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1. Purpose:
To determine the pipe to soil potential protection level and efficiency of Transformer Rectifier Unit.
2. Equipment:
Calibrated Multimeter.
3.2. Next conduct the continuity test. Continuity test means checking the multimeters working
condition whether it is good or not. At the time of continuity test, the following procedures will
be follow .First choose the continuity option on the multimeter switch, then touch the
black(+ve) cable with red(-ve) color cables, at this time one beep sound will appear this shows
the cables are in good condition if no beep sound then the cables are in damage condition .
3.3. Since sunlight easily affects multimeter display, Multimeter should not be shown directly in
sunlight.
3.4. Note all options (AC voltage & Current and DC voltage & current, Resistance and
Temperature) change the switch option accordingly.
3.5. After measurement switches off the multimeter.
4. Safety Measures while taking Transformer Rectifier Unit Monitoring:
4.1. Wear safety shoes, helmet, hand gloves etc.
4.2. Before TRU door open, should be check AC current using tester and carefully open to the
TRU door. While taking this kind of measurements compulsorily use hand gloves and safety
shoes.
4.3. Open TRU door carefully (you may find some small insects) with the TRU key. Once the
door is open then start taking the TRU readings.
5. Standard Safety Factors of Transformer Rectifier Unit Monitoring:
5.1. CP rectifiers have exposed electrical AC and DC terminals on the panel of the rectifier. The
voltage exposure varies with the rectifier rating and design. Do not make body contact with any
electrical terminal when the rectifier is energized and protect yourself from this hazard.
5.2. Take measurements with insulated meter probes intended for that purpose using a one-hand
method while avoiding contact to the probe end. Never press a probe end and a terminal or wire
between your fingers to make a contact.
5.3. Turning off the circuit breaker in the rectifier will render the front of the panel safe but will
not make the back or inside of the rectifier safe!
5.4. The AC disconnect outside the rectifier must be OFF (locked out/tagged out) before the
entire rectifier is safe to work on.
5.5. Confirm that the AC power is off by testing as breaker contacts can fuse together thus
making contact in the tripped position.
5.6. Lock out and tag the rectifier breaker or AC disconnect after turning OFF when installing an
interrupter, changing taps, replacing components, or installing and removing the rectifier.
This is a good habit to form and is required by code in many areas.
5.7. There is no testing that is required behind the panel with the rectifier energized with the
exception of measuring the input AC supply voltage. This AC voltage measurement is only to be
completed by persons properly trained and is only to be measured if the terminals are readily
accessible at the side of the rectifier. Remember that even with the rectifier breaker OFF; AC line
voltage still exists up to the rectifier circuit breaker.
5.8 Remember to turn OFF, lock out and tag the AC disconnect when working on or removing
rectifier components. No one else can then inadvertently turn the AC on before it is safe.
6. General Precautions:
6.1. Wear protective eyewear, gloves, shoes and other clothing.
6.2. Avoid open flames.
6.3. Avoid causing electric sparks especially in areas that may contain a hydrocarbon.
6.4. Know the handling/storage procedures for chemicals or other hazardous materials or
equipment.
6.5. Working at heights.
6.6. Animals, reptiles and insects
6.7. Vehicles: Drive defensively and be aware of hazard situations that could occur.
7. Common Procedure of Transformer Rectifier Unit Monitoring and Maintenance:
7.1. First arrange all safety tools equipments and wear safety shoes, hand gloves and helmets.
8.1 CAUTION: Only qualified personnel are to test and work on a rectifier. Safety is of the
utmost importance when working on an electrical device.
8.2 Determine if the rectifier or any associated electrical equipment is in an electrically
hazardous area. Do not open any explosion proof junction boxes unless otherwise qualified and
then only if the circuits are turned off and locked out/tagged out.
8.3 Do not work on or remove any rectifier component without first turning the upstream power
off and locking/tagging out.
8.4 When first approaching the rectifier confirm that the case is not electrically hot either by
taking an AC voltage-to-ground measurement or with a voltage alert device.
8.5 On first opening the rectifier identify any exposed terminals that will have a voltage and
take measures to protect yourself from them.
It is important to ensure that the power source in an impressed current system, such as a rectifier,
remains operational and that the cathodic protection system is connected with proper polarity.
The negative () terminal of the power source must be connected to the structure and the positive
(+) terminal must be connected to the anode bed (see Below Figure).
The proper connection of a rectifier is CRITICAL and if done improperly can result in
catastrophic damage to the structure that is supposed to be protected, resulting in loss of product,
structural damage, property damage, environmental damage, or loss of life. Often the cathodic
protection cables are either not identified or are incorrectly identified. It is therefore mandatory
to verify the proper connection polarity. This can be accomplished by measuring the structure-toelectrolyte potential near the power source both before and after the source is activated. A shift in
potential in the electronegative direction with the power source energized, confirms the correct
polarity. For this test the cable connected to the negative terminal of the rectifier should not be
used as the test lead for the structure-to-electrolyte potential measurement. When connecting a
rectifier to an AC power supply, the AC supply circuit should be dedicated and separately fused.
The rectifier should never share an AC circuit with normally interruptible facilities such as
lighting and pumps.
The voltage and current output of the power source should be monitored regularly to ensure that
the unit remains operational.
Basic rectifier operational data includes:
AC input voltage
DC output voltage and DC output current
Tap settings and/or potential set point (if constant potential) or current set point (if constant
current)
Anode-to-structure resistance.
11.6. Check d.c. output fuse. Check that external output circuit (groundbed and structure
connections) for open circuit. Check shunt signal by connecting milli-voltmeter on mV d.c.
Across shunt at and check mV is proportional to current. Shunt rating in amps Let this =A, then
0.075/A * OUTPUT AMPS =mV READING.
12. Cathodic Protection Transformer Rectifier:
Cathodic Protection Transformer Rectifier unit (TRUs) comprise of Automatic, Manual & CVCC controlled. CP-TRU is
used for cathodic protection of buried pipelines across the country, storage tanks at terminals /refineries and other
buried structures.
12.1. Applications:
12.1.1.
TRUs are used to prevent submerged (Soil or water) metallic structures from corrosion. All submerged
Pipelines (Oil, water etc.), concrete structure of bridges/ buildings / sea ports etc can be protected from corrosion by
doing CP.
12.1.2. TRUs impress DC Currents in to the Carbon-steel/steel structure to be protected in opposite direction to the
galvanic corrosion currents & protect the structure from corrosion.
12.1.3.
To obtain the optimum level of protection under varying conditions, it is necessary to vary the impressed
current continuously so as to maintain a constant level of protective potential at the structure. This continuous
monitoring and control can be achieved by providing an automatic control for the cathodic protection system.
12.1.4.
HIRECT offers several types of TRU which are designed, manufactured and tested under strict quality
12.2.Transformer:
All the Transformers used in TRUs are designed to give high efficiency with low loss. The coils are wound with high
conductivity, annealed, insulated electrolytic copper and core material is high permeability, low loss CRGO/CRNGO.
The insulation material used is of high standard Class F. Designed and tested as per IEC 76/IS 2026 standards.
12.3. Rectifier:
Rectifiers are based on internal quality standards and our own make Diodes / Silicon Controlled Rectifiers. Rectifier
circuits have different topology depending upon the load requirements.
12.4Modes of Operation
12.4.1. Auto Reference Mode
The operation of the TRUs in this mode will be fully automatic and will be controlled by reference electrode feedback.
The unit will automatically maintain reference voltage or P.S.P. within 15 mv of the set value under all conditions.
12.4.2. Manual Mode
The DC output voltage of TRU will be controlled in 24 symmetrical steps by means of a separate Autotransformer
with Coarse & Fine tapping.
12.4.3CVCC Mode
The unit will be operated in Constant Voltage or Constant Current mode. In constant voltage mode the DC output
voltage will be settable from 0 to rated value in step less manner by means of voltage adjustable pot.
In constant current mode the DC output current will be settable from 0 to rated value in step less manner by means of
current adjustable pot.
Types Of Unit
Control Element
The DC Output will be controlled through latest solid state Silicon Controlled Rectifiers
(SCRs) with plug in type control card of electronic circuits.
AC Inputs
DC Outputs
Meters
Indications
Mains ON , Auto Mode , Manual Mode , Auto Ref. mode , CVCC mode , under protection,
Over protection , All Ref. Fail , Current Limit.
Protection
Operational Climatic
TRUs are designed to work under severe environmental conditions with ambient
condition
Enclosures
Enclosures are fabricated from 2.5 mm/2.0mm/1.5 mm CRCA sheet and confirming to
IP55 degree of protection. Stainless Steel Cabinets for corrosive atmosphere. Lockable
doors shall be provided in the Front and Back. Polycarbonate window is provided viewing
meters and indications.
Finish
Powder coating /Paint of required shade and thickness with proper treatment to suit
corrosive/site conditions.
Motor Operated Valve (MOV) locations, this may pose a safety risk. Appropriate safety
precautions should always be considered.
No work shall be undertaken on Railway property without the written authorization and Indian
Railway Authority safe working procedures for work within the vicinity of railway lines shall be
obtained.