.
Vacuum Checks Tier 2 GREEN If RED - replace vacuum bottle
SF6 Gas Leakage If leakage is greater- need to de
Tier 3
Emission < 0.5% / year energize to inspect and rectify
PD Locator Tier 3 < 29dB If more, Inspect/Repair/Replace
If high leakage current – retest
Dielectric/
Tier 3 < 0.5mA by section. Refer to OEM & if
Pressure Test
require inspect & rectify.
If more than specified limit –
Contact
Tier 3 < 65 µΩ Refer to OEM & if require
Resistance
inspect & rectify.
Dielectric
If deviation is greater than
Dissipation Factor Tier 3 Deviation < 10%
replace defective parts.
(DDF) Tan δ
3.3 Maintenance Servicing Procedures
3.3.1 Off-Line Maintenance Services & Checks ( for AIS only)

1. Busbar Compartment
1.1. General Condition

No contamina on or adverse effects from environmental
influence
No rusted bolts, screws, nuts, metal work, etc
Interpanel gaps sealed
No dust deposits/debris/ foreign materials
3
1.2. Insulation Condition
No cracks, chips, dents or discoloura on
Insula on boots / jackets for busbar joints in good cond on
1.3. Electrical Joints

1. Exposed joints properly insulated
2. Bolts correctly sized and mounted
3. Electrical joints torque checked
4. No green deposits on busbar
5. Busbar torque checks
2. Breaker Compartment

influence
No rusted bolts, screws, nuts, metalwork, etc
No dust deposits/debris/foreign material
Heaters in good opera ng cond on and wiring not loose
2.2. Contact Condition

No p ng
No overhea ng / discoloura on
Good breaker contact engagement
Good breaker contact centering
No over greased and green deposit
2.3. Insulation Condition of Contact Spout

No cracks, dents or discoloura on
Insula on clean, no soot deposits
2.4. Interlock Operational Checks

3 Clips / Pins correctly seated / opened
Smooth mechanism opera on
Detailed checks where applicable
3. Cable Compartment

No contamina on or effects of environmental influence
Heaters in good opera ng cond on
3.2. Insulation and Phase Barriers Condition

No discharge / overhea ng marks
Insula on boots / jackets covering exposed electrical joint in
good cond on
Graphite / stress relief area not removed (where applicable)
3.3. Power Cables Condition

Good cable termina on and support
Cable opening properly sealed
Sufficient clearance between phases of power cables and metal
part
No physical damage/discharge marks

Sufficient clearance between phases at crossed cables
Power cables properly earthed
Back covers securely bolted
Power cable torque checks
No loose conne ons (screws, nuts, bolts, etc)
Sufficient power cable tail length & shed cones mounted
correctly
4. Instrument Transformers Checks and Tests

Refer to Test Format TR1-04 for CT
Refer to Test Format TR1-05 for PT
3
influence
No dust ingress/debris/foreign material
CTs & PTs mounted properly and no loose conne ons (screws,
nuts, bolts)
CT & PT wiring not hanging and secured properly to
compartment
PT star point of primary & secondary winding properly earthed
4.2. Insulation and Phase Barrier Condition

No physical damage (cracks, dents, chip, etc)
4.3. PT Fuse and Contact Engagement (where applicable)

No p ng / green deposits
No loose fuses or loose fuse clips
No discharge marks
PT fuse not blown
Good contact engagement with PT rack-in
4.4. Withdrawal P T Mechanism (where applicable)

Smooth opera on of PT shu er
Smooth opera on of withdrawable PT mechanisms/truck
PT shu er fully closed when PT is in disconnected pos on
Interlock levers dropped when PT is in connected pos on
PT DISCONNECTED/CONNECTED s rs correctly placed
4.5. Withdrawable/Isolatable PT Fuse Mechanism (where applicable)

Smooth opera on of isolatable PT fuse mechanism
PT shu er fully closed when PT fuse assembly is in disconnected
pos on
3 4.6. Metering Compartment and Multicore Cable Box

influence
Blown Bulbs / Fuses replaced
Components in good opera ng cond on (relays, meters,
transducers, etc)
Good wire termina ons at all components (relays, meter,
transducers, etc)
Good wire termina ons at mu ble box
3.3.2 -Line Maintenance Services (RMU)

1. General Condition
Influence
Blown bulbs /Fuses Replaced
Good cable termina ons at cable compartment.
Components earthed appropriately
2. Insulation Condition
No cracks, chips, dents or discoloura on
Insula on boots / jackets for busbar joints in good cond on
3. Cable Compartment

No contamina on or effects of environmental influence
3.2. Insulation and Phase Barriers Condition

No discharge / overhea ng marks
Insula on boots / jackets covering exposed electrical joint in
good cond on
Graphite / stress relief area not removed (where applicable)
3
3.3. Power Cables Condition
Good cable termina on and support
Cable opening properly sealed
Sufficient clearance between phases of power cables and metal
part
No physical damage/discharge marks
Sufficient clearance between phases at crossed cables
Power cables properly earthed
Back covers securely bolted
Power cable torque checks
No loose conne ons (screws, nuts, bolts, etc)
Sufficient power cable tail length & shed cones mounted
correctly
4. Electrical Joints
Exposed joints properly insulated
Bolts correctly sized and mounted
Electrical joints torque checked
3.3.3 Functional Checks and Tests (for AIS only)
1. Control Light Checks

Lamp test
Fault ind on
Phase indicator test
2. Operational Checks on Control Circuit

Correct opera on of heater circuit
Correct opera on of panel ligh ng
Correct Local/Remote/Supervisory switching (TRIP/CLOSE opera on)
Correct pos on ind on for breaker ON/OFF status :-
3 i) ON/OFF light ind

ii) ON/OFF supervisory ind
on
on
Correct pos on ind on for earth switch ON/OFF status :-
i) ON/OFF supervisory ind on
Correct pos on ind on for breaker MAIN/RESERVE Bus status :-
i) MAIN/RESERVE supervisory ind on
Correct opera on of inter-trip circuitry
Simula on of trip test (Trip on fault cond on)
Correct opera on of lockout circuitry
3.3.4 Mechanical Interlock Checks (AIS)
1. Breaker Checks
Correct ra ng
CONNECTED/DISCONNECTED s rs placed correctly
Secondary control plug can be inserted properly (where applicable)
Smooth rack-in/rack-out opera on
Breaker can be charged manually
2. Checks with Breaker in Connected Position

Shu ers in open pos on
Earth switch cannot be closed
Secondary control plug cannot be removed (where applicable)
Breaker cannot be racked out when breaker is in CLOSED Pos on
Breaker can be racked out when breaker is in OPEN pos on
3. Checks with Breaker in Intermediate Position

Breaker cannot be racked out when breaker is in CLOSED pos on
Breaker can be racked out when breaker is in OPEN pos on
Breaker can be closed electrically and manually
4. Checks with Breaker in Disconnected Position

Shu ers in close pos on
Earth switch can be closed and opened
Secondary control plug can be removed (where applicable)
Breaker cannot be racked/pushed in without secondary plug
connected (where applicable)
Breaker cannot be racked/pushed in when breaker is in CLOSED
3
pos on
Breaker can be racked/pushed in when breaker is in OPEN Pos on
Breaker can be closed electrically and manually
5. Safety Shutter Checks

Smooth opera on of safety shu ers
Padlock facility is aligned and available
Latching facili es are provided
Self-cancelling or spring return es fun oning properly
6. Earth Switch Checks

Smooth opera on of earth switch
Padlock facility is aligned and available
Earth switch blade mates with the fixed bar
6.1. Check with Earth Switch in Close Position

Breaker cannot be racked/pushed in into connected pos on
6.2. Check with Earth Switch in Open Position

Breaker can be racked in/racked out
7. Withdrawable PT/Isolatable PT Fuse Checks

Smooth opera on of PT shu er
Smooth opera on of withdrawable PT mechanisms
Smooth opera on of isolatable PT fuse mechanism
PT shu er fully closed when PT is in disconnected pos on
PT DISCONNECTED/CONNECTED s rs correctly placed
3
Chapter 4 Transformer 87
Chapter 4 Transformer
4.1 Overview
Distribution Transformer is usually utilized in Distribution Substation (PE).
Distribution transformer is a transformer that provides the final voltage
transformation in the electric power distribution system, stepping down the
voltage in TNB distribution system. Normally ratings for distribution
transformer are from 1000 kVA and below.
4.2 Transformer Categories

From maintenance point of view, transformers in TNB distribution system can
be divided into two categories as shown in Table 4.1.
Table 4-1: Transformer Category

Transformer
Category
Type Voltage Ratio
33/0.433kV,
Capacity
4
Oil-filled free
22/0.433kV, 100kVA to
Category 1 breathing distribution
11/0.433kV, 1000kVA
transformer
6.6/0.433kV
33/0.433kV,
Oil-filled hermetically
22/0.433kV, 100kVA to
Category 2 sealed distribution
11/0.433kV, 1000kVA
transformer
6.6/0.433kV
4.3 Distribution Transformer Arrangement

Figure 4.1 & Figure 4.2 illustrate the general arrangement of a typical
distribution transformer of Category 2 used in TNB distribution system at PE’s.
Detail design and specification of the transformer can be found in the TNB
Distribution Substation Design Manual issued by the Asset Management
Department.
Figure 4.1: Distribution Transformer (External View)

Figure 4.2: Distribution Transformer (Internal View)

4.4 Maintenance Testing
4.4.1 Overview
Transformer maintenance testing can be performed in 3 stage or ers as

described below.
There are 2 types of transformer maintenance tes ng as follow:-
Type 1 – maintenance tes ng for in service transformers (in service)
Type 2 – maintenance tes ng tripping of transformer due to system

fault or abnormal cond on based on Tier 1 result.
The cond on assessment methodology consists of analyzing each cond on.

The cond on indicators presented in the following subchapters are generally
regarded by U es as providing a sound basis for assessing transformer
cond on.
Table 4-2 : Transformer Maintenance Matrix

Transformer Transformer Maintenance
Diagnostic Technique
Category Type
Tier 1 (on-line cond on assessment)
Visual Inspe on Category 1 & 2 Type 1
Load Reading (sele ve) Category 1 & 2 Type 1
Category 1 &2
Infrared thermography Type 1
Category 1 & 2
Ultrasonic scanning Type 1
Tier 2 (off-line cond on assessment)

Insula on Resistance (IR) &
Category 1 & 2
Polariza on Index (PI) measurement Type 2
for main winding
Insula on Resistance (IR) & PIDAR Category 1 & 2
Type 2
measurement for Tx tail
Oil Sampling for Tank:
Category 1
Breakdown Voltage (BDV) Type 2
Tier 3 4
Turn-ra o measurement (TTR)
Winding resistance measurement
(WR)
Cond on Type 2
Oil sampling:
Based
Moisture Content
Dissolved gas analysis (DGA)
4.4.2 Maintenance Intervals
Under normal condition, the maintenance diagnostic testing for Tier 1, 2 and 3
on distribution transformers shall be conducted according to the maintenance
intervals in , and respectively.
Table 4-3 : Interval for Tier 1 Maintenance Testin g on Distribution

Transformers
TIER 1
Diagnostic Tool &

Component Interval Team
Techniques Equipment
Body &
Substatio
Visual Inspection Accessory N/A
3 months n Team
Transformer
6 months Airborne
Cable Box Vendor/
Ultrasonic Scanning Ultrasonic
Transformer 12 Team
4 months
Test Set
(Based on
Body & ENGR-
Infrared 750-36 Thermo Vendor/
Accessory
Thermography QR02) Camera Team
Transformer
Load Profiling for

Critical Transformer ILMAS FLUKE 1750 Vendor
Transformers
Table 4-4 : Interval for Tier 2 Maintenance Testing on Distribution

Transformers
TIER 2
Diagnostic Tool &

(IR) & Polariza on Vendor/
Transformer IR Tester
Index (PI) Substa on
Winding 5kV
measurement for Team
18
main winding
Months
(oil type) Vendor /
(IR) & PIDAR Transformer IR Tester
24 months Substa on
measurement for Tx Tail 5kV
(VCB) Team
tail
36 Months
Oil Sampling:
(RMU SF6) Vendor
Breakdown
Dieletric /
Voltage Oil Tank
Tester Substa on
(BDV)
Team 4
Table 4-5 : Interval for Tier 3 Maintenance Testing on Distribution

Transformers
TIER 3
Diagnostic Tool &

Turn-ratio Vendor/
Turn Ratio
measurement Tap Changer Substation
Test Set
(TTR) Team
Winding Winding Vendor/

Winding
resistance Resistance Substation
measurement Transformer
Test Set Team
(WR) Condition
Based
Oil sampling: Moisture Test

Vendor/
Moisture Set
Substation
Content Oil Tank
Portable DGA
4 Dissolved Gas
Analysis (DGA)
Test Set
Team
Note: In order to determine the maintenance interval for next maintenance

activity of each test, the maintenance interval should be multiplied with the
maintenance frequency multiplier in Table 1-1 based on condition indicated
by the test results.
4.4.3 Tier 1
4.4.3.1 Visual Inspection
(i) Inspect Transformer Guard condition

(ii) Check irregularities (heat, sound and smell) at transformer
(iii) Check transformer oil level.
(iv) Check transformer oil leaking
(v) Check condition cable clamp and transformer bushing for crack, dust,
oxidization and loose bolt
(vi) Inspect of any kind of animal intrusion at transformer.
(vii) Color deterioration and rust at transformer
(viii) Inspect silica gel condition.
(ix) Inspect tap changer position.
(x) Update in Routine Maintenance Checklist ( PSI)
4.4.3.2 Infrared Thermography
This test should be performed on energized transformer to detect heat

4
dissipated due to internal arcing, bad electrical contacts, hot spots or
overheating of conductors.
The following equipment and accessories are to be made ready at site:-
(i) Thermography scanner (camera)

(ii) Fully charged battery for the camera
(iii) PC Card
(iv) On-site test sheet
Figure 4-3: Example of Infrared Thermography Test Equi pment

Table 4-6 : Equipment Specification for Infrared Thermography

Item Specification
Object Temperature Measuring
-20°C ~ +600°C
Range
Measurement Accuracy ±2% of reading or ±2°C
Thermal Sensitivity < 0.05°C @ 30°C
Field of View/Min. Focus Distance 46° x 34°/7.5cm

Focal Plane Array (FPA),
Detector Type uncooled microbolometer, 320
x 240 pixels.
Spectral Range 7.5 ~ 14 µm
Operating Environment Temperature -10°C +50°C

4
1. Before scanning, record the transformer loading in Amps at transformer
circuit breaker
2. Press the ON/OFF button for a period of 15 seconds and confirm the
image gets displayed on the screen
3. Apply temperature compensation by keying into the camera, the

background and ambient temperature. Key in the emissivity of the
surface material of the equipment scanned for temperature
compensation of radiated heat from different materials.
4. Adjust the View Finder to acquire the clearest image
5. Parts to be scanned include transformer body, radiators, cable boxes &

bushing terminals if applicable.
6. Perform scanning
i) Search for hot spots and suspicious patterns

ii) Avoid using Auto adjust
iii) Fine tune Level/Span manually if necessary
iv) Adjust focus continuously to keep the image clear
v) Make sure all critical points are covered
vi) Make sure reflected ambient temperature obtained accurately
7. Record data captured to test sheet
Note: Any external light sources that may be reflected from the
surfaces scanned that may cause wrong interpretation of data for
example, reflection from light sources, sunlight, heat reflection and etc.
Ensure there are no cold drafts or winds blowing directly at then
equipment scanned.
4
Table 4-7 : Result and Action for Infrared Thermography

Condition
Result Action
Indicator
The hot spot temperature

difference between phases/top
Good
& bo om tank ≤ 5 degree Continue infrared thermography
cen ade at maintenance intervals
specified in Subchapter 4.4.2
5 degree cen ade < The hot
spot temperature difference
Fair
between phases/top & bo om
tank ≤ 10 degree cen ade
Inspect & repair:
1. HV & LV bushing terminals

& cable termina ons for
loose contacts
4
The hot spot temperature
difference between phases/top
Poor
& bo om tank > 10 degree
cen ade 2. Radiators & Tank for
accidentally closed valves or
blocked oil flow
Note: Priority for ac on taken should be given to equipment with poor

cond on indicator.
4 Figure 4-4 : Thermal Image

4.4.3.3 Ultrasonic Scanning
The objec ve of this test is to detect any par al discharge ac v es,

par ularly, corona and surface discharges.
Figure 4-5: Example of Ultrasonic Scanning Test Equipment (TEV Plus+)

4
Table 4-8 : Equipment Speci cation For Ultrasonic Scanning
Item Speci cation
1. Measurement Range -7 dBµV ~ 68 dBµV
2. Resolu on 1 dB
3. Accuracy ±1 dB
4. Transducer Sens vity -65 dB (0 dB = 1 volt/µbar rms SPL)
5. Transducer Centre Frequency 40 kHz
6. Heterodyning Frequency 38.4 kHz


possible to the air path.
that intermittent discharges will also be captured.
3. Record results in decibel (dB) and store any abnormal sounds for further
analysis where necessary. The instrument will capture both mechanical
vibration noise and partial discharge.
4. During the course of scanning, eliminate external noise sources (ex :
ballast, exhaust fan etc) that may interfere with the scanning.
Note: surface discharge will be detected by this system.
4 4.4.3.3.3 Test Result and Action
Table 4-9 : Result and Action for Airborne Ultrasonic Test

Result*
Action
dB Characteristic
Normal condition, with continuous

< 0 dB No Sound monitoring, will probably be safe and
failure free within 3 months period.
≥ 1 dB Tracking, Arcing Serious level, areas of the fault deemed

to be serious nature. Shutdown and
repair of the equipment within 3 months
≥ 4 dB Corona
would be required to avert failure.
Note: Also applies for cond on where the dB level below 0dB but
ultrasound characteris has been detected. Priority for corre ve
ac on is based on the following category:
Arcing =
Tracking = Serious
Corona = Intermediate
4.4.4 Tier 2
Under normal cond on, Tier 2 tests are carried out on all transformer
popula on based on the designated maintenance intervals. Tier 2 tests be
carried out in Offline Cond on Assessment.
Tier 2 maintenance tes ng are shown in .
4.4.4.1 O ine Condition Assesment

4
(i) Visual Inspe on ( refer 4.4.3.1)
(ii) Conduct Opera on Mechanism Test ( check mechanical moving parts
of tap changer)
(iii) Measuring distances of arc horn and ensure minimum clearance is
achieved (if any)
(iv) Check bushing for signs of broken, cracked, dust pollu on/salt and
flexibility bolt.Cleans bushings and change if necessary
(v) Check earthing cond on
(vi) Check any animal intrusion at transformer
(vii) Check cond on of cable termina on at transformer and cable clamp.
(viii) Check oil cond on for non- herma cally seal transformer and
conduct BreakdownVoltage Test
4.4.4.2 Insulation Resistance (IR)
Insulation Resistance technique basically measures the current flowing

through a dielectric or insulation structure when a dc voltage is applied.
Measurements of the transformer insulation resistance were performed
between high voltage winding and low voltage/earth winding respect to
ground. To verify the degradation or contamination of the insulation, connect
high voltage winding /low voltage winding and earth with respect to ground.
The requirement of the test is satisfied if the readings compared to the
factory test and have not defer to much from the factory test. Apply voltage
according to Table 4-10.
Figure 4-6 : Example of Insulation Resistance Test Equipment
Table 4-10 : Applied Test Voltage Based On Rated Voltage Equipment

Rated Voltage
< 600 V 12 kV 24 kV 36 kV
Equipment
Test Voltage 500 Vdc 2.5 kVdc 5.0 kVdc 5.0k Vdc
Table 4-11 : Equipment Speci cation For Insulation Resistance

Item Speci cation
Voltage 5 kVdc
Maximum Value Current 2 mA
Resistance 5 TΩ (digital meter)
4.4.4.2.2 Connection Diagram
1. Test Conne ons for High Voltage Winding Terminal to Ground Terminal
shown in Figure 4-7.
2. Test Conne ons for Low Voltage Winding Terminal to Ground Terminal
shown in .
3. Test Conne ons for High Voltage Winding Terminal to Low Voltage
Winding Terminals shown in Figure 4-9. 4
4. Wait for the measurement to stabilize according to table below :-
Table 4-12 : Measurement Stabilize According To Cable Type

Type of Cable
LV MV XLPE MV PILC
Time
1 minute 1 minute 10 minutes
Figure 4-7 : Test Connections For HV Winding Terminal to Ground Terminal
Figure 4-8 : Test Connections for LV Winding Terminal to Ground Terminal

4
Figure 4-9 : Test Connections for HV Winding Terminal to LV Wind ing

Terminal
Note: Priority for action taken should be given to equipment with

lower(worse) condition indicator.Tap changer must be in Tap 1
The results of insula on resistance measurement between high voltage

winding to ground, high voltage winding to low voltage winding and low
voltage winding to ground should meet the minimum requirement of
400 MΩ, whilst the minimum requirement for transformer tails is 1000 MΩ.
However, the other interpreta on for Insula on Resistance measurement is

by using Polariza on Index (PI) / Dielectric Absorp on Ra on (DAR) method
that can be referred to below.
IR10 min
PI =
IR1min
IR60sec
DAR=
IR30sec
PI = Test for transformer bushing or Transformer Tail (PILC cable only)

DAR = Test for Transformer Tail (XLPE only) 4
Table 4-13 : Result & Action for Insulation Res istance of Transformer
Windings
Condition
Result Action
Indicator
PI > 2.0
DAR ≥ 1.6 Good Normal to moderate
or IR ≥ 600 MΩ (Wdg)
conditions. Continue test
or IR ≥ 1500 MΩ (Tail)
as part of Tier 2 test at
1.5 ≤ PI < 2.0 normal intervals specified
1.1 < DAR < 1.5 Fair in Subchapter 4.4.2
or 400 MΩ ≤ IR < 600 MΩ (Wdg)
or 1500 MΩ ≤ IR < 1000 MΩ (Tail)
1.0 ≤ PI < 1.5

1.0 < DAR < 1.1 Poor Proceed with Turns-ratio
or 200 MΩ ≤ IR < 400 MΩ (Wdg) measurement (TTR) and
or 500 MΩ ≤ IR < 1000 MΩ (Tail) Winding resistance
4 PI < 1.0
measurement (WR)
DAR < 1.0 Bad

or IR < 200 MΩ (Wdg)
or IR < 500 MΩ (Tail)
Note: Priority for action taken should be given to equipment with poor
and bad condition indicator.
4.4.4.3 Continuity Test
Continuity test is carried out to verify the connection or continuity of the

distribution transformer.
Table 4-14 : Applied Test Voltage Based On Rated Voltage Equipment

Rated Voltage
< 600 V 12 kV 24 kV 36 kV
Equipment
Test Voltage 500 Vdc 2.5 kVdc 5.0 kVdc 5.0k Vdc
Table 4-15 : Equipment Speci cation For Insulation Resistance

Item Speci cation
Voltage 5 kVdc
Maximum Value Current 2 mA
Resistance 5 TΩ (digital meter)
4.4.4.3.2 Connection diagram
Figure 4.10 : Test Connection HV winding
Figure 4.11 : Test Connection LV Winding

4.4.4.3.3 Result
From the testing we can conclude two result which are:
Table 4-16 : Result analysis for Insulation Resistance test

Open Circuit No continuity or conductor core broken
Short Circuit Got continuity
4.4.5 Tier 3
4.4.5.1 Turns Ratio
The transformer turns ratio (TTR) test detects shorts between turns or layers
of the same coil, which indicates insulation failure between the turns. These
tests are performed with the transformer de-energized and may show the
4 necessity for an internal inspection or removal from service.
Figure 4-12 : Example of Turn Ratio Test Equipment


Table 4-17 : Equipment speci cation for Turn Ratio
Item Speci cation
1. Maximum voltage 100 Vdc
2. Output current 1A
1. This test should be performed on de-energized transformer.
2. Switching should be done by Authorized Person (AP) in accordance with

TNB Distribu on Division Safety Rules. Before going into opera on, local
safety regula ons and safety precau ons for the prote on against direct
or indirect contact of live parts have to be met accordingly.
3. Make sure that zero voltage cond on exists. The bushing/ transformer
tail termina ons of high voltage and low voltage terminals must be
isolated from the conne on lines.
4
4. Ensure that the applica on of the diagnos voltage does not lead to
flashovers to other nearby items which are in service.
5. Iden the configura on and vector group of the transformer before

conne ng the test lead of the Turns Ra o Meter to the test transformer.
6. Connect the coloured measuring leads of Turns Ra o Meter to the

respe ve bushing/transformer tail termina ons as shown in Figure 4-13.
7. Start the measurement.
8. Earth the test equipment to substa on earth.
9. When the measurement is completed, record the measured value in the

appropriate test sheet.
Figure 4-13 : Test Connections for Delta-Star Transformer
4 4.4.5.1.3 Test Result and Action
Table 4-18 : Result and Action for Turn Ratio

Condition
Result Action
Indicator
Good Normal to moderate conditions.

% deviation < 0.3
Continue test as part of Tier 2 test
at normal intervals specified in
0.3 ≤ % deviation < 0.5 Fair
Subchapter 0.
0.5 ≤ % deviation < 0.7 Poor

Replace a new transformer
% deviation ≥ 0.7 Bad
4.4.5.2 Winding Resistance
Winding resistance can detect broken conductor strands, loose conne ons,
and bad contacts in the tap changer. The resistance is measured on all taps of
a tapped winding to ensure that the on-load tap changer does not open circuit
during the tap changing opera on.
Because the winding resistance of most large transformers is of a rela vely

low value the four terminals method is used. The voltage leads must be
connected directly across the terminals of the transformer to eliminate the
effect of the current lead resistance.
Figure 4-14 : Example of Winding Resistance Test Equipment
Table 4-19 : Equipment Speci cation For Winding Resistance

Item Specifica on
Voltage 36 Vdc
1.Maximum Value
Current 10 A
2. Resistance Range 1 µΩ ~ 500 Ω
3. Corrected Reading 75°C

1. Change switch from tap to tap 1 (one) - full winding.

2. Make sure that the test on HV and LV is done separately.
3. Make the DELTA or STAR connection.
4. Record the observation.
5. Discharge transformer at bushing parts.
6. Repeat procedure 2 until 6 for test at another phase.
Table 4-20 : Result and Action for Winding Resistance

Result of % difference
Condition
between phases or Action
Indicator
from factory tests
4 % difference < 3 Good Normal to moderate conditions.

Continue test as part of Tier 2 test at
normal intervals specified in
3 ≤ % difference < 5 Fair Sub-Chapter 0.
Deviations at majority of tap

5 ≤ % difference < 7 Poor positions within the same phase.
Proceed with Turns-ratio Test,
Insulation Resistance Test and FRA
to find possible fault location. After
% difference ≥ 7 Bad repair, continue test as part of Tier 2
test at intervals specified in Sub-
Chapter 0.
Note: Priority for action taken should be given to equipment with poor and
bad condition indicator.
4.4.5.3 Oil Quality Analysis (OQA )
Oil Quality Analysis used on transformer oil includes some physical tests such
as dieletric strength, moisture content and DGA. Therefore, they are not
ind ve of overall transformer cond on that would lead to replacement.
4.4.5.3.1 Breakdown Voltage (BDV)
The dielectric test applies an AC voltage at a controlled rate to two electrodes

immersed in the dielectric liquid. The gap between the two electrodes is set at
a specified distance. When the current arcs across this gap, the voltage
recorded at that instant is the dielectric breakdown of the liquid. This
measurement is adversely affected by the presence of dirt, water condu ve
par es and wet fibres. However, a high breakdown voltage does not indicate
the absence of all contaminants.
Figure 4-15 : Example of Breakdown Voltage Test Equipment

4.4.5.3.2 Moisture or Water Content
Water may originate from the atmosphere or be produced by the

deterioration of insulating materials. At comparatively low water content, the
water remains in solution and does not alter the appearance of the oil;
dissolved water shall therefore be detected by chemical and physical
methods. The solubility of water in transformer oil increases with increasing
temperature. A low water content of mineral insulating oil is necessary to
achieve adequate electrical strength and low dielectric loss characteristics and
to maximize the insulation system life.
Figure 4-16 : Example of Moisture Meter Test Equipment

4.4.5.3.3 Oil sampling Procedures
a) Safety Precautions
Oil sampling is done offline on transformer by TNB authorized personnel or

by individual under permit and supervision of TNB authorized personnel. TNB
safety rules shall be strictly observed and followed at all e. Extreme
cau ons must be taken when sampling insula ng oil from transformer as to
ensure validity of test results that is truly representa ve of the oil in the
transformer.
Ensure that the transformer body is properly earthed and inspect the external
cond on of the transformer for any leaks or cond ons that may become
hazardous to the personnel when oil sampling is conducted. Ensure that
working zone is not obstructed and adequate safe working clearance is
observed at all e.
Iden the correct sampling point or valve intended for oil sampling (either
sampling of oil from bo om of the Tank, or conservator). Know the type of
valve and the appropriate sampling tools and adaptors to be used. 4
b) Before Sampling
Check that the oil level in the conservator. Know the total quan ty of oil to be
taken and always ensure that the oil level does not drop to below 1/3 of the
oil level in the conservator a er sampling completed. shows the quan ty of
oil required for various tests. Do not take oil sample if the oil level is already
below the 1/3 level in the conservator. If so, oil sampling can only be
conducted on the transformer topping up of oil. This is applied for either
sampling of oil from Tank, or any conservator.
Table 4.21 : Quantity of Oil Required According to Type of Tests

No. Test Volume (ml)
1. Moisture 50
2. Breakdown Voltage 300
Ensure the weather is conducive to carry out oil sampling. Do not carry out oil
sampling in rain, strong wind and at night e. Before oil sampling, ensure
the following steps are taken:
Clean the outside of the valve with a clean cloth to remove any loose
debris that may fall into the sample.
If drain plug is used, make sure the valve is closed before removing
the drain plug.
Prepare the area under the valve as to avoid oil spillage.
Slowly remove the drain plug.
4 Clean the inside of the valve with a clean cloth.

Install adapters to the drain valve and a ach tube can, as shown in
Figure 4.17.
Temperature of the oil sample shall

Adaptor be recorded during sampling
Valve
Transformer Plastic
tube Cap
Seal
Dark Brown Filled

Bottle Sample
500 mL bottle
Waste
Vessel
Figure 4-17 : Oil sampling using bottle from Transformer Drain Valve
c) Taking Oil Sample
Once the valve is totally prepared then sampling can commence. The oil
sampling procedure is in accordance to the combina on of standards IEC
60475 and IEC 60567. The la er standard is specific to oil sampling for DGA,
which is stringent and is thus applicable also to oil sampling for oil quality and
furan tests. The pra ce below provide detailed informa on concerning
taking the actual sample.
i) Flush the oil through the valve to clean sampling valve, adaptor and tube
as well as to remove debris and water from the oil prior to taking a
sample into waste vessel. Flushing and purging helps to remove any
debris and moisture, coats the plunger to create an adequate seal and
helps to remove air bubbles.
Figure 4-18 : Oil sampling valve showing water and debris accumulation
ii) Place tube into glass bo le, ensuring end of tube reaches the bo om or
touching the inner side of the bo le. Ensure the pressure inside the tank
is pos ve. Immediately close the valve is the pressure inside the
transformer tank is nega ve.
Figure 4-19 : Positive and Negative pressures
iii) Open sampling valve to about half fill the bottle then close valve. Rinse
the bottle 2 to 3 times to remove any debris remaining from the bottle.
Figure 4-20 : Rinse the bottle

iv) Steadily fill the bo le avoiding any splashing, aera on or bubbling which
likely to cause premature degassing of the oil. Take temperature of the oil
sample.
Figure 4-21 : Fill the bottle
v) Allow bo le to fill un just overflowing, remove the tube slowly and

close the valve. Allow for a headspace with 2 to 3 mm height at the p of
the bo le to ease placing of seal/stopper. Firmly place the seal/stopper
and screw cap. Ensure bo le is completely filled with oil. Up-end bo le to 4
check for air bubble. If there is an air bubble in the bo le, remove the
seal/stopper and cap, top up the bo le to just overflowing and replace
the seal/stopper and cap. Repeat the check for any air bubble.
Figure 4-22 : Seal the bottle

d) After Sampling
Cleanup is a necessary step of the sampling activity. The area should be left
cleaner than found so that possible hazards can be minimized for the next
sampling crew. Make sure that drain valves and sampling cocks are wiped
clean of oil and closed tightly. Remove all debris and tools from the area, and
cleanup any liquid spillage.
4
Figure 4-23 : Close the valve and cleaned
Inspect the level of oil in the conservator and carry out topping up is
necessary. All unused oil shall be scraped following the existing procedure.
e) Identi cation of Oil sample and Transformer Information
label shall be adhered on the sampling bo les and all informa on

below shall be clearly provided.
Transformer Information S Information Sample Information
TNB Sta on Name Sampling Date

Substa on Name Staff No Sampling Time
Transformer No. Sampling Point
TNB Fun onal Loca on Oil Sampling
& Equipment No. Temperature
Voltage Ra ng Weather Cond on
kVA Ra ng
Serial No.
Manufacturer
Year of Manufacture
Year of Commissioning 4
Preserva on Systems
Cooling Systems
Oil Volume (Litre or Kg)
Oil sampling form below shall also be filled and subm ed together with the
oil samples to TNBR.
Figure 4-24 : Sample of Data Sheet
f) Sample Storage and Transport
Samples should not be stored longer than 3 days before shipping to the
laboratory for analysis. Store bottles containing the oil samples in the dark to
prevent from photo-degradation, and keep them away from temperature
extremes and humid environments. They shall also be stored up-right and in a
secure manner for shipping.
When the sampling is completed, record the information in the appropriate

test sheet.
4.4.5.3.4 Test Results & Actions
Table 4-22 : Oil Quality Indicator for Tank

Limits
Property
Good Fair Poor Bad
Breakdown
> 40 30 to 40 20 to 29 < 20
Voltage (kV)
Water Content > 40

< 10 10 to 25 26 to 40
@ 20°C (ppm)
Figure 4.25 illustrates the corre ve ac ons required based on the results of
oil quality analysis and the cond on indicators. Details regarding the
ve ac ons namely oil recond oning, oil replacement/retrofi ng and
oil reclama on are further elaborated in Subchapter 4.4.6.1.
Figure 4-25 : Corrective Actions for Oil Quality Analysis Tank

4.4.5.4 Dissolved Gas Analysis (DGA)
Extraction and analysis of gasses evolved from oil degradation due to thermal
and electrical faults.
Figure 4-26 : Example of Portable DGA Test Equipment
4.4.5.4.1 Mechanisms of Gas Generation in Transformer Tank

4 Thermal and electrical stresses in a transformer lead to the decomposition of
both the oil and cellulosic insulating materials, resulting in the formation of
gaseous products which dissolve in the oil. The important gases produced in a
transformer are illustrated in .
Figure 4-27 : Key Gases and Fault

The identity and relation of the individual gases are indicative of the types of
fault that occur in a transformer while the rate of gas generation can indicate
the severity of the fault. The characteristic patterns and the relative
proportion of the dissolved gases associated with the main fault types are
summarised in through .
Figure 4-28 : Distribution of Gases by Fault Type

4
Corona
100
86
90
80
70
% dist ribut io n
60
50
40
30
13
20
0.2 0.2 0.5 0.1
10
0
H2 CO CH4 C2H4 C2H6 C2H2
Fault gases
Figure 4-29 : Percentage proportion of gases indicating Corona

Overheating of paper
100 92
80
% dist ribut io n
60
40
20 6.7
1.2 0.01 0.01 0.01
0
Fault gases
Figure 4-30 : Percentage proportion of gases indicating Overheating of Paper
4
Overheating of oil
70
63
60
% distribution
50
40
30
16 17
20
10 2 2
0.01
0
Fault gases
Figure 4-31 : Percentage proportion of gases indicating Overheating of Oil

Arcing
70
60
60
50
% dist ribut io n
40
30
30
20
10 5 3 2
0.1
0
Fault gases
Figure 4-32 : Percentage proportion of gases indicating Arcing
4
4.4.5.4.2 DGA Interpretation for Transformer Tank
Table 4-23 : DGA Interpretation Results for Tank

Fault Fault
Examples
Type Description
PD Partial Discharge in gas-filled cavities resulting from incomplete

Discharge impregnation, high-humidity in paper, oil super saturation
or cavitation, and leading to X-wax formation.
D1 Discharge of Sparking or arcing between connection of different or

Low Energy floating potential, from shielding rings, toroids, adjacent
disks, conductors of winding, broken brazing or closed
loops in the core.
Discharges between clamping parts, bushing and tank,
high voltage and ground within windings, on tank walls.
D2 Discharge of Flashover, tracking or arcing of high local energy or with

High Energy power follow-through. Short circuit between low voltage
and ground, connector, winding, bushing and tank, copper
bus and tank, winding and core etc.
4 T1 Thermal Fault
t ≤ 300°C
Overloading of the transformer in emergency situations.
Block item restricting oil flow in windings.
Stray flux in damping beams of yokes.
T2 Thermal Fault Defective contact between bolted connection (particularly

300 < t ≤ 700°C between aluminium busbar), contact within selector
switch, connection from cable and draw-rod of bushing.
T3 Thermal Fault Large circulating current in tank and core.

t > 700°C Minor current in tank wall created by high uncompensated
magnetic field.
Shorting links in core steel laminations.
D+T Discharge Fault consisting mixture of discharges D1 or D2 with

with Thermal thermal T1 or T2 or T3. Possible hotspot due to
Fault defective contacts with intermittent sparking or
arcing.
Limits for the key gas concentra on refer to below where Cond on 1
indicates normal cond on whilst Cond on 4 indicates serious cond on.
Table 4-24 : Limits for gas concentrations based on IEEE Std 57.104:1991
for Tank
Status H2 C2H2 C2H4 C2H6 CH4 CO TDCG
Cond on
100 35 50 65 120 350 720
1
Cond on 101 – 36 - 51 - 66 - 121 - 351 - 721 -

2 700 50 100 100 400 570 1920
Cond on 701 – 51 - 101 - 101 - 401 - 571 - 1921 -

3 1800 80 200 150 1000 1400 4630
Cond on > > > >

> 80 > 200 > 150
4 1800 1000 1400 4630
4
Table 4-25 : Result and Action for DGA Tank

Condition
Fault Type Action
Indicator
No indication of fault. All key gases and TDCG are

No Indication Good below the IEEE C57.104 Condition 1 limits. Continue
of Fault oil sampling for DGA monitoring at normal intervals
specified in Subchapter 0
Possible development of fault. One or more key

gases are above the IEEE C57.104 Condition 1 limits
Fair with TDCG below the IEEE C57.104 Condition 2 limits.
Continue oil sampling for DGA monitoring at frequent
intervals specified in Subchapter 0
Indicate presence of fault. One or more key gases

4 and TDCG are above the IEEE C57.104 Condition 2
limits. Continue oil sampling for DGA monitoring at
Poor frequent intervals specified in Subchapter 0 and
PD, T1, T2, T3,
D1, D2, D+T conduct Tier 2 test (plus PD detection for faults
involving PD, D1, D2 or D+T) when DGA trending
shows persistent condition of fault within 6 months
Indicate serious fault . One or more key gases are

above the IEEE C57.104 Condition 2 limits with TDCG
above the IEEE C57.104 Condition 3 limits. Continue
Bad oil sampling for DGA monitoring at frequent intervals
specified in Subchapter 0 and conduct Tier 2 test
(plus PD detection for faults involving PD, D1, D2 or
D+T) when DGA trending shows persistent condition
of fault within 3 months
*Note: The DGA condition indicator can be generated through DGA

Analysis Template
4.4.6 Corrective Actions
4.4.6.1 Replacement/Retro - lling of Oil (Draining, Flushing and Re lling)
This procedure is normally performed at site. Oil replacement can be

conducted when results of oil quality test indicates that Acidity or Power
Factor has reached a value of more than 0.2 mgKOH/goil and 0.5 % respe vely.
However, oil replacement can also be considered based on Life Cycle Cost
Analysis when the Acidity has reached 0.15 mgKOH/goil and at the same me
results of other tests such as IFT or BDV and Moisture Content is showing
poor/bad cond on.
During oil replacement process, the transformer is drained of the oil, its
interior is flushed with hot Naphthenic oil to remove the accumula on of bulk
sludge and then refilled with new oil. The old oil should be scrapped in
accordance with TNB disposal policy of waste material.
Transformer Tank vacuuming should follow the oil draining process as

described in the previous subchapter. 4
Neither flushing nor hand cleaning can remove the sludge that accumulates in
the voids of the insula on. Only approximately 25% of the surface of the
transformer winding can be reached through flushing and cleaning in a
workshop.
Changing the oil does not remove all the deposited sludge, especially those in
the cooling fins, trapped in the solid insula on and in between the windings.
Refilling the transformer with new unused oil should include the oil
recond oning process men oned above.
4.4.6.2 Testing the Transformer with Turns Ratio and Insulation Resistance
Tests
1. After completion of the tap changer overhaul, proceed with Turns Ratio
and Insulation Resistance Tests according to the procedures stated in
Subchapter 0.
Figure 4-33 : Carry out testing
4.4.6.3 Repair Work

4
Minor Involves external repair or replacement of component
Minor Repair
Repair
only without untanking or draining of oil,
Involves untaking of transformer not more than 8 hours

Medium
Medium Repair
Repair at site for repair work or replacement of component.
Involves untanking of transformer for repair work or

Major
Major Repair
Repair replacement of component of more than 8 hours. To be
performed at factory.
Figure 4-34 : Level of Repair Works

Table 4-26 : Corrective actions for irregularities found during visual

inspection
Condition
Condition Indicator
Indicator Components Action
Results
Ranking
Minor
Gasket – accessories
Sealing Repair
POOR,
degraded/damaged –
BAD
with/without oil leaks Gasket – main & conservator Medium
tanks Repair
Surface corrosion - POOR, Minor

with/without oil leaks BAD Tank body & cover, Repair
conservators, radiators,
POOR, pipeworks, cable boxes Minor
Paintwork peeling
BAD Repair
Tank body& cover,

Minor
Surface
cracked/chipped POOR,
conservator, radiators,
pipeworks, cable boxes
Repair 4
/punctured – BAD
with/without oil leaks Medium
Bushing
Repair
Tank body& cover,

Minor structural POOR, Minor
conservator, radiators,
damage BAD Repair
pipeworks, cable boxes
Tank cover,bushing support

Loose bolts/support POOR, Minor
HV & LV cable boxes,
not secure BAD Repair
secondary cable boxes
Minor
POOR, Repair
Low oil level Main conservator tanks
BAD
Condition
Condition Indicator
Indicator Components Action
Results
Ranking
Silica gel colour POOR, Minor

Breather
changed BAD Repair
POOR, Earthing connection, bushing Minor

Loose contact
BAD terminals Repair
Burnt POOR, Minor

Bushing terminals
marks/oxidation BAD Repair
Surface POOR, Minor

Bushing
contamination BAD Repair
POOR, Minor
Air flow blocked Cable box vents
BAD Repair
4 Malfunction
POOR,
BAD
Valves
Minor
Repair
POOR, Minor
Abnormal noise External components
BAD Repair
POOR, Bushing terminals, HV & LV Minor

Insulation degraded
BAD cables Repair
POOR, Minor
Dirty Gauges, indicators
BAD Repair
Presence of
POOR, Minor
encumbrance/weed/ Bay, compound
BAD Repair
animal nests
4.4.6.4 Maintenance Test Summary for Transformers
Table 4-27 : Summary of Recommended Actions for Tier 1 Tests

TIER 1
Diagnostic Condition
Component Action
Techniques Indicator
Body &
Visual Inspection Accessory Poor/Bad Minor/Medium Repair
Transformer
Transformer Reduce Loading &

Load Reading for
Circuit Poor/Bad Recalibrate Protective
Critical Transformers
Breaker Relay Settings
Inspect & repair HV &

LV bushing terminals &
cable
Infrared
Body &
terminations for loose
4
Accessory Poor/Bad
Thermography contacts as well as
Transformer radiators & Tank for
accidentally closed
valves or blocked oil
flow
Immediate shutdown
and repair of the
Cable Box terminal
Ultrasonic Scanning Poor/Bad
Transformer bushings/terminations/
cable box to avert fire
or failure.
TIER 1
Component Action
Tier 2 and/or Tier 3

Tests whichever
Dissolved Gas appropriate when DGA
Tank Poor/Bad
Analysis (DGA) trending shows
persistent condition of
fault within 3-6 months

TIER 2
Component Action
4 Insulation resistance
Based on Turns Ratio,
and Polarization
Transformer Winding Resistance,
Index (PI) and
Winding & Poor/bad Insulation Resistance
Dieletric Absorbtion
Tail to locate the possible
Ratio (DAR)
fault location.
measurement
Breakdown Voltage
Tank Poor/Bad Replace Oil
(BDV )

TIER 3
Component Action
Transformer
Turns-ratio Based on Turns Ratio,
Winding & Poor/bad
measurement (TTR) Winding Resistance,
OLTC
Insulation Resistance
Transformer
Winding resistance to locate the possible
Winding & Poor/bad
measurement (WR) fault location.
OLTC
Moisture Test Tank Poor/Bad Replace Oil
Dissolved Gas Replace Oil/ Replace

Tank Poor/Bad
Analysis (DGA) Transformer
4
Chapter 5 Maintenance Management

System
5.1 Overview of Maintenance Management System
Figure 5-1 : Maintenance Methodology and System Involved

Chapter 5 Maintenance Management System 141
Maintenance
Planning CBM DMMS
CBM Data DARAT
SG/ Tx/ (Risk)
Cable
Maintenance
Planning TBM TBM Data
ERMS-PM ERMS-FM
Maintenance Maintenance
Schedule Cost
ERMS Integrated
System
Diagnostic
CBM
Asset Value
Asset Detail
TBM
Maintenance Cost
Health Index
Life Cycle Cost
5
Maintenance Activity
Figure 5-2 : Total Integrated Mainten ance System

5.2 Data Record & Monitoring
The maintenance interval outlined in this guideline is determined based on

available data at the point of the analysis. The guideline shall be reviewed in
the future when more data is collected and where reliability and efficiency
indices could be determined.
Hence it is important that all observations during inspections, repair and
replacement work are properly recorded and documented by the State
Maintenance Unit in the Plant Maintenance Module of the Enterprise
Resource Management System (ERMS).
All the data inspections repair and replacement works are properly recorded
and documented through:-
1) ERMS – PM
2) Maintenance Planning (QR – 02)
3) Distribution Maintenance Management System (DMMS) – applicable
for 33kV & 11kV Transformers and Medium Voltage Underground
Cable
5
5.3 Overview of ERMS -PM
5.3.1 Maintenance Planning/Updating Activity for PE 11KV
All activities and data related to maintenance must be recorded in ENGR-750-

36-QR-02. This document can be obtained from PSI ENGR-750-36.
(i) Refer to PSI – ENGR-750-36 (PROSEDUR SENGGARAAN PE)

(ii) Update data in ENGR-750-36-QR-02
Apart from that, these data and activities must also be updated to HQ
according to the respective Operasi Wilayah.
(i) Access server \\129.6.70.241 > home > (find the respective Operasi
Wilayah folder)
Figure 5-3 : Accessing Server

5.3.2 ERMS – PM
All assets data must be keyed in into ERMS-PM by using transaction

IH01, IH06 & IH08. Please refer to PSI ENGR 750-39-QR-01.
Figure 5-4 : The Relevant Transacti on Codes for Data Entry
Figure 5-5: Transaction IH01


Table 5-1 : Functional Location Structure - TNBD

Structural Indicator TNBD (Structure for TNBD)
Functional Location Category D
Company Code 6001
Maintenance Plant 6000
Maintenance Planning Plant 6000
Planner Group As per Appendix 5-1 to Appendix 5-4
Edit Mask AAAA/AAA/ANNNNN/AAXXXXXX
| | | |||
Hierarchy Level 1 2 3 456
Note:
A – letter
N – number
X – combination of letter & number
Name of Hierarchy Level 1 Area/Station

2 Substation Type/HV Cable/
General Grouping
3 Voltage Levels
4 System Grouping
5 Subsystems/Bay
6 Equipment
5
Object Type Used to classify and group similar
systems or objects for ease of record
search and report generation. Object
Type is not mandatory but is highly
recommended to be assigned to
certain Functional Locations as listed
in Appendix 5-5
Table 5-2 : Description of Hierarchy Levels

Level
Description Required Appendix
No.
Level 1 Area/Station The list of 4-le er sta on
4-le er code for the sta on codes is as shown in Appendix
5-1.
Level 2 Substation Type/HV Cable The 3-le er grouping codes

3-le er coding to represent are as shown in Appendix 5-2.
main system grouping
Level 3 Voltage Levels The Voltage Level codes are as

First le er represents the shown in Appendix 5-2.
system voltage level and
followed by the sequence
number of substa on/cable
se on.
Level 4 System Grouping The System Grouping codes

1-le er code for System are as shown in Appendix 5-2.
Grouping.
Level 5 Sub-System The Sub-System Grouping

1-le er code for Sub-System codes are as shown in
Grouping. Appendix 5-3.
Level 6 Equipment
Max 6-characters code to
The recommended codes are
as shown in Appendix 5-4.
5
iden equipment.
Figure 5-8 : ERMS Functional Location Structure
5 Users can refer to Manual Asset Inventory for Asset Plant and Machinery or
Panduan ERMS-PM as a guide to use IH01, IH06 and IH08. Panduan ERMS-PM
can be obtained from the server \\129.6.70.241>home>PANDUAN ERMS-PM.
5.4 Appendices
Appendix 5-1: List of TNBD’s Business Areas and Station Codes
Business 4-Letter
No. State Station Name Area Station Code
1 Johor PBN (Johor) 6303 JPBN
2 Johor PK Batu Pahat 6330 JBPT
3 Johor PC Pontian 6333 JPON
4 Johor PK Johor Bahru 6340 JJBU
5 Johor PC Kota Tinggi 6341 JKTG
6 Johor PK Kulai 6342 JKLY
7 Johor PK Pasir Gudang 6345 JPGD
8 Johor PC Johor Jaya 6346 JJJY
9 Johor PCK Bandar Penawar 6347 JBPN
10 Johor PK Muar 6350 JMUR
11 Johor PC Segamat 6352 JSEG
12 Johor PCK Tangkak 6353 JTGK
13 Johor PK Kluang 6360 JKLU
14 Johor PC Mersing 6361 JMSG
15 Johor PCK Yong Peng #N/A
16 Kedah PBN (Kedah) 6202 KPBN
17 Kedah PK Alor Setar 6240 KALS
18 Kedah PC Jitra 6242 KJIT
19
20
Kedah
Kedah
PC Langkawi
PC Guar Cempedak
6243
6244
KLGK
KGCM 5
21 Kedah PCK Kuala Nerang 6245 KKNG
22 Kedah PC Pendang 6246 KPDG
23 Kedah PK Sg. Petani 6290 KSGP
24 Kedah PC Baling 6292 KBLG
25 Kedah PCK Sik 6293 KSIK
26 Kedah PK Kulim 6294 KKLM
27 Kedah PCK Bandar Baru 6295 KBBU
28 Kedah PC Kuala Ketil 6296 KKTL
29 Kedah PCK Serdang 6297 KSDG
30 Kelantan PBN (Kelantan) 6403 DPBN
Business 4-Letter
31 Kelantan PK Kota Bharu 6410 DKBU
32 Kelantan PCK Gua Musang 6411 DKRI
33 Kelantan PC Pasir Mas 6412 DPMS
34 Kelantan PC Pasir Puteh 6413 DPPH
35 Kelantan PCK Gua Musang 6414 DGUA
36 Kelantan PC Tumpat 6415 DTUM
37 Kelantan PC Bachok 6416 DBAC
38 Kelantan PK Tanah Merah 6417 DMER
39 Kelantan PCK Machang 6419 DMAC
40 Kelantan PCK Jeli 6461 DJEL
41 Kelantan PCK Kuala Balah 6462 DKBL
42 Melaka PBN (Melaka) 6302 MPBN
43 Melaka PC Alor Gajah 6315 MALG
44 Melaka PC Jasin 6316 MJAS
45 Melaka PC Masjid Tanah 6317 MMAT
46 Melaka PCK Merlimau 6318 MMER
47 Melaka PC Melaka 6302 MMLK
48 N Sembilan PBN (Negeri Sembilan) 6301 NPBN
49 N Sembilan PK Seremban 6320 NSBN
50 N Sembilan PC Tampin 6321 NTAM
5 51
52
N Sembilan
N Sembilan
PCK Kuala Kelawang
PC Port Dickson
6322
6324
NKKG
NPDN
53 N Sembilan PC Rembau 6325 NREM
54 N Sembilan PC Nilai 6326 NNIL
55 N Sembilan PK Kuala Pilah 6327 NKLP
56 N Sembilan PC Bahau 6328 NJEM
57 N Sembilan PC Gemas 6329 NGEM
58 Pahang PBN (Pahang) 6401 CPBN
59 Pahang PK Kuantan 6420 CKTN
60 Pahang PC Pekan 6422 CPEK
61 Pahang PC Rompin 6424 CROM
62 Pahang PCK Bandar Muadzam 6425 CBMS
63 Pahang PC Raub 6430 CRAU
Business 4-Letter
64 Pahang PK Bentong 6431 CBTG
65 Pahang PC Kuala Lipis 6433 CKLS
66 Pahang PK Temerloh 6450 CTML
67 Pahang PCK Maran 6451 CMRN
68 Pahang PC Jengka 6452 CJEN
69 Pahang PC Jerantut 6453 CJRT
70 Pahang PC Triang 6454 CTRI
71 Pahang PCK Tioman 6455 CTIO
72 Pahang PC Gebeng 6426 CGBG
73 Perak PBN (Perak) 6204 APBN
74 Perak PK Ipoh 6210 AIPO
75 Perak PC Kampar 6211 AKAM
76 Perak PK Bidor 6212 ABID
77 Perak PC Behrang 6213 ABEH
78 Perak PCK Cameron Highlands 6215 ACHL
79 Perak PC Parit 6218 APRT
80 Perak PC Hulu Kinta 6219 ATGR
81 Perak PK Taiping 6220 ATPG
82 Perak PC Batu Gajah 6221 AGAJ
83 Perak PK Kuala Kangsar 6222 AKSR
84 Perak PC Grik 6223 AGRK
85
86
Perak
Perak
PC Bagan Serai
PC Sg. Siput
6224
6225
ASER
ASIP
5
87 Perak PK Sri Manjung 6227 ASIT
88 Perak PK Teluk Intan 6250 ATEL
89 Perak PC Hutan Melintang 6252 AHML
90 Perak PCK Kg. Gajah #N/A
91 Perlis PBN (Perlis) 6201 RPBN
92 Perlis PCK Padang Besar 6271 RPBR
93 Perlis PC Kangar 6201 RKAN
94 P Pinang PBN (Pulau Pinang) 6203 PPBN
95 P Pinang PK Seberang Perai 6231 PBUT &
PBMT
Business 4-Letter
96 P Pinang PC Nibong Tebal 6232 PNTL
97 P Pinang PK Pulau Pinang 6260 PPPG
98 P Pinang PC Bayan Baru 6261 PBYB
99 P Pinang PC Bertam 6230 PBTM
100 P Pinang PC Butterworth 6231 PBUT
101 P Pinang PC Bukit Mertajam 6231 PBMT
102 Selangor PBN (Selangor) 6102 BPBN
103 Selangor PK Petaling Jaya 6130 BPJY
104 Selangor PC Subang Jaya 6131 BSJY
105 Selangor PK Klang 6140 BKLG
106 Selangor PC Kuala Selangor 6141 BKSL
107 Selangor PK Banting 6142 BBAN
108 Selangor PC Port Klang 6143 BPKG
109 Selangor PC Sg. Besar 6144 BSBR
110 Selangor PC Sg Pelek 6145 BSPL
111 Selangor PCK Telok Panglima Garang 6146 BPGR
112 Selangor PCK Salak Tinggi 6147 BSTG
113 Selangor PK Rawang 6150 BRWG
114 Selangor PK Shah Alam 6160 BSAM
115 Selangor PK Bangi 6180 BBBB
5 116
117
Selangor
Terengganu
PC Cheras
PBN (Terengganu)
6153
6402
BCRS
TPBN
118 Terengganu PK Kuala Terengganu 6440 TKTR
119 Terengganu PK Kemaman 6441 TKEM
120 Terengganu PC Dungun 6442 TDUN
121 Terengganu PC Besut 6443 TBST
122 Terengganu PCK Setiu 6444 TSTU
123 Terengganu PCK Kerteh 6445 TKTE
124 Terengganu PCK Kuala Berang 6446 TKBG
125 Terengganu PCK AMBS 6447 TAMB
126 Terengganu PC Marang 6448 TMRG
127 Terengganu PCK Batu Rakit #N/A
128 WP KL PBN (WP KL) 6101 WPBN
Business 4-Letter
129 WP KL PK ( KL Barat ) 6121 WKLB
130 WP KL PK ( KL Timur ) 6122 WKLT
131 WP KL PK ( KL Pusat ) 6123 WKLC
132 WP KL PK ( KL Selatan ) 6124 WKLS
133 WP Putrajaya PBN (Putrajaya & Cyberjaya) 6103 VPBN
134 WP Putrajaya PC (Putrajaya) 6103 VPTJ
135 WP Putrajaya PC (Cyberjaya) 6103 VCBJ
Appendix 5-2: Functional Location Naming Convention – Level 2, 3 & 4

Substation Type/HV Cable (Level 2)
PPU = Pencawang Pembahagian Utama(Applicable to Substation only)

PMU = Pencawang Masuk Utama (Applicable to Substation only)
SSU = Stesen Suis Utama (Applicable to Substation only)
PCE = Pencawang Elektrik (Applicable to Substation only)
KVT = Kabel Voltan Tinggi(Applicable to HV Cable & HV Overhead)
KVR = Kabel Voltan Rendah
SVR = Sesalur Atas Voltan Rendah
LAW = Lampu Awam
SVC = Servis
Voltage Levels (Level 3) System Grouping (Level 4)

5
G = 33 kV M = Primary System
H = 22 kV N = Secondary System
J = 11 kV P = Protection System
K = 6.6 kV Q = Control System
L = 0.415 kV R = Communication System
M = 0.240 kV X = Compound/infrastructure
N = No voltage level; Common Z = Building System
to substation
Appendix 5-3: Functional Location Naming Convention – Level 4 & 5

Sub-System Catalogue (Level 4 & 5)
Primary Sub-System Secondary Sub-System

(Letter M denotes primary system) (Letter N denotes secondary system)
MA = Transformer Bay NA = Transformer Bay

MB = Switchgear Bay NB = Switchgear Bay
MC = Transformer Tail NC = Capacitor Bank
ND = LV Distribution Board
NE = LV Feeders
Infrastructure Sub-System Building Sub-System

(Letter X denotes infrastructure (Letter Z denotes building system)
system)
ZA = Building
XA = Compound ZB = Fire-fighting System
XB = Lighting ZC = Water Supply
XC = Fencing ZD = AC Supply & Lighting
XD = Drainage ZE = Air-Conditioning System
XE = Sign Board ZF = Electrical System
ZG = Lift System
ZH = Building Automation
Protection Sub-System System
5 (Letter P denotes protection system)

PA = Battery Bank
ZI =
ZJ =
Sewerage System
Furniture/Fittings
Appendix 5-4: Functional Location Naming Convention – Level 4, 5 & 6

LEVEL 4-6
MATX1 = Transformer No. 1 NETX1F1 = LV Feeder 1

From Transformer No. 1
MATX2 = Transformer No. 2
NETX1F2 = LV Feeder 2
MANER1 = NER No. 1 From Transformer No. 1
MB2001 = Switchgear/Circuit NETX1F3 = LV Feeder 3

Breaker No. 2001 From Transformer No. 1
MB2002 = Switchgear/Circuit NETX2F1 = LV Feeder 1

Breaker No. 2002 From Transformer No. 2
NCCAP1 = Capacitor No. 1 NETX2F2 = LV Feeder 2

NDTX1 = Single LVDB for
Transformer No. 1 NETX2F3 = LV Feeder 3
NDTX2 = Single LVDB for
Transformer No. 2 NE1TX1F1 = LV Feeder 1
ND1TX1 = First LVDB for LVDB No. 1
Transformer No. 1
NE2TX1F1 = LV Feeder 1
ND2TX1 = Second LVDB for From Transformer No. 1
Transformer No. 1 LVDB No. 2 5
Appendix 5-5: Example of Functional Location

Functional Location FL Description
ATEL/PCE/J00152 TAMAN WAWASAN
ATEL/PCE/J00152/M PRIMARY SYSTEM
ATEL/PCE/J00152/MA TRANSFORMERBAY
ATEL/PCE/J00152/MATX1 TRANSFORMER 1
ATEL/PCE/J00152/MB SWITCHGEARBAY
ATEL/PCE/J00152/MB1 DARI PMU H/MELINTANG
ATEL/PCE/J00152/MB2 KE TX1 300 KVA
ATEL/PCE/J00152/MB3 KE TAMAN SRI BERNAM6
ATEL/PCE/J00152/MC TRANSFORMER TAIL
ATEL/PCE/J00152/MCTX1 TX1 TAIL
ATEL/PCE/J00152/N SECONDARY SYSTEM
ATEL/PCE/J00152/ND LV DISTRIBUTION BOARD
ATEL/PCE/J00152/NDTX1 LVDB TX1
ATEL/PCE/J00152/NE LV FEEDER
ATEL/PCE/J00152/NETX1F1 LV FEEDER 1
ATEL/PCE/J00152/NETX1F6 LV FEEDER
5 ATEL/PCE/J00152/X
ATEL/PCE/J00152/XA
INFRASTRUCTURE
COMPOUND
ATEL/PCE/J00152/XB LIGHTING
ATEL/PCE/J00152/XD DRAINAGE
ATEL/PCE/J00152/XE SIGNBOARD
ATEL/PCE/J00152/Z BUILDING SYSTEM
ATEL/PCE/J00152/ZA BUILDING
ATEL/PCE/J00152/ZB FIRE FIGHTING SYSTEM
ATEL/PCE/J00152/ZD AC SUPPLY

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Condition Based Maintenance Manual for

Distribution Substation (PE)

Asset Management Department

We would also like to express our appreciation to TNB representatives from

Pn. Hjh. Rosila bt. Dato’ Hj. Senan

As Malaysia progresses to achieve Vision 2020, the

TNB Distribution Division through Distribution Asset Management

Therefore, I would like to take this opportunity to congratulate the project

Chapter 2 Maintenance of Assets ..........................................

Chapter 3 Switchgear ..........................................................

3.2.4 Tier 2 .................................................................................................... 36

3.2.5.3 Dielectric Dissipa on Factor (DDF ) Tan δ .......................................... 69

3.3.2 Oﬀ-Line Maintenance Services (RMU) ................................................ 82

Chapter 4 Transformers ....................................................... 87

4.4.3 Tier 1 ....................................................................................................

Chapter 5 Maintenance Management System ...................... 140

5.4 Appendices ............................................................................................... 149

Electrical distribu on equipments are generally designed for a certain

Provide a standard maintenance level requirement and prac ces in TNB’s

To ensure the eﬀe ve implementa on of this manual in Distribu on Division

Method, instru ons and checklist to carry out inspe on and

1.3 Scope of This Manual

Equipment in operation consists of a large population with variety of

Chapter 2 – This chapter describes standard maintenance practices in TNB

Chapter 3 – Switchgear is the key components in the power system, hence it is

Chapter 4 – In this chapter, it is clearly explain on the built up of transformer

Chapter 5 – Information about all observations during inspections, repair and

1 In order to determine the maintenance interval of the equipment, the

Table 1-1: Maintenance Frequency Matrix

Thermography 12 month 12 month 12 month

1 Table 1-3 : Maintenance Interval for Distribution Transformer under In-

Chapter 2 Maintenance of Assets

Life Cycle Activities

Figure 2-1 : Life Cycle Activities

The maintenance interval or frequencies are categorized into calendar time,

2.3 Maintenance Scope

2.3.1 Electrical Assets 2

Condition based maintenance was introduced to try to maintain the correct

ONLINE CONDITION OFFLINE CONDITION CORRECTIVE

Figure 2-2: Category of Condition Based Maintenance

2 ONLINE CONDITION OFFLINE CONDITION CORRECTIVE

Figure 2-3: Category of Condition Based Maintenance for Switchgears

ONLINE CONDITION OFFLINE CONDITION CORRECTIVE

TIER 1 TIER 2 PLANNED

TIER 3 TIER 3 UNPLANNED

Figure 2-4: Category of Condition Based Maintenance for Transformers

2.3.2 Civil and Mechanical Work

Correc ve maintenance is carried out a failure or unacceptable cond on

CIVIL AND MECHANICAL

Figure 2-5 : Category of Civil and Mechanical Work

Air Insulated switchgear (AIS) : VCB,OCB

The distribu on system has predominantly indoor air insulated switchgear.

3.1.1 Air Insulated Switchgear (AIS)

Figure 3-1 : Typical Arrangement of 11 kV Air Insulated Switchgear (AIS),

(11) (10) (9)

Table 3-1 : Description in Rating of Circuit Breaker for 11 kV

Equipment Circuit Breakers with

3.1.2 Ring Main Unit (RMU): Oil/Gas

The suitability of indoor and outdoor applications depends on the degree of

In general, the RMU is a combination of two units of switches, which

Table 3-2 : Description in Rating of RMU for 11 kV

Voltage level 12kV

Con nuous normal current 630 A